Tag: Boeing

Boeing to take more than a decade to refit two 747s for Air Force One

7:30 pm

Utter incompetence: According to recent news reports, Boeing will not be able to deliver the two 747s it is refitting to be the president’s Air Force One fleet until 2029, even though it signed a $3.9 billion contract to do so in 2018.

The delay is startling given that Boeing isn’t building the planes from scratch. During Trump’s first term, Boeing started to overhaul two 747s that were built for a Russian airline that never took the jets.

This is more than absurd, it is obscene. Boeing is handed two flightworthy 747s and almost $4 billion, and it can’t refit the two planes in less than a decade? It seems one of the first things Trump should do once he returns to office next month is cancel this contract entirely, demand a refund from Boeing, and simply convert his present fleet of “Trump Force One” airplanes that he has been using since 2020 for use as president. Cheaper, faster, and certainly a wiser use of taxpayer money.

As for Boeing, this story illustrates once again how far this company has fallen. Remember, it was Boeing that conceived, designed, and built the 747. Moreover, its 747 has been used for decades for Air Force One. For its engineers now to be incapable to refitting another two 747s for this purpose seems inconceivable, and suggests those same engineers should not be trusted on any new planes they build.

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Union official accuses Boeing of more unsafe practices

10:44 am

According Craig Garriott, a union representative at Boeing’s satellite-manufacturing facility in Los Angeles, Boeing’s management has been allowing numerous safety violations to go unfixed in order to focus on profits and fast production.

Acquired by Boeing in 2000, the satellite manufacturing facility has long been considered one of Boeing’s more stable business units. It relies in part on a union workforce that Garriott said is responsible for constructing and testing satellites and their component parts.

“This is perhaps the most technical group of hourly people that you’ll probably find on this planet,” said Garriott, who estimated he’s raised between 300 and 400 safety violations over the past year. Those complaints, he said, range from obstructed fire extinguishers and fire alarms to concerns over heavy machinery blocking exits and trapping workers in certain parts of the factory.

In October, union workers filed a complaint with the Occupational Health and Safety Administration that, according to Garriott, highlighted unsafe conditions on the factory floor. Another technician at the facility, who spoke to CBS News on the condition he remain anonymous to protect his job, said safety had become “an afterthought” and quality had “degraded” over the past five to six years.

It is important to recognize that Garriott’s complaints might simply be the typical tactic of a union representative during or before contract negotiations. There are rumors Boeing plans to sell off its space subsidiaries, which would include this satellite division. Garriott might simply be putting public pressure on the company in order to give himself a better negotiation position if such a sale takes place.

It is also quite possible, based on Boeing’s recent very poor track record in quality control, that everything Garriott says here is also true.

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Boeing finally shuts down its DEI division

12:33 pm

Boeing's racist hiring goals in 2024
Boeing’s racist hiring goals in 2024

According to a report from Bloomberg news today, Boeing has now dismantled its Diversity, Equity, and Inclusion (DEI) division, with its head leaving the company.

Staff from Boeing’s DEI office will be combined with another human resources team focused on talent and employee experience, according to people familiar with the matter. Sara Liang Bowen, a Boeing vice president who led the now-defunct department, left the company on Thursday. [emphasis mine]

The highlighted phrase above tells us all we need to know. The focus under Boeing’s new CEO Kelly Ortberg will be “talent and employee experience,” not skin color or gender.

Bowen wrote the following in announcing her dismissal:

It has been the privilege of my lifetime to lead Equity, Diversity, and Inclusion at the Boeing company these past 5+ years. Our team strived every day to support the evolving brilliance and creativity of our workforce. The team achieved so much – sometimes imperfectly, never easily – and dreamed of doing much more still. [emphasis mine]

As far as I can tell, all that Bowen accomplished was to destroy the reputation of Boeing as a quality manufacturer of aerospace products. Instead, it became a place which hired people based on their race, and didn’t care if they knew the difference between a screwdriver and a forklift. The screen capture to the right comes from the company’s 2024 Boeing Sustainability & Social Impact Report [pdf], which is still online, as is the webpage of Boeing’s DEI division. Both still tout the racist quota goals of this DEI department that forced the company to consider race and gender above talent and experience in its hiring. Hopefully that ugliness will vanish soon as well.

Meanwhile, Boeing union employees on the west coast are about to vote on a third contract proposal, having rejected the previous two and going on strike since mid-September. I suspect the decision above to get rid of this poisonous DEI department will sit well with those union employees, and likely help to encourage them to approve the plan.

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ExoAnalytic now identifies more than 500 pieces from Intelsat satellite breakup

9:57 am

The private commercial space tracking company ExoAnalytic has now identified more than 500 pieces from Intelsat 33e satellite breakup.

Some of the smaller debris might actually quickly disappear as these pieces are possibly bits of solid fuel that will evaporate.

Much of the press has suddenly decided this failure is all Boeing’s fault, because the satellite was built by that company a decade ago. This seems a bit unfair, since Boeing’s problems now seem far removed from its design and construction of satellites then. At the same time one must wonder. Boeing built four of these type satellites for Intelsat, and the first was lost in 2019 when either it was hit by a meteor or had “a wiring flaw, which led to an electrostatic discharge following heightened solar weather activity.”

That means two of the four satellites have been lost, though the second, 33e, didn’t break-up until twelve years of operation, almost its expected lifespan. Furthermore, the other two satellites are still working fine.

