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A Factory Tour

Tim and I decided that to deter boredom on a Monday in Arlington while Jaci was at work- we could take a tour of the Boeing plant in Everett. Because of my experience at Porsche in Stuttgart I figured that it would be a PR junket for the company, and probably a large gift shop with very worthless (but expensive) logo gear. Cynical as I may have been, I assumed that at the very least, there might be some good history to learn; and it was a nice day to watch airplanes land and take off at Paine field. Anyway, we both figured it wouldn’t be something Jaci would be interested in- so we may as well check it out since we had the chance. Little did we know that we were in for a very pleasant surprise because the tour was absolutely riveting and educational!

When I looked online for Boeing tours, I discovered that this was actually a premier tourist attraction. I thought that we could probably just show up at the Future of Flight building- a tiny Boeing museum near the main plant, and that we would be able to get in on a simple tour of the grounds. I did not expect that we would need reservations (we did, we almost didn’t get tickets because we called the day before) and that usually the 6 scheduled 90 minute tours would fill up quickly. The tickets got you into the main plant- we were escorted there by bus- and we could see the entire factory floor, plus access to the interactive Boeing experience, and the Stratodeck to observe flight operations at Paine Field! They cost $15.50 a person, twice as much as a movie ticket, but very worth it!

The Largest Building in the World by Volume

Before entering the tour, we were asked by a well armed guard to lock our cell phones, cameras, and any other electronic gear in a rental locker. We weren’t sure if this was to stop industrial espionage, equipment interference, or flashes but the security was very tight. Other restrictions included a height restriction, and advice that if you couldn’t descend and climb 21 steep stairs or walk a kilometer they would have to provide an accessible option apart from the main group. This only made me positive that we were going to see some cool stuff, though!

After a short introductory video, we clambered aboard a very nice, modern coach bus for a short drive from the Future of Flight Building, across an access road that skirted the Paine Field runway, to the main manufacturing building. Along the way we passed dozens of brand new jets parked on the tarmac outside paint hangers and other support and fuel buildings. Soon, though, we were parked in front of a massive hanger door.

If you have ever been down the Mulkiteo Speedway, you will have noticed this humongous  hanger complex that is the largest building in the world by volume. In fact, you could fit all of the Walt Disney World  theme park inside of this building and still have room for an indoor parking lot that could hold 1200 cars! The doors, painted blue with Boeing logos are roughly the size of American football fields- 90 feet high by 300 feet long! It looks big, certainly, but when you are standing, engulfed by those doors, it makes you feel downright Lilliputian!

Assembling Twin-Aisle, Wide Body Aircraft

The tour guide (Paul) led us down into an access tunnel that was a kilometer long- each of the 6 manufacturing bays have one. The tunnel runs pipes, cords, and people safely below the assembly floor- in fact, it is used by Boeing employees for exercise during bad weather! The tunnel was long, well lit, and had a laminated concrete floor. I could just envision all the fun things I could do in that tunnel with roller blades, bikes, moving dollies and a tow rope (or vegetable oil and a mattress)…

Halfway down the tunnel we came to a giant freight elevator that took us to the top floor of the middle of the E-shed. The floor was a visitors lobby with security guards, speakers for the tour guide and an amazing overlook view of the 747-8 Assembly station! Previous, smaller jets like the 727 and 737 had been manufactured by a moving assembly line (picture a giant scaffolding on wheels that grew over an aircraft being assembled as it moved down the assembly floor). Unfortunately the 747 was much to massive to be assembled in this way- so it is assembled in static stations.

In the front bay doors are giant aluminum sheet metal cutters, then stations for wing assembly. Wing skeletons are then connected with their control structures in a wing assembly area. The fuselage also has separate assembly structures running gown the far end of the bay. Then coming back down the other side of the bay all the pieces are put together. First, the central fuselage piece are attached to the wings, then the plane moves forward to a giant oven that cures the sealant. The plane moves forward where the front fuselage and tail pieces are moved by ceiling crane to be affixed the central portion and wings. This assembly area has air wing shaped concrete platforms that perfectly fit the growing aircraft. These structures are also used for access to add wiring and other control and structural elements.

After the main assembly, the landing gear is placed on the aircraft, from which point it moves forward as a single structure. Two more angled parking spots allow the plant workers to add the interior as well as do any testing and structural work that needs to be done. Needless to say, this bay is big enough for 5 747 aircraft lined up from nose to tail with space between! It is a massive scale! Sorry that I don’t have pictures- but again, they wouldn’t allow us to bring the camera on the tour.

