Few aircraft are more closely watched than the Boeing 737.
asserted
aircraft → watch → 737
Since first rolling off the assembly line in 1967, it has been in continuous production, and more than 12,000 airframes have been sold.
asserted
airframes → roll → production
In the process, it has created a legacy that has defined modern air travel, shaping how airports are built and the business models of airlines.
asserted
airports → create → airlines
Boeing 737s are everywhere in global aviation – comprising whole fleets in some cases, and making up the backbones of others, such as those of Qantas and Virgin’s domestic operations.
asserted
737s → comprise → Qantas
In recent years, however, the world’s most important commercial airliner has received attention for another, troubling, reason.
asserted
airliner → receive → reason
The 737 has been tainted by design defects and quality control failures, most notably highlighted by the tragic crashes of two 737 MAX 8 jets in 2018 and 2019, which led to a worldwide grounding and direct US Federal Aviation Administration production oversight.
asserted
which → taint → grounding
The aviation icon now sits at the centre of a crisis of trust, but is, in a way, a symbol of American – and even Western – manufacturing.
asserted
icon → sit → manufacturing
The symbolism is underpinned by commercial realities.
asserted
symbolism → underpin → realities
The other pressing reason the 737 gets so much attention
asserted
reason → get → attention
is that the world’s airlines remain hungry for new, more efficient 737 MAX airframes.
asserted
airlines → remain → airframes
The MAX uses 20 per cent less fuel than previous versions of the 737.
asserted
MAX → use → 737
Boeing says the MAX line offers airlines greater profit potential and it averages 7 per cent lower operating costs with up to 14 per cent lower maintenance costs than its competitor.
asserted
it → say → competitor
This masthead recently secured access to a Boeing factory (after lengthy negotiations with the company) in Renton, Washington state.
asserted
masthead → secure → Renton
The 737 begins life as the fuselage, shipped in by train from Kansas, where it’s made, and enters the factory.
asserted
it → begin → factory
Fuselages arrive by rail, in the distinct green colour of their protective primer.
asserted
Fuselages → arrive → primer
From there, each fuselage is rolled and lifted into position in an elevated part of the factory, where it is inspected.
asserted
it → roll → factory
Insulation, electronic, hydraulic, and mechanical parts are then installed.
asserted
parts → instal → ?
At this point, the fuselages are lined up closely three abreast as they undergo their first three “flow days” – a term for the station of production.
asserted
they → line → production
It takes 10 flow days, with each day representing a specific stop along the assembly line for the fuselage – to put a 737 together.
asserted
day → take → 737
The first three comprise wiring (about 70 kilometres’ worth), and putting in hydraulic tubing, flight control cables, the dorsal fin, and the controls within the flight deck.
asserted
three → comprise → deck
A protective cover for the radar at the tip of the plane’s nose is also installed in this phase.
asserted
cover → instal → phase
The pacing of production is designed with enough of a gap to allow for minor delays or unexpected changes.
asserted
pacing → design → delays
On day four, the fuselages are moved down from the upper level of the factory onto the floor.
asserted
fuselages → move → floor
To get them into lines, a crane mounted in the ceiling of the enormous facility moves them through a special gap in the wall into three parallel floor assembly lines.
asserted
crane → get → lines
Here the fuselages are spread out nose to tail.
asserted
fuselages → spread → tail
The three floor assembly lines are called the West Line, the Central Line and the East Line.
asserted
lines → call → ?
This year Boeing opened a North Line for 737 production.
asserted
Boeing → open → production
Based in Everett, Washington, the North Line will expand Boeing’s capacity to build 737 MAX-family jets to meet market demand, including a current order backlog of 4300.
asserted
Line → base → 4300
In the Renton factory, movement by crane happens at night, and it takes about an hour per fuselage.
asserted
it → happen → fuselage
The factory runs 24 hours a day year-round except Christmas and the Thanksgiving holiday in late November.
asserted
factory → run → November
Compared with Airbus factories, Boeing’s shop floor is more densely filled with equipment, and seems more like a factory.
asserted
floor → compare → factory
Staff call out to each other over the machine sounds of production.
asserted
Staff → call → production
Workstations where specialised tasks and technical problem-solving take place are positioned along the floor.
asserted
tasks → take → floor
Between the buildings, staff move on shuttles, cars and scooters.
asserted
staff → move → shuttles
The train line bringing the fuselages from Kansas comes right through the campus.
asserted
line → bring → campus
This is when it gets its wings, horizontal and vertical stabilisers, and landing gear.
asserted
it → get → wings
(The winglets, or tips of wings that flare up and down, are primarily made at Boeing’s Melbourne facility in Fishermans Bend.)
asserted
that → flare → Bend
From there, the plane can rest on its own weight and is ready for the next step, in which the toilets, galleys and water and wastewater tanks are installed.
asserted
toilets → rest → which
The side walls, overhead bins and forward galleys are installed the day after.
asserted
walls → instal → ?
Carpeting and seats come on day eight.
asserted
Carpeting → come → day
…and 10 more, not listed.
The Aporia