All in all, that suggests to me that though there may be a technical cause that can be traced back to the company, it is more likely we are simply seeing a random expression of the dangers of space to engineering, by anyone.

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Boeing considering selling its space division

11:55 am

According a Wall Street Journal exclusive today (behind a paywall), the company is now exploring the possibility of selling off its space division.

The NASA business that Boeing is exploring a sale of includes the troubled Starliner space vehicle and operations that support the International Space Station, but excludes the unit building NASA’s Space Launch System, the newspaper reported.

The U.S. planemaker’s shares rose 0.6% in afternoon trading.

Boeing’s space division includes its Starliner capsule and its work on NASA’s SLS rocket, as well as building many of the modules on ISS and operating it for NASA.

If this is so, it appears the new CEO, Kelly Ortberg, has decided that in order to get the company back on track it needs to focus on Boeng’s first and central business, building airplanes. Space is a distraction that is not helping the company bottom line right now in any way. Furthermore, NASA in 2020 told Boeing it would not entertain any new project bids from the company because its past bids were so poorly conceived. That decision remains in effect now, four years later. Since then Boeing has only have gotten a renewal contract to build more SLS rockets, plus a contract to develop a new airplane wing, but little else.

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Boeing forced to take another $250 million charge on Starliner

9:19 am

Because of the continuing problems getting its Starliner manned capsule operational, Boeing has now taken another $250 million charge on the project, raising the total spent of its own money to $1.85 billion.

The company’s original fixed-price contract with NASA to deliver the capsule was $4.2 billion. The bulk of that won’t be paid until Starliner begins flying astronauts commercially, and NASA has now delayed that until 2026 at the earliest. The company’s new CEO, Kelly Ortberg, has now made it clear that he is focused on imposing changes to fix the bankrupt engineering management culture that has caused it so many failures in so many of its recent projects, not just Starlner. In his remarks announcing the company’s third quarter results, he said this:

The trust in our company has eroded. We’re saddled with too much debt. We’ve had serious lapses in our performance across the company which have disappointed many of our customers.

In addressing these issues Ortberg listed a whole range of changes, many of which focused on getting managers more closely involved in design and construction, or as he said, management needs “to be on the factory floors, in the back shops and in our engineering labs.”

Whether he will succeed is unknown. Its factory workers today rejected a new contract offer, continuing their now six-week strike that has halted work on company’s airplane business. In addition, Boeing reported a loss of $6 billion in that third quarter report.

One thing Ortbeg did make clear this week however: Boeing is not walking away from its Starliner contract with NASA. At a minimum it will complete that initial fixed price contract. Whether it will go on to fly more Starliner missions however Ortberg left open. I suspect he remains in negotiation with NASA over this issue.

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NASA appears to be about to drop Boeing’s Starliner from its manned mission schedule in 2025

10:17 am

In a short announcement outlining its planned two manned ISS missions for 2025, NASA by omission revealed that it now does not expect Boeing’s Starliner capsule to be ready for the second manned flight in July 2025, as previously planned.

Previous updates had noted what capsule would launch the astronauts, with the plan to have Dragon launch the February 2025 crew and Starliner the July 2025 crew. It was assumed in those earlier updates that Starliner would be certified for operational use after the completion of its first manned demo this past summer. This new update does not provide this capsule information, instead saying the following:

The timing and configuration of Starliner’s next flight will be determined once a better understanding of Boeing’s path to system certification is established. This determination will include considerations for incorporating Crew Flight Test lessons learned, approvals of final certification products, and operational readiness.

Meanwhile, NASA is keeping options on the table for how best to achieve system certification, including windows of opportunity for a potential Starliner flight in 2025.

It appears NASA is pulling back from that certification, based on the various technical issues experienced by Starliner during that demo mission, issues that eventually forced NASA to return the capsule unmanned. As such, this announcement yesterday suggests that there is serious negotiations going on between Boeing and NASA as to what will happen next. It appears the agency wants Boeing to fly another demo mission — on Boeing’s dime — before putting astronauts on board and paying for a mission. The Starliner contract was fixed price, and until Boeing successfully completes that manned demo mission NASA is not obligated to pay it any additional funds.

I suspect Boeing is telling NASA it can’t afford to do this, and if NASA doesn’t pony up some bucks for that demo flight it will simply not do it, and NASA will be stuck with just SpaceX as its manned ferry to ISS.

Unconfirmed reports had suggested NASA was considering issuing Boeing a separate contract to do a cargo mission to ISS using Starliner, thus allowing it to pay the company to fly a test mission outside of the fixed price contract. This NASA update yesterday suggests these negotiations are on going, but likely cannot be completed until after the election. A new administration might balk at such a deal.

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Boeing replaces the head of its defense/space/security division

4:24 pm

Ted Colbert
Ted Colbert

Boeing today announced that the head of its defense/space/security division, Ted Colbert, has been removed, effective immediately.

New Boeing CEO Kelly Ortberg in his first significant move since taking over in August, said Ted Colbert would be leaving and Steve Parker, the unit’s chief operating officer, would assume Colbert’s responsibilities until a replacement is named at a later date.

One project that Colbert was in charge of was Starliner, a program that has cost the company at least $1.6 billion in overruns because of numerous faulty engineering problems.