A Stunning View

Too soon we were pulled from the overlook to move on with the rest of the tour. 747s are awesome, humongous, recognizable aircraft, and to see their birth was pretty extraordinary. However, as we went back down the tunnel to be transported by the bus to the new hangers, we were in for a similar surprise.

The new hangers were built to create the new 777 and 787 aircraft. As before we were taken to a tunnel to be lifted to the top overlook floor. However, the top overlook floor for the 777 and 787 bays was much, much nicer. Digital TVs, scale models, carpet, and sofas greeted us along with the fabulous view of the future of the airline industry (and its pretty cool present).

If you don’t know too much about the aircraft that carry you when you travel, it may be a surprise to you that there are only really 2 companies that manufacturer your ride- Airbus and Boeing. Boeing aircraft used to be dominant in an airline’s fleet, but Airbus’ sleeker, more efficient planes soon gained a significant market share (think PC vs. Mac). While the 747 had been the workhorse of International Travel – the A340/380 could carry more passengers, farther, for less fuel. Boeing’s answer was the 777.

The 777 is a twin-aisle wide bodied, twin engine aircraft with the farthest range of any commercial aircraft, ever. It is sleek, fuel efficient, and it is the airframe that has carried me back and forth across the Atlantic all except one time. It is an amazing piece of engineering with over 6 million components. In fact the landing gear (seen above) is so high tech, it is the single most expensive component on the plane except for the engines!

We were treated by  a view of the moving assembly line that creates the 777. The line- a scaffold on wheels that grows over aircraft as it is assembled – moves at 1.6 feet per minute and can be accessed by stair by the workers. Once again, overhead cranes carry pieces of the aircraft from their assembly bays to the moving line. We watched as the 35th 777 for Egypt Air was being finalized on the cleanest factory floor I’ve ever seen.

However, the 777 is not the future. The future is Boeing’s 787 Dreamliner aircraft that just had its first flight a few weeks ago.

The Future of Flight

Walking around a partition in the gallery we came to a view of the newest bay that is now being used to assemble the 787 Dreamliner. The 787 is a modern 250 seat aircraft that is made of lightweight, stronger than steel composite material. The modern GE engines are super fuel efficient, and that combined with its light weight gives the 787 an excellent range at highly economic costs.

The stronger material also allows the aircraft to be pressurized at 6000 feet, way more comfortable than the 8000 FAA mandated pressure that is normal now. In addition, the air is humidified, which means no more dry mouth! The composite wings also can bend 12 feet in either direction- meaning that they absorb much of the turbulence! Very soon, airline passengers should be treated to lower cost, way more comfortable flights on these amazing aircraft!

787s are manufactured in a completely new way as well. Parts are no longer manufactured at the Boeing plant, but completed and integrated in specialty plants around the world. They are flown to the Everett plant via the Dreamlifter- a mega lifter created specially by Boeing for the job- essentially a modified 747 whose upper deck has been extended the entire length of the aircraft (it looks like a giant hot dog). The tail is on a giant hinge that can swing out to load entire sections of the 787 at once! Once flown to Everett, the Dreamliner can be assembled at a rate of one aircraft every three days!

To manage the global dispersion of the 787 manufacturing, the newest bay has a modern command center that looks like it belongs in NASA or a SciFi movie! Massive screens track the locations of all the parts as well as the percent completion of every 787 aircraft in production. Reps from every company involved are also forced to man the command center (presumably so that if something goes wrong they can immediately be chewed out!) Manufacturing of the 787 is a modern, technologically, and communication savvy process that is extremely sophisticated and impressive!

A Beautiful Day Watching Air Operations

After the tour, we went back to the Future of Flight museum to look around. We got to play in a real cockpit, design our own aircraft, and experience an interactive tour of the engines. While we were playing like kids in a candy store, we had the misfortune of hearing the massive wind-up of 4 Rolls Royce jet engines that indicated we missed the take off of one of the enormous Dreamlifters. Because of that, though, we discovered that there was an observation deck with a cafe where we could watch the testing air operations for the new aircraft!

The tour was more than I could have expected. Boeing really took care of their guests, providing access without disruption, and allowing complete viewing of the aircraft manufacturing process. The galleries and viewing areas were impeccably designed and furnished, and very comfortable. I could not ask for a better experience in a factory! If you are in Everett, the Boeing Future of Flight Tour is a must see!

More pictures of the day: