Boeing – Page 16 – Behind The Black

NASA selects full crew for first operational Dragon mission

April 1, 2020 10:23 am Robert Zimmerman

Even though SpaceX’s first demonstration manned mission to ISS has not yet occurred, NASA yesterday announced the selection of the full four person crew for the second flight, set for later this year and intended as the first operational mission to ISS, lasting six months.

This announcement tells us several things, all good. First, it appears NASA has now definitely decided that the demo mission, presently scheduled for mid-May, will be a short-term mission. They had considered making it a six-month mission, but it now appears they have concluded doing so will delay the demo launch too much.

Second, that NASA is solidifying its plans for that operational flight, the second for Dragon, including a tentative launch date later in 2020, is further evidence that they intend to go through with the demo mission in mid-May.

Finally, it appears that NASA has decided that it will not buy more seats on Russian Soyuz capsules, something that they had previously hinted they needed to do because the agency was worried the American capsules would not be ready this year. The article describes the negotiations on-going with the Russians about the use of Dragon, as well as the future use by Americans of Soyuz. NASA wishes to have astronauts from both countries fly on both spacecraft (Starliner too, once operational), but Russia is as yet reluctant to fly its astronauts on Dragon. They want to see that spacecraft complete more missions successfully.

Regardless, future flights of Americans on Soyuz will cost NASA nothing, as the agency wishes to trade the seats on the U.S. capsules one-for-one for the seats on Soyuz. It also means that NASA has decided it doesn’t need to buy Soyuz flights anymore, as it now expects Dragon to become operational this year.

3 comments

New inspector general report slams NASA’s SLS management

March 10, 2020 10:20 am Robert Zimmerman

A new report [pdf] by NASA’s inspector general released today harshly slams the management of NASA for the never-ending cost overruns and scheduling delays that have plagued the agency’s effort to build and launch the Space Launch System (SLS).

From the report’s introduction:

Based on our review of SLS Program cost reporting, we found that the Program exceeded its Agency Baseline Commitment (ABC)—that is, the cost and schedule baselines committed to Congress against which a program is measured—by at least 33 percent at the end of fiscal year 2019, a figure that could reach 43 percent or higher if additional delays push the launch date for Artemis I beyond November 2020.

… [T]he SLS Program now projects the Artemis I launch will be delayed to at least spring 2021 or later. Further, we found NASA’s ABC cost reporting only tracks Artemis I-related activities and not total SLS Program costs. Overall, by the end of fiscal year 2020, NASA will have spent more than $17 billion on the SLS Program—including almost $6 billion not tracked or reported as part of the ABC.

The graph below, taken from page 45 of the report, illustrates the management failures here quite starkly.
» Read more

11 comments

NASA confirms seriousness of 2nd Starliner software issue

February 7, 2020 5:38 pm Robert Zimmerman

At a press conference today, NASA and Boeing officials confirmed the rumors that there was a second software error during Starliner’s unmanned demo mission in December that might have caused a serious failure had it not been caught on time.

[After the first software error], engineers began reviewing other critical software sequences as a precaution and discovered yet another problem. Software used to control thruster firings needed to safely jettison the Starliner’s service module just before re-entry was mis-configured, set for the wrong phase of flight.

Had the problem not been found and corrected, the cylindrical service module’s thrusters could have fired in the wrong sequence, driving it back into the crew module and possibly triggering a tumble or even damaging the ship’s protective heat shield.

While a detailed analysis was not carried out at the time, “nothing good can come from those two spacecraft bumping back into one another,” said Jim Chilton, a senior vice president for Boeing Space and Launch.

That two different software errors were not caught prior to flight has NASA demanding a complete review of Boeing’s quality control systems. And NASA here is correct. Boeing as a company appears to have fundamental quality control issues up and down the line, in all its projects. A complete review appears warranted.

6 comments

NASA safety panel raises more questions about Boeing and Starliner

February 7, 2020 10:05 am Robert Zimmerman

In its quarterly meeting yesterday, NASA’s safety panel raised more questions about the software problems during the unmanned demo mission of Boeing’s Starliner manned capsule in December.