Colbert might not be to blame for the endless problems at Starliner, but the fish stinks from the head. He also might be very qualified, but sadly, as his picture shows, he is a minority, and since Boeing went all in on DEI racist hiring quotas a few years ago, which makes the skin color and gender of an applicant a major qualification in hiring, one can’t help wondering if he was a DEI (Didn’t Earn It) hire. At Boeing that policy created a goal to increase black staffing by 20%. Its full report [pdf] makes it very clear it no longer made talent, experience, or skill the primary qualification for getting hired, but skin color and sex took precedence.

As I said, one cannot help wondering if Colbert was hired not because of his great management and engineering knowledge, but because he happened to born with a dark skin color. If so, that might help explain the failures in this paricular division.

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Boeing employees reject deal of union and company and go on strike

8:47 am

In another blow to the company, Boeing’s employees have gone on strike after overwhelming voting to reject a new deal their union officials had negotiated with the company that had called for a 25% salary increase across the board.

Members of the International Association of Machinists District 751, which represents about 33,000 Boeing workers in Washington state, walked off the job when their contract expired at midnight on Thursday night. Almost 95 per cent rejected the deal endorsed by their bargaining team on Sunday and 96 per cent voted to strike, easily exceeding the two-thirds majority needed to trigger a walkout.

Many of the union’s members expressed anger on social media, criticising the deal and accusing IAM leaders of settling for too little. Many had been ready to strike, partly fuelled by residual anger from a 2014 deal that eliminated defined-benefit pensions.

Boeing on Thursday said it was ready to renegotiate a deal to halt a crippling strike.

Right now Boeing’s credit rating is “one notch above junk” and if the strike isn’t settled quickly that rating could drop more. It will also prevent the company from taking any action to recover from its numerous problems that are limiting sales of its airplanes and its military and space products.

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Starliner lands in New Mexico unmanned without problems

9:47 am

Boeing’s Starliner manned capsule landed last night at White Sands in New Mexico, the undocking, de-orbit, and descent occurring as planned with no hitches.

The mission however was not a full success. Intended as the first manned demo flight of the capsule, it did not complete that demonstration. It took astronauts up to ISS, but did not bring them home. NASA made the decision that the technical problems during launch and docking to ISS were sufficient enough to preclude putting the astronauts back on board for the return flight.

NASA says it “will review all mission-related data” before deciding whether to certify the capsule for operational manned flights. The agency has essentially two choices. First, it could decide that the successful return with no hitches of this manned flight, even with no one on board, fulfilled Boeing’s obligations. It will certify the capsule, allowing Starliner’s next manned mission to fly with NASA paying the bill. Doing so however would likely expose NASA to a lot of bad publicity, since the press right now sees Boeing as the root of all technical evil, and will pile on to the agency for putting safety last.

Second, NASA could avoid that bad press and play hard-nosed and demand another manned demo flight, on Boeing’s dime, as required by contract. If so, however, expect Boeing to refuse to do it, citing the cost and the company’s fiscal responsibility to its shareholders. Even if successful Boeing is unlikely to ever recover those costs through passenger sales.

Based on this negotiating situation, I predict NASA will choose the former. The successful landing suggests this is probably the right decision. It however will not do so immediately, but will release a series of announcements touting the positive results from its review of that “mission-related data”. By dribbling out each positive result bit-by-bit, the goal will be to soften the press so that when the agency finally certifies Boeing for that next manned mission and thus agrees to pay for it, the press will not pile on so hard.

At least, that will be the agency’s hope. The mainstream propaganda press however doesn’t usually read NASA press releases, and even when it does it knows so little about the subject that it almost always comes to the wrong conclusion. Moreover, its present desire to attack Boeing in all conditions will likely help it report these stories badly.

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Will NASA give up on Starliner after its present contracts are completed?

11:17 am

According to an article today at Ars Technica, there are indications that NASA will not buy any further flights of Boeing’s Starliner capsule after it finally completes its present three-launch contract.

NASA hasn’t decided if it will require Boeing to launch another test flight before formally certifying Starliner for operational missions. If Starliner performs flawlessly after undocking and successfully lands this weekend, perhaps NASA engineers can convince themselves Starliner is good to go for crew rotation flights once Boeing resolves the thruster problems and helium leaks.

In any event, the schedule for launching an operational Starliner crew flight in less than a year seems improbable. Aside from the decision on another test flight, the agency also must decide whether it will order any more operational Starliner missions from Boeing. These “post-certification missions” will transport crews of four astronauts between Earth and the ISS, orbiting roughly 260 miles (420 kilometers) above the planet.

NASA has only given Boeing the “Authority To Proceed” for three of its six potential operational Starliner missions.

Apparently NASA has not decided whether to commit to any more Starliner operational manned flights behind those first three.

There are obvious good reasons for NASA’s hesitancy, most of which center on Boeing and its inability to get Starliner flying without technical problems. One that isn’t as obvious however is ISS itself. Boeing has taken so long in getting Starliner flying that the end of ISS in 2030 is now looming. There are only so many manned flights that NASA needs to buy before the station is decommissioned. Afterward the agency will still need to hire ferrying services to the new privately owned stations, but it is too far in the future to consider either SpaceX or Boeing for those decisions.

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That sonar-type sound heard on Starliner’s speakers was simply feedback

9:01 am

In a short post today NASA noted that the mysterious sonar-type sound heard on Starliner’s speakers over the weekend was nothing more than simple feedback caused by an “audio configuration between the space station and Starliner” and that the sound stopped when that configuration was adjusted.

