Step inside Boeing's South Carolina Dreamliner factory
For most of its history, Boeing has been synonymous with the Seattle area. Although the global aerospace company has facilities across the U.S. and abroad, it was founded in Seattle, and for most of its history, it built its commercial aircraft at two Seattle-area factories.
In 2011, Boeing opened a third commercial factory, this one in Charleston, South Carolina.
The new location came to be after Boeing purchased the South Carolina-based operations of two suppliers in 2008 and 2009: Vought Aircraft Industries and Global Aeronautica, which built components for Boeing.
Boeing absorbed both operations and combined them, before opening a final 787 assembly and delivery line on the site two years later.
The Charleston site operates alongside Boeing's Everett factory in Washington state, which produces wide-body commercial jets.
Boeing said that it needed the second assembly line in order to "expand our production capability to meet the market demand for the airplane" and that it chose the Charleston site due to the component work already being done on the property.
However, the announcement came during a period of turbulent relations with its Washington-based union, leading to allegations that the plane-maker was attempting to illegally circumvent the union. Boeing has since allegedly fought any effort by Charleston workers to unionize.
Boeing said in 2020 that it would consolidate 787 production in Charleston instead of splitting it between South Carolina and Washington, a move which was completed the following year.
TPG had a chance to tour the factory last December ahead of an event marking United Airlines' new order for up to 200 airplanes.
Saying that Boeing makes the Dreamliners at its factory is a bit misleading because Boeing — just like Airbus, Embraer and other airframe makers — doesn't actually manufacture much of the plane itself.
More: The 787 Dreamliner: What are the differences between an -8, -9 and -10?
Instead, the company outsources components to specialized manufacturers, while building a few parts itself. Then, Boeing gathers each of the components and assembles them as the final product.
So really, the Charleston facility is more of an assembly plant.
Because of this, as you drive around the facility, which is located on the grounds of the airport, you won't only see 787s in various states of completion. You'll also spot a rare aircraft type: Boeing's custom "Dreamlifter."
The Dreamlifter is a converted 747-400 with roughly triple the cargo volume thanks to its bulbous hull. Boeing designed the type in the mid-2000s specifically to transport large components for the 787 — such as wings — from suppliers to its manufacturing plant. Other oversized cargo aircraft at the time were too small.
The four Dreamlifters, which are operated for Boeing by cargo carrier Atlas Air, primarily pick up Dreamliner wings, made by Mitsubishi Heavy Industries in Japan, as well as several fuselage sections, frames, horizontal stabilizers and other parts from Leonardo in Italy, and drop them off in Charleston.
The Dreamlifters also deliver disassembled sections of the main fuselage, which are built by several suppliers including Spirit AeroSystems in Wichita, Kansas, Leonardo in Italy and Kawasaki in Japan. Meanwhile, thousands of other components are shipped using a variety of modes of transportation.
During TPG's visit, two of the Dreamlifters were on-site.
Boeing still builds some components itself, though — in particular the aft section, or back, of the airplane.
Unfortunately, Boeing asked us to agree not to photograph some parts of the facility, since it uses proprietary technology and methods in the manufacturing process. Still, we were able to get a look and take photos in some areas.
Once the aft section is completed, workers bring it over to a final assembly building.
There, the aft section is joined to the fuselage, and the wings and other structures are attached to the main body. The plane moves down the assembly line, and the aircraft interiors are installed, along with flight control systems. The vertical stabilizer has already been painted by the time the plane enters final assembly, and the livery is applied to the rest of the aircraft once it completes its run through the assembly line.
Finishing touches are put on, and each individual airplane is flown for a grueling test program before being delivered. During TPG's tour, a 787-9 bound for Turkish Airlines landed after returning from nearly three hours of testing over the Atlantic Ocean.
The Charleston facility has 787s parked all around waiting to be delivered. The Federal Aviation Administration ordered 787 deliveries to pause in mid-2021 after numerous concerns arose surrounding Boeing's quality control process in Charleston. Deliveries resumed late last summer.
Because of the year-plus pause in deliveries, which came just as air travel demand was beginning to return following pandemic-era lows, Boeing is working to get a backlog of completed airplanes to airline customers.
Between the pandemic and the delivery pause, the company also slowed the production line. Boeing is targeting a rate of five completed Dreamliners each month, according to Lisa Fahl, senior director of quality.
The line peaked at 14 new airplanes per month between Charleston and Everett, Fahl said, suggesting that output could scale up in the future.
It's not clear when production will speed up, but as United's order demonstrates, there's heavy demand for new Dreamliners — and there will likely continue to be for years to come.
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There’s a lot to love about the Amex Gold. It’s a fan favorite thanks to its fantastic bonus-earning rates at restaurants worldwide and at U.S. supermarkets. If you’re hitting the skies soon, you’ll also earn bonus Membership Rewards points on travel. Paired with up to $120 in Uber Cash annually (for U.S. Uber rides or Uber Eats orders, card must be added to Uber app and you can redeem with any Amex card), up to $120 in annual dining statement credits to be used with eligible partners, an up to $84 Dunkin’ credit each year at U.S. Dunkin Donuts and an up to $100 Resy credit annually, there’s no reason that foodies shouldn’t add the Amex Gold to their wallet. These benefits alone are worth more than $400, which offsets the $325 annual fee on the Amex Gold card. Enrollment is required for select benefits. (Partner offer)Pros
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Cons
- Not as useful for those living outside the U.S.
- Some may have trouble using Uber and other dining credits
- You may be eligible for as high as 100,000 Membership Rewards® Points after you spend $6,000 in eligible purchases on your new Card in your first 6 months of Card Membership. Welcome offers vary and you may not be eligible for an offer. Apply to know if you’re approved and find out your exact welcome offer amount – all with no credit score impact. If you’re approved and choose to accept the Card, your score may be impacted.
- Earn 4X Membership Rewards® points per dollar spent on purchases at restaurants worldwide, on up to $50,000 in purchases per calendar year, then 1X points for the rest of the year.
- Earn 4X Membership Rewards® points per dollar spent at US supermarkets, on up to $25,000 in purchases per calendar year, then 1X points for the rest of the year.
- Earn 3X Membership Rewards® points per dollar spent on flights booked directly with airlines or on AmexTravel.com.
- Earn 2X Membership Rewards® points per dollar spent on prepaid hotels and other eligible purchases booked on AmexTravel.com.
- Earn 1X Membership Rewards® point per dollar spent on all other eligible purchases.
- $120 Uber Cash on Gold: Add your Gold Card to your Uber account and get $10 in Uber Cash each month to use on orders and rides in the U.S. when you select an American Express Card for your transaction. That’s up to $120 Uber Cash annually. Plus, after using your Uber Cash, use your Card to earn 4X Membership Rewards® points for Uber Eats purchases made with restaurants or U.S. supermarkets. Point caps and terms apply.
- $84 Dunkin' Credit: With the $84 Dunkin' Credit, you can earn up to $7 in monthly statement credits after you enroll and pay with the American Express® Gold Card at U.S. Dunkin' locations. Enrollment is required to receive this benefit.
- $100 Resy Credit: Get up to $100 in statement credits each calendar year after you pay with the American Express® Gold Card to dine at U.S. Resy restaurants or make other eligible Resy purchases. That's up to $50 in statement credits semi-annually. Enrollment required.
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- Explore over 1,000 upscale hotels worldwide with The Hotel Collection and receive a $100 credit towards eligible charges* with every booking of two nights or more through AmexTravel.com. *Eligible charges vary by property.
- No Foreign Transaction Fees.
- Annual Fee is $325.
- Terms Apply.