NASA’s Aerospace Safety Advisory Panel (ASAP) revealed today that a second software error was discovered during the uncrewed Boeing Starliner flight test in December. Had it gone undetected during the flight, it had the potential to cause “catastrophic spacecraft failure” during reentry. The panel wants a complete review of Boeing’s software verification processes before NASA decides whether a second uncrewed flight test is needed. In an email this evening, Boeing said it appreciates the input and is working on a plan with NASA to address all the issues and decide what comes next.

In that Boeing email it noted that it was “unclear” what the consequences would have been if this second software issue had not been fixed.

The safety panel also called for an overall organizational review of the entire Boeing company, similar to the review done to SpaceX after Elon Musk was videoed taking a toke on a joint during a podcast interview.

The decision on whether Boeing will be required to fly another unmanned demo mission is targeted for before the end of February.

One comment: While there is clear evidence here that Boeing had issues on that demo flight that must be resolved before humans fly on Starliner, we must also recognize that NASA’s safety panel has an unfortunate tendency to overstate risk, demanding margins of safety that are frequently unrealistic for an endeavor pushing the envelope of exploration. That panel has also exhibited an almost corrupt bias against private commercial space, while looking past much more serious safety issues in the NASA-built SLS and Orion programs.

At the same time, the larger corporate issues here with Boeing do appear far more systemic and concerning that those that occurred with SpaceX. A cold independent audit of the company by NASA could actually do Boeing a lot of good.

4 comments

Boeing budgets for extra unmanned Starliner test

January 30, 2020 9:30 am Robert Zimmerman

Capitalism in space: Boeing has put aside $410 million in its next budget to pay for a possible second unmanned Starliner test, just in case NASA demands it.

The company said in its fourth quarter earnings release Jan. 29 that it was taking the charge “primarily to provision for an additional uncrewed mission for the Commercial Crew program, performance and mix.” It noted that NASA was still reviewing data from the Orbital Flight Test (OFT) mission in December that was cut short, without a docking at the International Space Station, by a timer problem.

“NASA is in the process of reviewing the data from our December 2019 mission,” Greg Smith, chief financial officer at Boeing, said in an earnings call. “NASA’s approval is required to proceed with a flight test with astronauts on board. Given this obligation, we are provisioned for another uncrewed mission.” Neither he nor Boeing’s new chief executive, David Calhoun, elaborated on that during the call, which was devoted primarily to issues related to the company’s 737 MAX airliner.

It might be too early to say, but my instincts are telling me that this decision, made very quickly, is a very good sign for Boeing. It suggests that Calhoun doesn’t fool around, that he takes very seriously the need for Boeing to serve its customers. In the past Boeing would have lobbied NASA, its customer, to pay for a possible additional flight (something NASA is not required to do according to the contract). Now Boeing instead makes it clear that it has accepted the responsibility of that additional flight, right off the bat, something that any good and healthy company should do.

3 comments

NASA picks Axiom to build three private commercial modules on ISS

January 28, 2020 10:05 am Robert Zimmerman

Capitalism in space: NASA today picked the new space station company Axiom to build three modules to ISS, designed to operate as a private commercial operation.

The first segment launch is targeted for 2024. The three segments will include a node with multi-ports, a crew module, and a research module, and will be the “hotel” for private tourists that Axiom hopes to send to ISS two or three times per year. The entire section will also be designed to eventually separate from ISS when that station is retired and operate, with more additions, as an independent station.

This decision did not include the actual contract, only the choice of company to build this new section of ISS. Later negotiations will determine the fixed price amount that NASA will pay.

Why did NASA pick Axiom, which has not yet launched anything, and bypass Bigelow, which has launched two independent test modules and one that has been attached to ISS and working successfully now for several years? This quote explains:

Although Axiom is a relatively young company, having been formed only four years ago in 2016, there is no lack of experience within the company’s ranks.

Axiom’s Co-founder and CEO is Micheal Suffredini, who formerly worked at the Johnson Space Centre (JSC) as the program manager for the International Space Station project.

The Axiom team also includes Michael Lopez-Alegria, a former NASA astronaut who flew on the space shuttle three times and commanded the 14th Expedition to the ISS, as well as former shuttle commanders Brent Jett and Charles Bolden, the latter of whom served as NASA’s 12th administrator from 2009 to 2017.

