The flaw may affect about 90 already-built Dreamliners that the company has not yet delivered, Boeing said on Tuesday.
It will inspect each plane for improperly sized gap-fillers within the horizontal stabilizer, a tiny wing attached to a jet’s tail. A handful of 787s on the final assembly line within Boeing’s North Charleston, South Carolina, facility will also need to be inspected for the faulty gap-fillers, known as shims, and repaired.
In the near-term, Boeing’s latest production glitch is likely to exacerbate a shortage of new aircraft as airlines struggle to keep up with a post-pandemic jump in air travel. The US planemaker and its rival, Airbus SE, have been contending with supplier and labor strains that are crimping their ability to ramp up production.Dreamliner production won’t be halted, Boeing said.
Boeing and US regulators are still determining what action, if any, will be necessary for the in-service 787 fleet, Boeing said. The flawed stabilizer parts, which were discovered last week, aren’t considered an immediate safety of flight issue by US regulators. That means that emergency repairs aren’t needed for Dreamliners already in commercial service at airlines.
The US planemaker paused 787 deliveries earlier this year, and is only just recovering from tiny structural defects that halted Dreamliner shipments during 2021 and 2022. Boeing targets increasing output of the Dreamliner to a 10-jet monthly pace by mid-decade, a goal that’s crucial to meeting Chief Executive Officer Dave Calhoun’s target of generating $10 billion in cash by 2025 or 2026.
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