Boeing has again halted deliveries of 787s after it discovered an “analysis error” by a supplier related to the aircraft’s forward pressure bulkhead. “In reviewing certification records, Boeing discovered an analysis error by our supplier related to the 787 forward pressure bulkhead,” states the manufacturer. “We notified the [US Federal Aviation Administration] and have paused 787 deliveries while we complete the required analysis and documentation.” The issue was discovered within the past week. Boeing adds that there is no immediate safety concern for the in-service fleet of 787s, and production of the type is continuing as normal. Spirit AeroSystems supplies the forward pressure bulkhead for the 787 and has been approached for comment. Boeing says that while near-term deliveries will be impacted, the latest issue “is not expected to increase airplane rework”, and it does not anticipate any change to previous guidance that it plans to deliver 70-80 787s this year. “We are communicating with our customers and will continue to follow the lead of the FAA,” the manufacturer adds. Boeing resumed deliveries of 787s in August 2022 following a 10-month hiatus after the FAA raised concerns about its proposed method of inspecting aircraft that had identified quality issues relating to gaps in the forward pressure bulkhead.
That saw the backlog of built but undelivered 787s swell to around 100 aircraft, most of which were planned to be delivered this year following re-work. Boeing has indicated that it plans to raise production of new 787s to five per month by the end of 2023, and then to 10 per month in 2025-26. Data shows that the airframer has 575 787s on order, including aircraft that have already been built and not yet delivered, and options for a further 249.