Rewards Rate
| 4X | Earn 4X Membership Rewards® points per dollar spent on purchases at restaurants worldwide, on up to $50,000 in purchases per calendar year, then 1X points for the rest of the year. |
| 4X | Earn 4X Membership Rewards® points per dollar spent at US supermarkets, on up to $25,000 in purchases per calendar year, then 1X points for the rest of the year. |
| 3X | Earn 3X Membership Rewards® points per dollar spent on flights booked directly with airlines or on AmexTravel.com. |
| 2X | Earn 2X Membership Rewards® points per dollar spent on prepaid hotels and other eligible purchases booked on AmexTravel.com. |
| 1X | Earn 1X Membership Rewards® point per dollar spent on all other eligible purchases. |
Intro Offer
You may be eligible for as high as 100,000 Membership Rewards® Points after spending $6,000 in eligible purchases on your new Card in your first 6 months of Membership. Welcome offers vary and you may not be eligible for an offer.As High As 100,000 points. Find Out Your Offer.Annual Fee
$325Recommended Credit
Credit ranges are a variation of FICO® Score 8, one of many types of credit scores lenders may use when considering your credit card application.Excellent to Good
Why We Chose It
There’s a lot to love about the Amex Gold. It’s a fan favorite thanks to its fantastic bonus-earning rates at restaurants worldwide and at U.S. supermarkets. If you’re hitting the skies soon, you’ll also earn bonus Membership Rewards points on travel. Paired with up to $120 in Uber Cash annually (for U.S. Uber rides or Uber Eats orders, card must be added to Uber app and you can redeem with any Amex card), up to $120 in annual dining statement credits to be used with eligible partners, an up to $84 Dunkin’ credit each year at U.S. Dunkin Donuts and an up to $100 Resy credit annually, there’s no reason that foodies shouldn’t add the Amex Gold to their wallet. These benefits alone are worth more than $400, which offsets the $325 annual fee on the Amex Gold card. Enrollment is required for select benefits. (Partner offer)Pros
- 4 points per dollar spent on dining at restaurants worldwide and U.S. supermarkets (on the first $50,000 in purchases per calendar year; then 1 point per dollar spent thereafter and $25,000 in purchases per calendar year; then 1 point per dollar spent thereafter, respectively)
- 3 points per dollar spent on flights booked directly with the airline or with amextravel.com
- Packed with credits foodies will enjoy
- Solid welcome bonus
Cons
- Not as useful for those living outside the U.S.
- Some may have trouble using Uber and other dining credits
- You may be eligible for as high as 100,000 Membership Rewards® Points after you spend $6,000 in eligible purchases on your new Card in your first 6 months of Card Membership. Welcome offers vary and you may not be eligible for an offer. Apply to know if you’re approved and find out your exact welcome offer amount – all with no credit score impact. If you’re approved and choose to accept the Card, your score may be impacted.
- Earn 4X Membership Rewards® points per dollar spent on purchases at restaurants worldwide, on up to $50,000 in purchases per calendar year, then 1X points for the rest of the year.
- Earn 4X Membership Rewards® points per dollar spent at US supermarkets, on up to $25,000 in purchases per calendar year, then 1X points for the rest of the year.
- Earn 3X Membership Rewards® points per dollar spent on flights booked directly with airlines or on AmexTravel.com.
- Earn 2X Membership Rewards® points per dollar spent on prepaid hotels and other eligible purchases booked on AmexTravel.com.
- Earn 1X Membership Rewards® point per dollar spent on all other eligible purchases.
- $120 Uber Cash on Gold: Add your Gold Card to your Uber account and get $10 in Uber Cash each month to use on orders and rides in the U.S. when you select an American Express Card for your transaction. That’s up to $120 Uber Cash annually. Plus, after using your Uber Cash, use your Card to earn 4X Membership Rewards® points for Uber Eats purchases made with restaurants or U.S. supermarkets. Point caps and terms apply.
- $84 Dunkin' Credit: With the $84 Dunkin' Credit, you can earn up to $7 in monthly statement credits after you enroll and pay with the American Express® Gold Card at U.S. Dunkin' locations. Enrollment is required to receive this benefit.
- $100 Resy Credit: Get up to $100 in statement credits each calendar year after you pay with the American Express® Gold Card to dine at U.S. Resy restaurants or make other eligible Resy purchases. That's up to $50 in statement credits semi-annually. Enrollment required.
- $120 Dining Credit: Satisfy your cravings, sweet or savory, with the $120 Dining Credit. Earn up to $10 in statement credits monthly when you pay with the American Express® Gold Card at Grubhub, The Cheesecake Factory, Goldbelly, Wine.com, and Five Guys. Enrollment required.
- Explore over 1,000 upscale hotels worldwide with The Hotel Collection and receive a $100 credit towards eligible charges* with every booking of two nights or more through AmexTravel.com. *Eligible charges vary by property.
- No Foreign Transaction Fees.
- Annual Fee is $325.
- Terms Apply.