The space station audio system is complex, allowing multiple spacecraft and modules to be interconnected, and it is common to experience noise and feedback. The crew is asked to contact mission control when they hear sounds originating in the comm system. The speaker feedback Wilmore reported has no technical impact to the crew, Starliner, or station operations

In other words, this is not a rare event, and from the beginning was not considered by the astronauts, ground engineers, or NASA management to be a matter of concern. The fix was apparently simple and straightforward, and is part of the work done whenever any new vehicle gets docked and tied into ISS’s systems.

It appears however to have caused many in the news media and in the space world to go nuts simply because it was linked to Starliner and Boeing. This is similar to the recent pattern of assigning all blame to Boeing whenever any Boeing-built plane has technical problems, even if that plane had been purchased by the airline decades earlier and its maintenance was solely the responsibility of the airline for that long.

Boeing is definitely a company in trouble, on many levels. We shouldn’t however look for problems there in the company when they clearly don’t exist.

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NASA names revised crew for next manned Dragon mission to ISS

9:34 am

NASA today named the two astronauts who will fly on the next manned Dragon mission to ISS, to be launched on September 24, 2024 for a six month mission, where they will be joined by the two astronauts who launched on Boeing’s Starliner in June but now will return with them when their Freedom capsule returns in February 2025.

NASA astronaut Nick Hague and Roscosmos cosmonaut Aleksandr Gorbunov will launch no earlier than Tuesday, Sept. 24, on the agency’s SpaceX Crew-9 mission to the International Space Station. NASA astronauts Zena Cardman and Stephanie Wilson, previously announced as crewmates, are eligible for reassignment on a future mission. Hague and Gorbunov will fly to the space station as commander and mission specialist, respectively, as part of a two-crew member flight aboard a SpaceX Dragon.

The updated crew complement follows NASA’s decision to return the agency’s Boeing Crew Flight Test uncrewed and launch Crew-9 with two unoccupied seats. NASA astronauts Butch Wilmore and Suni Williams, who launched aboard the Starliner spacecraft in June, will fly home with Hague and Gorbunov in February 2025.

With Starliner now scheduled to return on September 6th and Freedom not arriving until around September 24th, there will be an eighteen day period when Wilmore and Williams will have a limited and more risky lifeboat option on ISS. If an incident should occur that requires station evacuation there is room to squeeze them inside SpaceX’s Endeavour Dragon capsule presently docked there, but they will return without flight suits. Their Dragon flight suits will not arrive until September 24th, on the next Dragon. The suits they used on Starliner will not work on Dragon.

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Starliner to return unmanned on September 6

8:44 am

NASA today announced that Starliner will undock from ISS on September 6, 2024 at about 6:00 PM (Eastern) and will then land six hours later at White Sands in New Mexico.

The announcement touts Starliner’s ability to fly autonomously, but based on what we know this is really not something to brag about. All Dragons do this routinely whether they are manned or not. Starliner required an upload of software to reconfirgure it for this, since it had originally been configured for a manned return and apparently that original software was not designed for an unmanned return.

In other words, the spacecraft as presently designed doesn’t have the ability to switch from autonomous to manned in a simple manner.

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Starliner will return unmanned; crew will return in February 2025 on Dragon

10:51 am

Starliner docked to ISS
Starliner docked to ISS.

In a briefing today, NASA’s administrator Bill Nelson announced that Boeing’s Starliner capsule, launched in June on its first manned mission, will return unmanned and that the two astronauts it brought to ISS — Butch Wilmore and Suni Williams — will return in February 2025 as part of the crew of the next Dragon manned mission, scheduled to launch in late September.

Nelson made it a point to note that NASA’s past inactions to protect astronauts on two different shuttle missions, thus leading to their deaths, was a factor in this decision. The agency now decided safety must come first, and since Starliner’s return abilities still carry uncertainties that relate directly to safety, it decided to use a more reliable and tested Dragon capsule to return those astronauts back to Earth. During the entire briefing and Q&A session it became very clear that NASA is now paying very close attention to its engineers and their conclusions, rather than dismissing those conclusions because of other management concerns, as it did during those previous two shuttle failures.

Nelson also stated that NASA still wants to use Starliner as a second crew vehicle to ISS. He noted that he has spoken to Boeing’s new CEO, who apparently committed to getting Starliner fixed and operating. It remains undecided whether another test manned flight will be required of Boeing (at Boeing’s cost) before NASA certifies it as an operational vehicle. Whether any other customers will be willing to use the capsule remains unlikely until Boeing has flown a lot of Starliner NASA flights with no problems.

At this moment they are looking to bring Starliner back in early September, using a simplified undocking system to get the vehicle away from ISS quickly. The next Dragon mission will launch no earlier than September 24th carrying two astronauts and two empty flight suits that Wilmore and Williams use during their return.

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Starliner decision expected tomorrow, August 24

9:04 am

According to a NASA update today, the agency will hold “an internal Agency Test Flight Readiness Review” to discuss whether to return Starliner manned or unmanned on Saturday morning, August 24, 2024 and then hold a press conference immediately afterward to discuss the results of that review.

What makes this review and press conference different from all previous Starliner reviews and conferences is that NASA administrator Bill Nelson will attend.

NASA Administrator Bill Nelson and leadership will hold an internal Agency Test Flight Readiness Review on Saturday, Aug. 24, for NASA’s Boeing Crew Flight Test. About an hour later, NASA will host a live news conference at 1 p.m. EDT from the agency’s Johnson Space Center in Houston.

