How a Boeing 787 Dreamliner is Built ?
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How a Boeing 787 Dreamliner is Built ?

September 12, 2019

– [Narrator] Last week, I was invited to Boeing South Carolina in Charleston to see their operation. This is also in conjunction
with the world’s first Boeing 787-10 delivery
to Singapore Airlines. First, let’s look at the Dreamlifter. Four modified Boeing 747-400 jumbo jets called the Dreamlifter carry the 787 parts and
assemblies between Japan, Italy, Wichita, Kansas, North Charleston, South Carolina, and Everett, Washington. These big aeroplanes carry
three times as much cargo by volume as the standard
747-400 Freighters. (mellow rock music) I started my day with a media
tour from the meeting room, which has an amazing view of the Final Assembly Line of Boeing 787. I’m also going to show you the
Final Assembly of Boeing 787, the Midbody Operation where
they build the mid-fuselage, the Aftbody Operation where the aftbody and tail cone is built, and Boeing Interiors
Responsibility Centre, where they manufacture
over-bins, et cetera. – I guess like, you know real quick, tell us the advantage of the 787. If you have a customer
who want to buy the 787, what would you tell them? – It’s the best passenger
experience for passengers. The most fuel-efficient
aeroplane for airlines. And it can take people
anywhere they want to go. – Right. – So that’s what I would tell people if they wanted to buy a 787. – And how long it took from
scratch to build a 787? – You know Sam, that’s
a really hard question. Because it’s not like buying a car, like you go to a car dealer
and there’s a car sitting there and you say, “I want that car.” We work with our customers,
they plan out over years, even decades, what their
fleet wants to look like. And we plan with them when
to give them the aeroplanes that’s the most advantageous for them. And every airline has
a different interior, they have different options. They want the aeroplane
exactly the way they want it. So it’s a long process. And depending upon when
they need the aeroplane to what they want in the aeroplanes — – So guys, behind me is the
Boeing South Carolina plant the Boeing 787 Final Assembly Line. So the plane were all
built here, the Dreamliner. Especially the 787-10, only built in South
Carolina in Charleston. – This factory, less than a
decade ago, was marshland. And so I am certainly excited to have the opportunity
to lead this factory. And walk in every day and
see the progress we’ve made. When I think about, nothing existed here about a decade ago, to where we are today, it is really, really exciting. Back in 2011, we opened Final Assembly. In April of 2011. In September, we began the
build of the first 787. And then we rolled that
out in April of 2012. So just seven months from starting the 787 here in Charleston to rolling out. And that was a big day. And then today, here we are getting a
chance to celebrate delivery of our first 787-10 with Singapore. So in this Final Assembly, we have about 1.2 million square feet. So that’s about 10
American football stadiums, 1.2 million square feet. We have eight positions, we break our build up into positions. So we start here with position zero, and we move down to the end of the factory for the third position. And then we have position
four through eight, four through seven, on the other side. So our forward section, which
also consists of the cockpit, comes from Wichita, Kansas. Our midbody rolls right from
the other factory across here. Delivered in midbody is our sections. And you’ll have a chance to
see that, from Italy and Japan. And then of course, we
build from carbon fibre, the aft body here onsite. The wings come from Japan, as well as wingtips from South Korea. And parts all over the world. It’s the one place here in Charleston, Boeing South Carolina, where we can talk about the
787 from freezer to flight. Currently, we are building
at 12 a month 787s. We will be moving to 14 a month in 2019. We have a really strong partnership with our Everett team as well. We have one production
system, one build plan. And of course it is
certainly important for us, we have one certificate. And we deliver a high-quality
product to our customers. – [Engineer] This is the
heart of the programme. Everything takes shape here. And then from here, once the
airplane’s painted, tested, we will fly some sections to Everett. Same thing, we put it on the Dreamlifter. So as you see right here,
this is the wing box. Down at Final Assembly
they’re gonna take a wing and attach it to it. So that is the backbone to the wing to attach to the aeroplane. And then this cell is
where we start putting all the electrical wires,
some of the systems. So there’s about 76
miles of electrical wire that goes into a 787, roughly. So it’s all gonna happen in this cell. So they’re gonna start putting
all the electrical wires, and systems like ducts, and hydraulic runs, waste tubes, and air conditioning type of ducts. So anything that has to do with a system it happens in this cell. – So in Aftbody, this
facility, it’s two parts. A composite facility, and an assembly and installation facility. We start our composite build using this quarter-inch composite tape. And I’m gonna pass this around, you’ll feel it, it’s kind of tacky. It’s resin-infused carbon fibre. And if you look down onto
one of these machines, this is an automated
fibre placement machine. It places this, it’s called
tow, quarter-inch tow. If you look, you’ll see that there are a number of these yellow
spools in this box. That is a temperature-controlled, humidity-controlled environment. That keeps that carbon fibre
tacky so it doesn’t dry out. The carbon fibre, there’s
32 of those spools, feed through that machine
to the orange head, the end effector. It feeds all 32 plies,
tows, up to that head. Such that when it lays composite
material on the mandrels, the barrel section, it’s laying down an eight-inch
swath of composite material. And we wind that around the entire barrel. Whether it’s a 47 section or a 48. So if section 47 is the
aft passenger compartment, and then 48 is where the
horizontal stab vertical fin attach to the aeroplane. To get this surface finished that doesn’t look like
this composite tape, we add a layer of
electric discharge cloth. So if lightning strikes the
aeroplane, it dissipates. And then also, surfacer. So you can have a nice smooth
surface finish to paint. So this facility does
all the composite work and all of the assembling
and installation work for all aftbodies. Dash-8s, dash-9s and 10s
for the entire programme. – [Narrator] So every
aftbody is built here? – Every aftbody is built in this facility. Alright, so after we’ve
come out of the autoclave, you have a completed structure
for the exterior skin. We have a trim and drill machine that cuts out all of the
cutouts in the aeroplane. Whether it’s the horizontal stab cutouts, forefront and 47 section,
all the passenger windows, the passenger door entry, bulk cargo door. Again at the end of this process, now we have a finished
barrel that has all the skin that we use to drill and
fasten all those again, internal hoop frames to section 48. And it’s called the QuadBot, because we have one, two, three, four, independent KUKA robots
integrated by electroimpact. They did the end effector design. And it drills, selects the
right grip length fastener, seals it, and inserts the fastener. We load our floor grid next. The floor grid comes as
a preassembled module. It’s rolled into the barrel. And it’s mechanically
fastened to the frames, to the edge of the floor grid itself. And then after the join process, we go to the right side of our factory. And the right side is where we do all of our systems installation. – [Narrator] The Interiors
Responsibility Centre team fabricates and assembles 787
Dreamliner interior components. Including storage bins,
closets, partitions, ceiling panels, class
dividers, overhead crew rest, video control station, and
flight attendant modules. Well, I hope the video
gives you an insight into Boeing’s South
Carolina 787 operation. Thanks to Boeing team there for the tour, and it’s always a pleasure
to share the video with you. (mellow rock music)

