Manufacturing and suppliers
After stiff competition, Boeing announced on December 16, 2003, that the 787 would be assembled in its factory in Everett, Washington.[5] Instead of building the complete aircraft from the ground up in the traditional manner, final assembly would employ 800 to 1,200 people to join completed subassemblies and to integrate systems.[35] Boeing assigned its global subcontractors to do more assembly themselves and deliver completed subassemblies to Boeing for final assembly. This approach was intended to result in a leaner and simpler assembly line and lower inventory,[36] with pre-installed systems reducing final assembly time by three-quarters to three days.[37][38]
Assembly of a "Section 41", the nose section of the Boeing 787
Subcontracted assemblies included wing manufacture (Mitsubishi Heavy Industries, Japan, central wing box)[39] horizontal stabilizers (Alenia Aeronautica, Italy; Korea Aerospace Industries, South Korea);[40] fuselage sections (Global Aeronautica, Italy; Boeing, North Charleston, USA; Kawasaki Heavy Industries, Japan; Spirit AeroSystems, Wichita, USA; Korean Air, South Korea);[41][42][43] passenger doors (Latécoère, France); cargo doors, access doors, and crew escape door (Saab AB, Sweden); software development (HCL Enterprise India);[44] floor beams (TAL Manufacturing Solutions Limited, India);[45][46] wiring (Labinal, France);[47] wing-tips, flap support fairings, wheel well bulkhead, and longerons (Korean Air, South Korea);[48] landing gear (Messier-Dowty, UK/France);[49] and power distribution and management systems, air conditioning packs (Hamilton Sundstrand, Connecticut, USA).[47][50] Boeing is considering bringing construction of the 787-9 tail in house; the tail of the 787-8 is currently made by Alenia.[51]
To speed up delivery of the 787's major components, Boeing modified four used 747-400s into 747 Dreamlifters to transport 787 wings, fuselage sections, and other smaller parts. Japanese industrial participation was very important to the project, with Japanese companies co-designing and building of 35% of the aircraft. This was the first time outside firms were given a key role in the design of Boeing airliner wings. The Japanese government also provided support with an estimated US$2 billion in loans.[52] On April 26, 2006, Japanese manufacturer Toray Industries and Boeing announced a production agreement involving US$6 billion worth of carbon fiber, extending a 2004 contract and aimed at easing production concerns.[5] In May 2007 final assembly on the first 787 began at Boeing's Everett, Washington plant.[53]
The 787 project became less lucrative than expected for some subcontractors. Finmeccanica had a total loss of €750 million on the project by 2013.[54]