Axiom is also working alongside several companies with extensive experience with the ISS program, this includes Boeing, who has made several of the modules that make up the US Segment, including Node 1 and the US Laboratory Module. Axiom is also working alongside Thales Alenia Space, Maxar Technologies and Intuitive Machines to get this project off the ground. [emphasis mine]

In other words, it appears it’s not what you know, it’s who you know. This is not to say that the individuals and companies listed above do not know much, but that the company’s real experience with building private modules is lacking. Boeing has built NASA’s modules, but those were for the government and were therefore costly. I have grave doubts they could do this inexpensively, though I could be wrong.

The key will be whether they aim to make their profits from their commercial customers, or use NASA (and the federal government) as their cash cow. The track record of most of Axiom’s partners suggests the latter. For example, Bigelow built and launched its BEAM module to ISS for $17 million, and got it done in three years. We don’t yet know the cost of Axiom’s modules, but their target build-time is already longer, at four to five years

Don’t get me wrong. I applaud NASA’s approach here. They are ceding ownership and construction to a private company, and allowing its work to be commercialized for profit, something that NASA routinely opposed for decades. I just worry that the company it has chosen will be not up to the task, and is not focused on making those profits.

7 comments

Boeing flies 777X for the first time

January 27, 2020 8:46 am Robert Zimmerman

On January 25 Boeing successfully flew its new giant 777X commercial airplane for the first time.

Originally unveiled at the 2013 Dubai Airshow, the 777X is an advance on the engineering and interior innovations of the 777 and 787 Dreamliner. The twin-engine jetliner is available in the 777-8 and 777-9 variants with ranges of up to 8,700 nm (10,012 mi/16,110 km) and seating between 350 and 425 passengers.

The key innovation of the 777X is its lightweight wing design based on a composite spar made from over 400 miles (644 km) of carbon tape cured in a specially-built autoclave. This allows the aircraft to have a wingspan of 235 ft (72 m) – a span so long that the wings have folding sections at their tips so the plane can fit in conventional boarding gates.

The test flight lasted just under four hours. The pictures at the link illustrate clearly emphasize the lightweight wings, which look tiny compared to the two engines.

Boeing desperately needs a success, considering the string of problems almost all of its major projects have been having recently.

0 comments

Boeing abruptly exits DARPA’s experimental spaceplane project

January 22, 2020 5:37 pm Robert Zimmerman

Boeing today announced it is pulling out of DARPA’s Experimental Spaceplane Program, cancelling development of its Phantom Express-1 hyposonic plane.

The Pentagon’s Defense Advanced Research Projects Agency says Boeing is dropping out of its Experimental Spaceplane Program immediately, grounding the XS-1 Phantom Express, even though technical tests had shown the hypersonic space plane concept was feasible. “The detailed engineering activities conducted under the Experimental Spaceplane Program affirmed that no technical showstoppers stand in the way of achieving DARPA’s objectives, and that a system such as XSP would bolster national security,” DARPA said in a statement issued today.

Boeing has provided no clear explanation for this exit. I suspect it might have to do with their other problems related to the 737-Max airplane and the costs it is imposing on the company. Also, the program called for the first test flights in 2020, and it might also be that Boeing had doubts about meeting that goal.

Right now I wonder if Boeing will have to return any of the cash DARPA provided it for the work done so far, out of the total $146 million award. Moreover, at least two other companies had bid for this contract, Masten and Northrop Grumman. Will Boeing’s exit now allow them to pick up the pieces? Or has Boeing’s contract win and sudden exit mainly achieved the goal of stymieing their compeition?

Overall, this decision by Boeing is just another black mark on the company, just one of many that has occurred in the past few years.

UPDATE: It appears that Doug Messier at Parabolic Arc suspects the same Machiavellian maneuvers from Boeing as I.

A couple of years ago, a friend made the surprising predication that DARPA’s Experimental Spaceplane Program (XSP) — a R&D effort designed to produce a rocket capable of being launched 10 times in 10 days — would never see any hardware built.

The reasoning went like this: the winning bidder, Boeing, really wasn’t interested in the technology. The company was actually interested in government funding and keeping other companies from developing the system.