The only reason a politico like Nelson would participate in such proceedings is because he has taken control of the decision-making process, and will make the decision himself. The review is likely to educate him as best as can be done in this short time, and he will then decide whether the two astronauts who launched on Starliner, Butch Wilmore and Suni Williams, will return on it in the next week or so, or will stay on board ISS until February 2025 and return on the next Dragon crew capsule scheduled to launch to ISS in late September.

Nelson might have decided to get involved on his own, but I am certain that if so it was strongly “encouraged” by officials above him in the White House. There is an election coming up, and the risks involved in using Starliner to return the astronauts must be weighed in connection not just with its engineering concerns but with its political ramifications also.

Nelson’s decision will also provide us a strong indication of a future Harris administration’s attitude toward space.

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NASA delays Starliner return decision to end of month

9:17 am

In a short FAQ posted by NASA today, the agency quietly revealed that the decision on whether to bring Starliner back with its astronauts on board has been delayed till the end of August.

NASA now plans to conduct two reviews – a Program Control Board and an Agency Flight Readiness Review – before deciding how it will safely return Wilmore and Williams from the station. NASA expects to decide on the path forward by the end of August.

It appears the agency has decided to bring more people into the decision-making process. In the briefing last week, it was then planning only one review, expected to be completed before the end of this week. It now sounds like a second review will occur after the first, pushing the decision back one more week.

All of NASA’s actions in the past three weeks have suggested an increasing involvement by upper management, possibly including White House officials. With an election coming up, the politicans who are supposed to be in charge have apparently inserted themselves into this process and are demanding greater review. I expect in the end the decision will fall to them, and might even be announced by NASA administrator Bill Nelson himself.

These actions have also suggested that upper management does not like the risks involved in returning the crew on Starliner. Politicians do not like to have bad things happen on their watch. We should therefore not be surprised if the decision is made to send Starliner home unmanned.

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Sierra Space in negotiations to buy ULA

10:26 pm

According to the Reuters news agency, Sierra Space is negotiating with the joint owners of ULA, Boeing and Lockheed Martin, to buy the rocket company.

The sources, which are all anonymous, said the sale price is in the range of $2 to $3 billion. Those same sources said no deal has yet been worked out, and might not happen at all.

For Sierra, the deal would give it its own launch vehicle, Vulcan, for placing its Dream Chaser mini-shuttles into orbit. It would also give it a profit stream from the many military and commercial launch contracts already on ULA’s manifest. The combined cababilities of ULA and Sierra will create a formidable new player in the aerospace launch market.

For Boeing, it would provide it some much needed cash that it will be able to use to both restructure and revitalize its presently questionable operations.

It is unclear what Lockheed Martin will gain from the sale, other than the cash and the removal of this Frankenstein-like partnership with Boeing, which in the long run has probably not done it a lot of good.

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NASA leaning now to send Starliner astronauts home on Dragon, in February 2025

11:01 am

Though a decision will not be made until next week, during a press briefing today the nature of the briefing and the wording by NASA officials suggested that they are now leaning strongly to having the two Starliner astronauts, Butch Wilmore and Suni Williams, return on the next Dragon capsule to launch to the station on September 24, 2024 and return in February 2025.

My conclusion is based on several subtle things. First, no Boeing official participated, the second time in row that they were excluded. Second, this briefing included some new individuals who rank higher in the chain of command, and whose opening statements were clearly written carefully in advance and were read aloud.

Third, and most important, the wording of those statements repeatedly indicated they are looking at Dragon return more seriously. For example, NASA’s chief astronaut Joe Acaba suggested strongly that the two astronauts were now well prepared for an eight month mission, rather than coming home in August 2024. Other statements by officials suggested they themselves are less confident about returning on Starliner. Though the data suggests they can return safely, there remains enough uncertainty to make some people uncomfortable.

One factor not stated but is certainly controlling the situation now is the upcoming election in November. The Democrats who control Washington and the White House will allow nothing to happen that could hurt their election chances. We must therefore assume people in the White House are now in control and are the ones who now intend to make the decision about Starliner’s return.

Based on these factors, we should expect NASA to announce next week that the crew will return in a Dragon capsule. In order for the return to happen on Starliner NASA and Boeing engineers must somehow convince those politicos that the return would be entirely safe. Since these politicos are always risk adverse, it would shock me if they can be convinced. It could happen, but understanding the politically framework is important.

The officials stated that they have scheduled the final review next week, and it appears the decision will be announced then.

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NASA inspector general blasts Boeing’s management relating to its work on SLS’s new more powerful upper stage

9:52 am

Boeing's schedule slips in building SLS's upper stage
Boeing’s schedule slips in building SLS’s upper stage

In a report issued today [pdf], NASA’s inspector general harshly criticized the Boeing managment and operations at its Michoud facility, where the company is developing SLS’s new more powerful upper stage. From the report’s executive summary:

Quality control issues at Michoud are largely due to the lack of a sufficient number of rained and experienced aerospace workers at Boeing. To mitigate these challenges, Boeing provides training and work orders to its employees. Considering the significant quality control deficiencies at Michoud, we found these efforts to be inadequate. For example, during our visit to Michoud in April 2023, we observed a liquid oxygen fuel tank dome—a critical component of the SLS Core Stage 3—segregated and pending disposition on whether and how it can safely be used going forward due to welds that did not meet NASA specifications. According to NASA officials, the welding issues arose due to Boeing’s inexperienced technicians and inadequate work order planning and supervision. The lack of a trained and qualified workforce increases the risk that Boeing will continue to manufacture parts and components that do not adhere to NASA requirements and industry standards.

