The Boeing 787-8 Dreamliner

Tips for Potential BCA Advanced Composite Suppliers

In the early production days of the 787 Dreamliner, I had a challenging four-year international assignment with Boeing Commercial Airplane Company. My role, along with a large team of engineers and quality specialists, was to conduct technical audits prerequisite to supply the advanced composite fuselage and wing assemblies of the 787.

Much of the frustration and delay that composite suppliers and auditors alike endured throughout that process was unnecessary. Suppliers did not have a complete understanding of what was required; auditors were inconsistent with their interpretation of the requirements.

I now consult for suppliers wanting to do business with Boeing partners.

As of August 2021, Boeing now is on a recovery path from the duel crisis of the 737 MAX grounding and the COVID-19 impact on air travel and worker safety. This path to recovery may offer opportunities to global composite suppliers early in 2022 at best.

Obtaining a contract from a Boeing partner is only the first step. Assume a supplier already has AS 9100 & AQMS certifications. What comes next?

• NADCAP AC7118 Certification

• D6-53993 – Qualification of Sources for Composite Parts to BAC 5317, BAC 5578 or BAC 5353

• BAC 5980 – Nondestructive Inspection of Composite Parts and Structures

• D6-55902 – Qualification of Equipment for Fabrication of Composite Structure

• D6-49327 – Qualification of Autoclaves and Ovens for Curing Composite Structure

• BSS 7341 – Part/Tool Thermal Profiling Procedure

• BSS 7082 – Preproduction Verification Procedures and Requirements

• BSS 7085 – Approval Process for Composite Part Manufacturing Plans

• BSS 7029 – First Part Qualification Procedures and Requirements for Composite Part

It may be a while before Boeing seeks new composite suppliers. However, when they do, C-B-D has a proven track record in cost-effectively guiding suppliers through this overwhelming array of qualification events. If your organization is preparing a BCA work package, we can help you survive it! For more information please call us at 831-200-1222.