Critics have blamed outsourcing for the company’s recent lapses: some twelve hundred suppliers design and manufacture parts for Boeing planes. “There were a number of issues that we had,” Larson said. “But we’re coming out of that. We can’t build airplanes fast enough.” He walked me over to a half-finished 777 that was about to have its wings attached. “I remember my very first fuselage join,” he said. “The mechanics drilled about eight hundred holes, then started inspecting the skin around them. I thought, This is going to take forever!” The wings have to be mated to the body with gaps of five- to ten-thousandths of an inch. Then they’re bolted on with just enough torque to flex and hold fast, even in the most severe turbulence. In Boeing’s stress tests, they can bend almost forty-five degrees and snap back, and withstand years of flexing without structural fatigue. “It’s not a piece of farm equipment,” Larson said. “It’s a life-support system. At thirty-five thousand feet, you can’t pull over.”
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This story was originally featured on Fortune.com
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