boeing plant tour charleston sc

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.

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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.

Boeing Tours

Boeing future of flight and boeing everett factory tour.

Boeing Future of Flight is one of Washington State's premier aerospace attractions, welcoming guests to enjoy the Boeing Everett Factory Tour, Gallery, Sky Deck and Boeing Store. Boeing Future of Flight is located in Mukilteo, WA next to Paine Field and the Boeing Everett Factory, just 25 miles north of downtown Seattle.

Step inside the world's largest factory for a behind-the-scenes look at the Boeing Everett Factory and 777 assembly line. Each tour is an 80-minute guided experience with a front row view of current airplane production, the Everett site’s history, and the central role it plays in the future of commercial aviation. Tours are available Thursday–Monday.

Learn more about the Everett, WA tour

James S. McDonnell Prologue Room Air and Space History Exhibit in St. Louis

The James S. McDonnell Prologue Room Air and Space History Exhibit showcases the pioneers of aviation, their achievements and those of the thousands of workers who turned dreams into reality. The Prologue Room is located in the Boeing-St. Louis headquarters adjacent to Lambert-St. Louis International airport. The Prologue Room is open for self-guided tours weekdays during June, July and August only. Guided tours are available to groups of 10 or more throughout the year.

Learn more about the St. Louis tour

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Go behind the scenes at boeing: factory tours are back.

Boeing's Everett factory, renowned as the largest building in the world by volume, once again opened its doors to the public on October 5

by Enrique Perrella

November 1, 2023

Photo: Courtesy of Boeing Commercial Airplanes

After a lengthy hiatus due to the COVID-19 pandemic, the Boeing Factory Tours are back, offering aviation enthusiasts and curious minds a chance to witness the magic of aircraft production.

For years, the Boeing Factory Tour has been a sought-after experience, attracting more than six million visitors from around the globe since its inception in 1968. The tour provides a glimpse into the fascinating world of aviation, with a behind-the-scenes look at the assembly line of iconic Boeing aircraft, which included the 747, 767, 777, and 787 Dreamliner.

Christi Medlyn, Boeing Future of Flight general manager, shared the excitement surrounding the reopening with Business Traveler USA .

“We’ve been closed for the tour portion of the experience for three and a half years. In the meantime, we invested in this space to give people a great brand experience for Boeing. It’s not just about airplane manufacturing; it’s about the full enterprise,” she explained.

A Renewed Factory Tour

Boeing’s Future of Flight location has undergone a transformation over the past few years to complement the factory tour. It now offers an immersive experience that covers various aspects of Boeing’s operations, including sustainable fuels, autonomous flight, and satellite technology.

In addition, hands-on activities and STEM learning opportunities have been introduced, allowing visitors to engage with drones and robots.

Visitors will notice several enhancements to the Boeing Factory Tour experience. The new route through the factory offers a unique perspective, taking guests from the Boeing Future of Flight Museum to the massive Everett factory, where tens of thousands of employees support airplane production.

The tour also includes access to the site’s underground system of factory tunnels and an observation balcony providing an exclusive, sweeping view of the current 777 assembly line where Boeing’s future flagship, the 777X, will also be manufactured. Lufthansa and Emirates are the first two airlines expecting to take delivery of the new variant of the Triple Seven.

Photo: Boeing 777X. Courtesy of Boeing Commercial Airplanes

Furthermore, visitors are treated to a comfortable bus tour that takes them through various sections of the airport tarmac. The journey starts from the area where new planes are fueled for the first time and continues to where Boeing 737 fuselages arrive on train wagons from Wichita, Kansas.

Sometimes, brand-new Boeing 777s without engines can be spotted, and other rare planes like Boeing 767 military tankers can be seen as they are prepared for delivery. During every portion of the tour, a knowledgeable guide provides detailed explanations of every aspect and responds to any questions from curious visitors.

However, the tour isn’t the only attraction. Boeing Future of Flight features the Boeing Gallery, showcasing nearly 150 past, current, and future Boeing products and services, including the intriguing Passenger Air Vehicle (PAV) or personal flying car.