Messier isn’t sure either, noting that the pull out might also have occurred due to the arrival of Boeing’s new CEO, only a week earlier.

9 comments

Boeing looking to borrow up to $10 billion because of 737-Max problems

January 21, 2020 9:20 am Robert Zimmerman

Boeing apparently is in discussions with several banks in an effort to secure a $10 billion loan to help it deal with the costs related to the suspension of production of the 737-Max airplane after two fatal crashes.

Boeing is in talks with banks to secure a loan of $10 billion or more, according to people familiar with the matter, as the company faces rising costs stemming from two fatal crashes of its 737 Max planes. The company has secured at least $6 billion from banks so far, the people said, and is talking to other lenders for more contributions. The total amount could rise if there is additional demand from banks, one person familiar with the matter said.

Liquidity isn’t an immediate concern, analysts have said, but the new debt shows Boeing is shoring up its finances amid the cash-sapping fallout of the two crashes — one in Indonesia in October 2018 and another in Ethiopia in March last year — that killed all 346 people aboard the two flights.

The amount Boeing is seeking to borrow is more than what some analysts were expecting. For example, Jefferies earlier this month forecast Boeing would issue $5 billion in debt this quarter.

I must emphasize that this story relies on anonymous sources, and is reported by CNBC, a division of NBC, one of today’s least reliable news sources.

More trustworthy information should become available on January 29, when Boeing makes its next earnings report.

11 comments

A detailed look at Boeing’s recent aircraft problems

January 16, 2020 2:33 pm Robert Zimmerman

Link here. The article is entirely focused at reviewing only Boeing’s recent aircraft projects (Boeing 787, Boeing 747-8, Boeing KC-46A, Boeing 777X and Boeing 737 MAX), all of which appear to have had a lot of development issues.

The worst of the lot was the KC-46A, with many of the problems shared by our incompetent federal government. Initially proposed in 2001 (that is not a typo), the contract award did not occur until 2010, with delivery of the first 18 planes set for August 2017. The GAO predicted this delivery would be late, and the GAO was right.

Worse, Boeing has had cost overruns on the tanker totaling $3.4 billion above the initial fixed cost development contract of $4.9 billion (that is also not a typo).

The article also cites far too many examples of where Boeing requested waivers in order to meet schedule, even though the waiver allowed serious safety issues to linger, a behavior that reminded me strongly of NASA’s management during the shuttle program, resulting in the loss of two shuttles because the agency preferred to push its schedule rather than deal with serious engineering problems.

When you add the delays, cost overruns, and sometimes absurd mistakes that have occurred during Boeing’s development of SLS, this article is far more disturbing. It gets worse when you consider the issues that have delayed the launch of Starliner, some of which (the parachutes) should not have been an issue considering Boeing’s half century of experience.

All told, these problems portray a company that is akin to our federal government, badly managed and ripe for disaster. While the U.S. aerospace industry would take a deep hit if Boeing went under, that hit however would likely be temporary, especially considering the problems Boeing is having.

Freedom must allow bad businesses to fail so that fresh faces not bogged down by old problems can come to the fore and replace them. If Boeing collapsed I suspect a host of new companies would quickly appear, all likely more capable of producing what the nation’s aerospace industry needs. Because right now, Boeing is certainly not doing the job.

6 comments

Boeing releases video of Starliner’s first orbital demo flight

January 16, 2020 9:25 am Robert Zimmerman

Capitalism in space: Boeing has released a video showing what it was like to be on its Starliner capsule during its first orbital demo flight on December 20, 2019.

Flying alongside the uncrewed Starliner’s only official passenger — a spacesuit-clad, instrumented dummy (or anthropometric test device) named “Rosie” (after the World War II icon Rosie the Riveter), Snoopy, in plush doll form, served as the vehicle’s “zero-g indicator.” The video shows the doll floating weightless at the end of its “leash” after the Starliner entered Earth orbit.

The video is embedded below the fold. It is relatively boring, which actually is a good thing. The interior of the capsule does not seem much disturbed during each phase of the flight, from launch, separation from launch vehicle, and touchdown.
» Read more

1 comment

Tag: Boeing