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  1. I helped build part of this plant. I was not proud of helping them (Boeing). First the plant was built on a swamp not Marsh as the ignorance shows in the lack of facts. Boeing executives think with money and not common sense. I've had several friends loose jobs here and it's because no boss backs up their subordinate. I feel sorry for those that work for them. Layoffs are frequent and they adopt the I'm better than the average person mentality. I want to puke everytime I see the sign and someone wearing a Boeing shirt. They should be embarrassed to represent them.

  2. I feel aviation is the only or the sole circumferance that makes me insatiable and cormorant , I'm too cormorant and insatiable to feed my senses with avionics, I guess no one who peek or sneak an eye over this field and become not cormorant or not insatiable or not cormorant to get more knowledge in this spectrum

  3. The company has no responsibility goes on to say that it has no blame for so many fatal accidents with is planes!

  4. High quality product, leaving metal shavings in the plane, which could migrate into an electronic system and cause a short.

  5. Its Built Like Shit, Parts are from all around the world and only assembled at a Boeing Plant, Keep on Cost Cutting Boys u already killed more than 300 people on the Max one day the Crap)Liner will have its day too. Its a Putrid POS , Dubbed the Crap)Liner

  6. well plenty of capacity on the 737 line now… boeing have assured customers that the controls in the cockpit wont be affected by titanium shavings that cut though control cables as they have a backup FBW system for just such an event. Warning light in the cockpit is extra though.

  7. Ask to tour the "Gallery" in Everett. This is where a ten person team from an airline spends one week selecting all of the options. There are some 1500 choices to be made, 30 different service carts (reduced from 60 choices); 30 different lavatories, do you want a bidet? No problem. The waste tubes used to be aluminum but in testing a penny traveling 90 mph would not make the turn and punch a hole in the side causing a leak. Waste tubes are now titanium.

  8. And the Prophet Muhammad described the Women 2:56 AS ( Missing Brain & Religion )
    In Arabic Pronounced ( Nakesat Aqel & Deen )
    Nakesat : Means have less
    Aqel : Mean Brain
    Deen: Mean Religion
    I wonder if that old Nancy Pelosi agrees with that

  9. Oh hell no ! Dis bitch that popped up at 2:55 scared me yo , eew no no she looks like shes very very mean in person , very rich and conceded , ugh. And the bitch probably dont even know anything about airplanes besides where and what they look like inside

  10. I wouldn't fly on a 787 product for any amount of money due to the sloppy assembly procedures and lack of quality control.
    Shame on you Sam, your nothing but a promoter of the Boeing products, what next Sam say the best 737 max is a great aircraft?

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