Global Fastener News

Fastener Shortage May ‘Jeopardize’ Boeing 787 Delivery Date

Jason Sandefur

Replacing “thousands of temporary fasteners” on its first 787 Dreamliner has caused further delays for Boeing, potentially pushing the Dreamliner’s maiden flight weeks beyond its revised deadline for the end of September, the Seattle Times reports.
“Almost eight weeks after the jet rolled out with great fanfare in Everett, mechanics are still working to finish the airplane’s structure, which was partly dismantled after the July 8 rollout ceremony,” writes Dominic Gates of the Times.
Boeing dismantled much of the first 787 to install electrical and hydraulic systems and also to replace temporary fasteners used because permanent ones were not available when the fuselage was first assembled.
A tight aerospace fastener market has led to a critical shortage of fasteners for the 787 (see FIN 6/13/07). Alcoa Fastening Systems reportedly worked nonstop to complete design work and manufacture the 9 different fastener types to Boeing’s factory in Everett, WA.
Complicating matters, specifications for 787 fasteners reportedly came near the end of the program’s detailed engineering design process, giving fastener makers a late start in tooling up to produce the unique fasteners.
Boeing 787 communications director Adam Morgan told FastenerNews.com in June that the decision to use temporary fasteners was not hastily made.
“We’ve known about (the fastener shortage) for months and have also known for months that parts would arrive with temporary fasteners,” Morgan told FastenerNews.com.
At the time Morgan expressed confidence that the fastener issue an item labeled “high risk” by 787 executive Scott Strode — would not derail 787 production.
Given the latest developments, it appears the Dreamliner’s first delivery date of May 2008 “could be in jeopardy,” the Times reports.
“The program schedule is already tight,” writes Gates. “If the first airplane flies at the end of next month, that leaves only seven months for flight tests if the jet is to enter service on time in May 2008.” �2007 FastenerNews.com