The report also notes that delivery of that upper stage has been delayed from 2021 to 2027 (as shown by the graph to the right, taken from the IG report), and its cost has risen from $962 million to almost $2.8 billion. It also notes quite bluntly that:

Boeing’s quality management system at Michoud does not effectively adhere to industry standards or NASA requirements, resulting in production delays to the SLS core and upper stages and increased risk to the integrated spacecraft. … Boeing’s process for addressing contractual noncompliance has been ineffective, and the company has generally been nonresponsive in taking corrective actions when the same quality control issues reoccur.

Sound familiar? It should. These issues appear to be the same kind of quality control problems that have plagued Starliner, and are also the same kind of problems that had NASA reject Boeing’s bid to provide cargo to its Lunar Gateway station, and state while doing so that it will no longer consider future Boeing bids until the company straightens itself out.

It appears from today’s inspector general report that Boeing has fixed nothing. The report recommends some additional supervision of Boeing from NASA, and more importantly suggests the agency “institute financial penalties for Boeing’s noncompliance with quality control standards.”

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NASA has decided to consider bringing Starliner down unmanned

10:32 am

Starliner docked to ISS
Starliner docked to ISS.

It appears that upper management at NASA has decided to force the agency to consider bringing Starliner down unmanned and extending the ISS mission of the two Starliner astronauts to a nine month mission.

The situation is definitely complicated, and no change as yet as been made. The schedule of dockings to ISS has been reconfigured to make this option possible. It appears this is the present plan:

First, they need to upgrade the software on Starliner for an unmanned mission. Apparently the present software on board is not satisfactory for an unmanned docking, even though a different Starliner has already done an unmanned docking last year. For this mission, the software relied on the astronauts to take over manually should there be an issue during undocking. In the previous unmanned demo, the software would react and prevent a problem. For reasons that make no sense, the software on the manned mission did not have this capability. Reinstalling this software will give them the option to send the two astronauts down on Dragon and returning Starliner unmanned.

Second, the next Dragon manned mission has been delayed until late September to allow time for these software upgrades, as well as give NASA and Boeing more time to analyze the situation and decide if a manned return on Starliner is possible. If they decide to not use Starliner, the Dragon capsule would come up to ISS with only two astronauts, and the two Starliner astronauts would then join them on their six month mission, coming home in the spring. For the Starliner astronauts Butch Wilmore and Suni Williams this would mean their mission will now be 8-9 months long, far longer than the original one-two week mission.

As to why these options are now being considered, it appears to me that both Boeing and NASA engineers were willing to return the astronauts on Starliner, but have been ordered to consider these options by higher ups. It appears that the last hot-fire thruster tests on ISS left everyone with some uncertainties about the situation. Engineers are fairly certain that the reasons some thrusters did not fire as planned during docking was because teflon seals expanded because of heat to block fuel flow. The problem is that these seals showed no problem at all in the most recent test on ISS. That difference creates some uncertainty as to whether they have really identified the cause of the problem. Imagine having an intermittent problem your car mechanic cannot constently make happen.

Because the thrusters did work as intended, Boeing and NASA seemed ready to return Starliner manned. In the agency review last week it appears others at the top were less sanguine (including Bill Nelson, NASA’s administrator), and demanded these new options be considered. Based on this speculation, it is almost certain Starliner will come home empty.

Whether this will have significant consequences remains uncertain. During the press briefing today, NASA officials said the agency might still certify Starliner for operational manned missions even if the capsule comes home unmanned.

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Next manned Dragon mission to ISS delayed until September 24, 2024

12:10 am

NASA tonight announced that the next manned Dragon mission to ISS has been delayed until September 24, 2024, a pushback of more than a month caused by the thruster issues on Boeing’s Starliner capsule presently docked to the station.

This adjustment allows more time for mission managers to finalize return planning for the agency’s Boeing Crew Flight Test currently docked to the orbiting laboratory. Starliner ground teams are taking their time to analyze the results of recent docked hot-fire testing, finalize flight rationale for the spacecraft’s integrated propulsion system, and confirm system reliability ahead of Starliner’s return to Earth. NASA and Boeing continue to evaluate the spacecraft’s readiness, and no decisions have been made regarding Starliner’s return.

Since both manned capsule use the same port, Starliner must undock before a Dragon can arrive.

The schedule change also eliminates scheduling conflicts with a Soyuz capsule bringing Russian astronauts to the station in mid-September, and will also allow the launch to switch launchpads so as to not conflict with the SpaceX launch of Europa Clipper, scheduled for October 10, 2024 (though that launch remains in doubt due to other problems with the spacecraft itself).

NASA will be holding a briefing on the status of Starliner at 12:30 pm (Eastern) on Wednesday, August 7, 2024.

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NASA/Boeing push back final decision of Starliner return

8:58 am

Starliner docked to ISS
Starliner docked to ISS.

Someone at NASA getting cold feet? According to a NASA posting today, the review that was supposed to happen this week to determine a return date for Starliner and its two-astronaut crew has been postponed until next week as engineers continue analzying the results of the recent thruster hot fire tests, both on the ground and on ISS.

