Boeing 787-8 Design, Certification, and Manufacturing Systems Review

This final report is in response to the Federal Aviation Administration's (FAA) and Boeing Commercial Airplanes' (Boeing) assignment to validate the work conducted during the Boeing 787 (B787) certification process and further ensure the airplane meets the intended level of safety. On January 31, 2013, the FAA and Boeing jointly formed the B787 Critical Systems Review Team (CSRT) to conduct a comprehensive review of the B787's critical systems, including the airplane's design, manufacture, and assembly, and provide recommendations. From February 1, 2013, to July 31, 2013, the CSRT, composed of FAA and Boeing subject matter experts, conducted in-depth reviews of B787 critical systems based on in-service data and using safety risk management principles. These subject matter experts have backgrounds in both engineering (systems, structures, and propulsion) and manufacturing/quality. The CSRT used in-service and in-production issues to focus its review. To further define the scope of its activities, the CSRT employed a safety-risk methodology to prioritize areas for review.