The Above and Beyond exhibit offers immersive simulations, and visitors can snap selfies with the Destiny Module from the International Space Station.

The open-air Sky Deck provides breathtaking views of Paine Field, the factory, and the enchanting North Cascade Mountains in the distance. It’s not unusual to spot brand-new planes parked on the deck, preparing for their journey into the skies.

And for those looking to take home a piece of aviation memorabilia, the Boeing store offers a wide range of souvenirs, from sweatshirts to scale model jets, coffee mugs, and vintage Boeing pilot jackets for kids and adults.

Overwhelming Response

The reopening of the Boeing Factory Tours has been met with overwhelming demand. Visitors have expressed their excitement and appreciation for the improved experience.

“It has been overwhelmingly positive, as we have been sold out every day. The pent-up demand and excitement around our product has been contagious. We are pleased with the positive visitor reviews received so far,” Christi Medlyn said.

“We’ve invested in every aspect of the experience, from the script to the exhibit content. We’ve added new elements and updated the storytelling.”

“Even though the experience is a bit different from the last time, we have made significant investments in every aspect. You will see the difference even while walking down the booth hallways,” Medlyn added.

Focus on the Boeing 777

While the tour has shifted its focus from the 747 to the 777 experience, it continues to captivate visitors, old and new, with its rich history and innovations in the world of aviation.

With the entire assembly line for the 787 Dreamliner now operational at Boeing’s South Carolina plant, the facility at Paine Field is exclusively dedicated to the Triple Seven family of planes. This includes the present 777 Freighter, along with the new 777X, along with the occasional 767 Freighter.

“After the 747 and the 787 were no longer being manufactured in Paine Field, we had to alter our route,” Medlyn explained. “As a result, we are now focusing on improving the 777 experience while incorporating new elements that highlight the entire family of Boeing Commercial Airplanes. We aim to discuss sustainability and introduce fresh perspectives to our storytelling.”

“So, we looked at everything from the script to the exhibit content. We added a little bit of Boeing history that you’ll see in the theater experience through a video at the beginning of the tour.”

Whether you’re a seasoned aviation enthusiast or just curious about the marvels of flight, the Boeing Factory Tours are ready to deliver an unforgettable experience you’ll be eager to share with your friends for months to come.

So, mark your calendars, aviation fans, because this is a rare opportunity to step inside the world of Boeing, where dreams of flight become reality. The Everett factory, Boeing’s crown jewel, is ready to inspire and educate once again.

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Inside the Boeing South Carolina B787 Factory

In November 2009, Boeing broke ground in North Charleston, South Carolina, on a revolutionary manufacturing facility for the B787 Dreamliner.

Final Assembly

The 787 final assembly building opened in 2011, provide expanded production and delivery capability to help the company fulfill orders for 787-8 and 787-9 from more than 60 customers. worldwide. The first 787 Dreamliner built in South Carolina rolled out in April 2012. By the end of the decade, Boeing plans to increase total production to 14 Dreamliners per month.

In final assembly, the three main fuselage sections, wings, horizontal stabilizer, vertical fin, and tailcone of the 787 are integrated. Teammates then install the engines, landing gear and other systems.

B787 Operation Cycle

Boeing South Carolina is the only site that has the full production cycle –“freezer to flight”.

Freezer is the fabrication from raw composite material. (which is kept in a freezer)

From Fabrication, some assemblies go to Puget Sound and the others go to Final Assembly just next door.

Next is decorative paint.

After paint, airplanes go to the Flight Line for fuel, testing.

Final step is delivery.

The new 787-10 Dreamliner will be built exclusively in South Carolina. At 224 feet (68.27 meters) in length, the 787-10 will be the longest Dreamliner to date. Carrying 330 passengers in a two class configuration.

Aftbody and Midbody

Every 787 aftbody and midbody is build in South Carolina, then some of them shipped to Everett, Washington by Dreamlifter and some of them were moved across by enormous cranes to the final assembly position at South Carolina.

The carbon-fiber tape used in the 787 is approx. 6.4mm wide and 0.2mm thick.