The wording of this posting is intriguing, to say the least:

Teams are taking their time to analyze the results of recent docked hot-fire testing, finalize flight rationale for the spacecraft’s integrated propulsion system, and confirm system reliability ahead of Starliner’s return to Earth from the International Space Station.

Forward work for the team also includes finalizing the spacecraft’s undocking procedures and operational mitigations that could be used in flight, if needed, to build further confidence in the system. Meanwhile, Starliner ground and mission support teams are continuing to prepare for undocking by participating in integrated simulations with space station operations teams.

Following the completion of Starliner’s return planning, which is expected to continue into next week, more information will be shared about the agency’s return readiness review preparations and subsequent media briefing. As always, astronaut safety remains the top priority for both NASA and Boeing. [emphasis mine]

Up until this posting, I have been confidently predicting the two astronauts would return on Starliner. Now I am not so sure. It seems the data from the hot fire tests, especially the most recent tests on the Starliner capsule docked to ISS, was not as encouraging or did not confirm the conclusions drawn from the previous ground-based tests, and have required further analysis. This might not in the end make a difference, but the wording of this NASA’s press release, including the highlighted emphasis on astronaut safety, suggests NASA is at least considering the idea of bringing the astronauts home on a Dragon capsule.

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Boeing names new CEO, set to take over on August 8, 2024

10:32 am

Boeing today named a new CEO, Robert “Kelly” Ortberg, who among the candidates being considered appears to be the only one who did not have a long career at Boeing.

Ortberg emerged as a leading candidate only recently. Others who were reportedly considered for the job included Patrick Shanahan, a former Boeing executive and now CEO of its most important supplier, Spirit AeroSystems, and another longtime Boeing executive, Stephanie Pope, who recently took over the commercial airplanes division.

Ortberg led Rockwell Collins from 2013 to 2018, when it merged with United Technologies and wound up as part of RTX, the company formerly known as Raytheon. He retired from RTX in 2021.

He will take charge of the company as of August 8, 2024.

It remains to be seen if Ortberg can fix things. As the article notes, since 2019 Boeing has lost more than $25 billion, and has been saddled with numerous quality control failures in almost all its technical divisions, from building airplanes to providing maintenance to building space capsules. The failures in its airplane divisions resulted in several crashes that killed 346 people, and caused it to accept a deal with the Justice Department that included a fine of $243.6 million to avoid a criminal trial. That deal however has not yet been accepted by the judge in the case.

Ortberg will have to demonstrate somehow that the culture at Boeing itself has changed. The first thing he could do to indicate he is serious about doing so would be to shut down entirely Boeing’s Diversity, Equity, and Inclusion (DEI) bureaucracy. Getting rid of that poisonous race-based anti-quality program would go a long way in convincing others that Ortberg means business, and wants to put talent, skills, experience first in everything Boeing does, something previous CEOs have clearly not done.

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Boeing completes full series of static hot fire engine burns on Starliner while docked to ISS

9:38 am

Boeing announced today that engineers have successfully completed a full series of static hot fire engine burns testing all of Starliner’s attitude thrusters while still dockecd to ISS.

The one-pulse firings were designed to confirm the performance of each thruster. Aft-facing thrusters were fired for 1.2 seconds and all others for .40 seconds. Between each firing, the team reviewed real-time data and all thrusters performed at peak thrust rating values, ranging from 97-102%. The helium system also remained stable. Additionally, an RCS oxidizer isolation valve that was not fully seated previously, was cycled several times during today’s testing and is now operating normally.

This is the second time the spacecraft has been hot fired successfully while docked, an integrated operation the station and Starliner teams will also conduct during future long-duration missions.

This result is not a surprise, based on the information provided during the most recent briefing. It confirms the data obtained during previous hot fire tests both on a Starliner on the ground and the Starliner docked to ISS. Not only does it appear that Boeing has enough information to fix this problem so it does not occur again, it has proven unequivocally that these thrusters as well as the helium leaks inside the thruster systems pose no unusual risk for a return in the capsule.

NASA and Boeing have a planned review of these results this coming week, when we should expect them to name a return date, likely sometime in the first two weeks of August.

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NASA/Boeing: Cause of Starliner thruster failure identified

10:21 am

According to NASA and Boeing officials, ground static fire engine tests have now identified the likely cause of the thruster failures on the Starliner capsule during its docking to ISS in early June, and puts them in a position next week to determine a return date for the capsule and its two astronauts.

It appears the problem is related to teflon seals in the thrusters, detected while engineers did a series of tests on the ground with another Starliner capsule. Based on this information, Boeing thinks it can fix the problem on future capsules, while also insuring there will be no problems returning the astronauts from ISS.

The thrusters in question are all attitude thrusters, where there is a lot of redundancy and the issue has been seen to be well controlled from the start. The larger thrusters used for the undocking and de-orbit burn have been tested as well, and have not shown any similar issues at all.

The ground tests have also identified the cause of the helium leaks within the capsule engine system. Boeing will use this data to fix later capsules as well. These leaks are not a concern for the return to Earth.

The plan now is to do in the next few days one more set of static fire tests with the capsule docked on ISS, doing short bursts with all the attitude thrusters to further confirm what has been learned on the ground. If that goes as expected, a final meeting next week will determine the return date for the capsule and crew.

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NASA and Boeing complete ground static fire tests of Starliner

11:20 pm

According to a press announcement tonight from NASA, the agency and Boeing have now completed the static fire tests using a Starliner ground capsule to duplicate the engine burns required to bring the in-space capsule back to Earth, carrying its two astronauts.

