In a significant shift for its production strategy, Boeing has officially concluded repair operations at its dedicated 787 Dreamliner rework facility, redirecting its skilled mechanics to bolster the 777X production program. This development, announced by Boeing Commercial Airplanes CEO Stephanie Pope in early March 2025, marks the end of a challenging chapter for the 787 Dreamliner that began in 2020 with the discovery of small fuselage gaps. These manufacturing defects, though not compromising structural integrity, failed to meet Boeing’s stringent specifications, leading to a costly five-year repair process that diverted resources and delayed deliveries to airline customers. The final repaired aircraft, a 787-10 built in South Carolina in December 2020, recently completed its rework in Everett, Washington, closing out a backlog of 122 stored Dreamliners.
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The fuselage-gap issue first surfaced in fall 2020, halting 787 deliveries almost entirely until August 2022, with only 14 planes delivered between November 2020 and that resumption date. The labor-intensive fixes required meticulous disassembly and reassembly to address paper-thin gaps at fuselage joints, costing Boeing an estimated $6.3 billion in abnormal expenses by 2023. Completing this rework allows the company to dismantle what Pope referred to as “shadow factories”—temporary setups that pulled hundreds of mechanics away from building new aircraft. With this phase behind them, Boeing is now reallocating those workers to the 777X program, a next-generation widebody jet that promises enhanced efficiency and capacity but has faced its own delays, with certification now targeted for 2025.
This transition comes at a critical juncture for Boeing. While the 787 repair saga concludes, production challenges persist. In North Charleston, South Carolina, a growing inventory of newly built 787s remains grounded due to parts shortages, notably business-class seats awaiting certification and heat exchangers disrupted by the ongoing war in Ukraine. Boeing CEO Kelly Ortberg recently noted progress in sourcing alternative heat exchanger supplies, yet the seat delays remain a bottleneck. Meanwhile, the 777X, an update to the successful 777 series, awaits its debut with 481 orders on the books, nearly half from Emirates. Stored 777X jets, once certified, will require extensive preparation—relubrication and system updates—before entering service, adding pressure to streamline production.
Boeing’s decision to reassign mechanics reflects a broader effort to refocus on new aircraft rather than legacy fixes. The Everett plant, where the final 787 repairs were completed, will now ramp up support for the 777X alongside ongoing 767 and KC-46 tanker production, following the 747’s retirement in 2022. This move aligns with Boeing’s long-term goal of stabilizing its widebody programs after years of setbacks, from the 787’s initial woes to the 737 MAX crises. By reallocating talent to the 777X, Boeing aims to accelerate certification and delivery timelines, addressing customer demand for larger, more efficient aircraft on premium routes. Despite lingering supply chain hurdles, this strategic pivot signals confidence in turning the page on past troubles and positioning the 777X as a cornerstone of its future lineup.