Boeing has found an additional 787 manufacturing problem that affects the aircraft’s horizontal stabilisers, following the recent disclosure of two other issues. The issue relates to extra force used when clamping together certain components, which could lead to an aging issue, says the airframer. “A nonconformance was discovered with Boeing Salt Lake’s production of 787 horizontal stabilisers,” it says. “During the build process, certain components were clamped together with greater force than specified by engineering, which could lead to premature aging of this part of the airplane. It is addressing the issue with aircraft still in the production process, and is checking to see if remedial work is required for in-service 787s. “This is not an immediate safety of flight issue as none of the airplanes in service are within a window where they could begin to experience this aging. Safety and quality are Boeing’s highest priorities. We have taken the appropriate steps to address this production issue and ensure that the requirements are clearly defined and understood.” The announcement follows the recent revelation of two separate manufacturing issues. One relates to shims of the incorrect size being installed on some aircraft. The other issue relates to some aircraft having areas of skin that fail to meet skin flatness specifications. While 787s that have just one of these issues can still operate, aircraft with both issues need to be grounded. As such, Boeing’s issued a grounding order related to eight 787 aircraft operated by Singapore Airlines, United Airlines, and Air Canada. All Nippon Airways also advised that one of its 787-10s was grounded at the behest of Boeing. The shim and flatness issues have also prompted the US Federal Aviation Administration to launch a probe into manufacturing issues at the airframer. Fleets data indicates that there are 740, 787s in service and 244 in storage. In addition, there are 526 orders for the widebody.

Source: Cirium

Airbus A220 operators are being instructed to modify drain tubing after an incident in which rainwater dripped into the avionics bay and tripped a circuit breaker during taxi, causing an engine to shut down. Rain had entered the aircraft through the main cabin entry door while it was open, according to Transport Canada. This caused drains to overflow and led to dripping on the forward avionics bay below. “Water ingress into the forward avionics bay could short-circuit the equipment in the area and lead to a loss of air-data sources,” says the regulator. This might result in a reduction in function and an increase in the crew’s workload, it adds. A220 operators are being ordered to modify the aircraft, within 12 months, by removing forward galley slotted drain covers, fitting solid blanking plates, and blocking drain tubing to prevent water travelling from the forward galley into the avionics bay. All A220s are fitted with Pratt & Whitney PW1500G geared turbofan engines.

Source: Cirium

The US Federal Aviation Administration has launched an investigation into manufacturing issues that could affect some Boeing 787s, as ANA confirms that Boeing asked it to ground one 787-10. “The Federal Aviation Administration is investigating manufacturing flaws affecting certain Boeing 787 jetliners,” says the FAA. “The agency continues to engage with Boeing. It is too early to speculate about the nature or extent of any proposed Airworthiness Directives that might arise from the agency’s investigation.” In late August, Boeing ordered that eight recently-built 787s be removed from service because of two “distinct manufacturing issues". A Wall Street Journal report, citing an internal FAA memo, says US regulators are reviewing lapses in quality control at the company’s Charleston factory. The two issues appear to be “nonconforming” rear fuselage sections, as well as how the company produces shims for the 787 at Charleston. Reports have suggested that the issue relates to aircraft produced at Charleston in 2019, although Boeing is apparently assessing the entire 787 fleet. All Nippon Airways (ANA) has removed one Boeing 787-10 from service following an advisory from Boeing. The aircraft bears the registration JA901A (MSN 62685), according to the airline. ANA did not cite the specific circumstances related to JA901A’s service withdrawal. “We have been notified of the situation by our valued partner Boeing and immediately removed the one aircraft dedicated to international flights from service,” says ANA. “As the launch partner of the 787 and operator of the largest 787 fleet in the world, we will work with our partners and regulators to develop a solution. While we are still assessing the situation, with the reduced market demand for global destinations, this aircraft doesn’t need to be returned to service immediately.” According to data, JA901A was handed over to the airline on 30 June 2019. The jet was placed in storage on 16 August 2020. The carrier has one other 787-10, JA900A (62684), that is listed as in service. Overall, ANA’s 787 fleet comprises 64 787s, of which 13 are in storage. In addition, it has orders for 12 additional -10s and nine -9s. Vietnam Airlines, which operates 11 787-9s and four 787-10s, says it contacted Boeing upon learning about the structural issue. “We contacted Boeing regarding this matter,” says Vietnam Airlines. “Boeing confirmed that the issues were found on eight airplanes which initiated a continued operational safety program and safety determination. None of these planes is within Vietnam Airlines.” Of its four 787-10s, three examples were delivered in 2019. Cirium fleets data lists its entire 787 fleet as in service. FlightGlobal has yet to receive comment from other Asia-Pacific 787 operators. Boeing’s initial grounding order, first disclosed by The Air Current, related to eight 787 aircraft operated by Singapore Airlines, United Airlines, and Air Canada.

Source: Cirium