Teams completed ground hot fire testing at White Sands and are working to evaluate the test data and inspect the test engine. The ongoing ground analysis is expected to continue throughout the week. Working with a reaction control system thruster built for a future Starliner spacecraft, ground teams fired the engine through similar inflight conditions the spacecraft experienced on the way to the space station. The ground tests also included stress-case firings, and replicated conditions Starliner’s thrusters will experience from undocking to deorbit burn, where the thrusters will fire to slow Starliner’s speed to bring it out of orbit for landing in the southwestern United States.

Engineers now need to complete a review of those tests, followed by a full review leading to a decision as to when the astronauts will return on Starliner. No dates have yet been set, but expect these reviews to be completed within two weeks, and that Starliner will likely be scheduled for return in early August, prior to the scheduled launch of the next Dragon manned mission in mid-August.

All this assumes the FAA will clear SpaceX to resume launches before then. SpaceX is apparently ready to resume this week, but we have no indication the FAA will go along.

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Starliner return delayed until after ground thruster tests are completed and analyzed

9:15 am

Starliner docked to ISS
Starliner docked during the unmanned demo
flight in May 2022

According the NASA and Boeing officials yesterday, they are in the process of doing ground thruster tests to emulate the problems that occurred on the thrusters during docking procedures to ISS in early June, and will not decide on a return date for Starliner until after those tests are completed and analyzed, expected sometime in the next two weeks.

It appears some of the ground tests were delayed slightly due to the arrival of Hurricane Beryl in Texas.

It is very important to note that the astronauts are not “stranded” on the station, as a lot of news organizations are still claiming. The thrusters on Starliner that failed are part of the service module, which will not return to Earth when the astronauts come home on the the capsule. They therefore want to do as much research as possible beforehand in order to determine the cause of the failures in order to prevent them on future capsule flights. For example, the ground tests are first attempting to duplicate precisely what happened during docking, and will then do tests attempting to duplicate what will happen during de-orbit.

In the meantime, they appear to have no doubt that they can use Starliner for return, no matter what. At the moment only one thruster appears out-of-commission, and none of the thrusters that failed during docking are used for the de-orbit burn. They are only used for orientation, and the capsule has ample redundancy for this function sufficient for de-orbit.

In addition, it is a good thing for them to extend Starliner’s total flight time. I suspect even if everything had worked as planned they would have extended this mission as they have. This allows them to prove out the in-space operation of the capsule and service module. So far it appears that operation has been excellent, which is one reason they are willing to delay the return to do the ground tests.

Overall, my impression is that the situation is entirely under control, and in fact NASA is reasonably satisfied with the capsule’s operation in general. It appears that the agency will likely have no problem in flying future manned missions with Starliner, though it will want the thruster issue solved beforehand.

As for Boeing, these problems have stained its reputation further, and have likely made it much more difficult to sell future capsule flights to other customers. I would say however that after listening to the last few press briefings it seems to me that Boeing’s manned space division is now doing the proper due diligence it should have done before. For example, the thruster problems appear to be related to overheating during use, which is a very fixable issue.

These facts actually makes me more confident in the capsule, and future potential customers should do the same review themselves.

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$243.6 million plea deal allows Boeing to avoid a criminal trial

9:59 pm

The Justice Department and Boeing have made a plea deal so that the company can avoid a criminal trial for breaking its previous plea deal over 737-Max plane crashes that killed 346 people.

Under the agreement, Boeing will plead guilty to a criminal fraud charge stemming from the fatal crashes in Indonesia in October 2018 and in Ethiopia less than five months later that killed a combined 346 people.

Boeing must also pay the hefty fine [$243.6 million], invest at least $455 million in compliance and safety programs, and have an independent monitor oversee Boeing’s safety and quality procedures for three years

The company had made similar deal in 2021 with Justice when it became clear it had deceived FAA regulators about the software on new 737-Max planes that caused these crashes. This new deal is because the company apparently violated that 2021 deal, and allows it to avoid a criminal trial.

A judge still has to approve this new plea deal. Many families of the deceased oppose it, demanding instead that company managers be put on trial. Even if the judge accepts it, Boeing will still be liable for other more recent incidents.

All in all, Boeing comes off as a morally corrupt and incompetent company that was willing to cut corners, lie about it, thus allow more planes to crash because of its actions.

No wonder everyone wants to blame Boeing for every single incident that has recently occurred on various commercial jets, even though in many cases the blame resides more with the maintenance departments of the airlines that had purchased the planes. And no wonder no one believes the claim that the astronauts that flew up to ISS in June are not “stuck” there. They probably aren’t, but why believe anyone from such a compny.

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Starliner return delayed again, until July

10:08 pm

NASA tonight announced that it is once again delaying the undocking from ISS and the return to Earth of Boeing’s Starliner capsule, carrying two astronauts, with the return date a as-yet unspecified date in July.

The move off Wednesday, June 26, deconflicts Starliner’s undocking and landing from a series of planned International Space Station spacewalks while allowing mission teams time to review propulsion system data.

It seems to me that they have decided the more time Starliner spends in space right now, the more data they can gather about its flightworthiness in the future. Remember, the first manned Dragon demo mission stayed at ISS for more than two months.

Their approach however — announcing small delays over and over again — is extremely poor PR. It makes it seem as if the capsule’s various issues — thrusters, helium leaks, and valves — are a more serious than I think they are.

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