Boeing Rolls Out First Factory-Complete 737 at Higher Rate

first factory-complete Next-Generation 737 at the production rate of 35 
airplanes a month on Dec. 4. The new 737-800 was towed to nearby Renton Field 
where Boeing conducts functional testing and first flights for all new 
airplanes. Though the airplane still must undergo testing and painting, the 
milestone represents a major step in demonstrating that Boeing is on track to 
achieve its announced rate increase of the popular jetliner to 35 a month in 
early January when it delivers the airplane to Norwegian Air Shuttle. 

“The team took lessons from past rate increases and said, ‘We can do this 
better,’ and all indications are that they have,” said Beverly Wyse, vice 
president and general manager of the 737 program. “We owe a special thanks to 
our partners in Boeing Supplier Management and Fabrication who have kept 
shortages at an unprecedented low level for this stage in the rate process.” 

Teams have been preparing for more than a year in some cases. An example of 
early preparation can be seen in the production line where employees install 
electrical systems into the newly built wing boxes. The team eliminated a 
line where employees worked on both left-hand and right-hand wings and moved 
those employees to extended lines where they were dedicated to either the 
right-hand or left-hand wings, removing variables that slowed down 
production. Additionally, in August, improvements to efficiency such as 
arranging the work and the work environment so that employees can more easily 
complete their tasks supports a rate of up to 42 airplanes a month. 

Boeing has taken a three-fold approach to prepare for the rate increases on 
the 737 program. The company is making production processes more efficient by 
working with employee process improvement teams; increasing the production 
capacity with capital investments and making the site footprint more 
efficient by moving some production areas and expanding others; and 
decommissioning outdated equipment. 

Boeing will increase the 737 rate to 38 airplanes a month in the second 
quarter of 2013 and to 42 airplanes a month in the first half of 2014.