Boeing expands search for structural defects on 787 Dreamliners

Boeing has widened its inspections of newly built 787 Dreamliner planes to hunt for additional manufacturing defects that could prematurely age the jets’ carbon-fiber frames. While US regulators say the faults don’t pose an immediate hazard, the emergence of another flaw in Boeing’s most advanced jetliner is slowing deliveries and raising doubts about quality controls. The company didn’t deliver any 787 jets in November, Chief Financial Officer Greg Smith said earlier this month, citing inspections that took longer than expected. The latest issue involves tiny variances, or wrinkles, in the interior lining where composite fuselage barrels are linked to create the Dreamliner’s structure. In some instances, the so-called join “may not meet skin flatness tolerances,” Boeing said. The Chicago-based planemaker has asked suppliers to review their processes, adding that “certain items” had come to light as it beefed up its quality assurance program over the last 12 months. Boeing is inspecting 787s in factories, as well as newly built aircraft that are awaiting delivery, said a person familiar with the matter. Boeing and the FAA are analyzing data to determine the best course of action for Dreamliners that are already in service. The FAA confirmed that it’s working with Boeing on the issue but didn’t provide additional details.<br/>