If all the carbon fiber used in a single 787 Dreamliner were streteched out in a line, it would reach from Charleston, SC to Los Angeles, CA - a distance of 2,200 miles.

The 787 is the first airliner with a fueslage composed of one-piece composite barrel sections rather than the thousands of aluminum sheets used in conventional airplane fuselages. This construction creates a lighter structure that uses 1.2 million fewer fasteners than the structure of a non-composite airplane.

Interiors Responsibility Center

The interiors responsibility center team fabricates and assembles 787 Dreamliner interior components, including stowage bins, closets, partitions, ceiling panels, class dividers, overhead crew rests, video-control stations and flight attendant modules.

Singapore Airlines became the world's first Boeing 787-10 customer.

Very nice and interesting article and visuals. How did you go about to get permission from Boing to take pictures in their assembly hall, etc. Thank you.

Does the Charleston factory offer any public tours of their facility outside of these dedicated media events?

I did ask this but seems no public tour in Charleston yet! 🙁

where’s the indoor sunglasses-wearing selfie?

You’re way way too good to be on Boarding Area 🙂

Awesome article!

Love the details..

– Happy Boeing investor

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AEROTECH® Americas

Boeing Charleston facility/plant tour

Date: March 25, 2019 Time: 1:00 – 3:45 p.m. Price: $50  (make selection during event registration)

Tour Timeline

The maximum tour limit for is 50 persons; reserve your seat by March 8, 2019.

Tour guidelines: 

• Visitor badge must be worn at all times.
• No cameras, video recorders, or camera phones are permitted inside the plant as defined in Boeing Policy, PRO-2783.
• Remain with escort at all times
• No open-toed shoes or open heels
• No high-heeled shoes: Heels must be shorter than 2-in high with a heel base larger than 1-in square.
• Visitors must adhere to the tour path as defined by their tour guide.
• Boeing escorts will remain with their visitors at all times and visit only those areas defined on the visitor badge
• Boeing is a tobacco-free workplace, and tobacco use of any kind is prohibited on Boeing property.

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Virtual Site Tours

See innovation in action with a series of Virtual Site Tours hosted by Boeing. Students will be transported around the U.S . to visit unique Boeing facilities, where they’ll learn more about the people and products leading the way to the future of air travel. Each video is paired with a companion activity that incorporates project-based learning, student collaboration, and hands-on STEM problem-solving

Boeing Unmanned Refueling Facility: St. Louis, MO

Get an inside look at the future of aviation at a Boeing facility that manufactures the world’s first unmanned refueling aircraft. See how drone technology is being used to revolutionize aircraft capabilities for the US Navy, and meet the pilots who control this amazing technology remotely from a desk! Students will meet a variety of dedicated Boeing team members as they tour a ground control station and go aboard a state-of-the-art aircraft carrier.

Boeing Training and Professional Services Campus: Miami, FL

Visit a Flight Training Center where the people who work on airplanes are trained in keeping passengers safe. Get a behind-the-scenes look at the state-of-the-art facilities and rigorous training processes that are used to prepare everyone from mechanics to pilots to flight attendants for their role in passenger safety. Students will be introduced to a variety of Boeing team members as they tour the structures lab and go inside a cutting-edge flight simulator.

Boeing’s Vertical Lift Division: Philadelphia, PA

Go behind the scenes of one of the most advanced helicopter manufacturing centers in the world to learn how vertical lift vehicles are created. Visit Boeing’s complex in Ridley Park, Pennsylvania, where over 6,000 employees work daily to build and restore the powerful H-47 Chinook and other aircraft. Students will meet a chief test pilot and discover how extended reality technology is used to solve problems on the manufacturing floor.

Boeing Additive Manufacturing Center: Auburn, WA

Explore the amazing ways Boeing uses additive manufacturing—better known as 3D printing—to design and manufacture thousands of its parts and tools. Take a tour of the Center of Additive Manufacturing Excellence, where parts, tools, and prototypes are created to support state-of-the-art aircraft. Students will hear from a variety of experienced manufacturing professionals and learn how specialized simulation software and lasers are used to help streamline the process.

Spectrolab Solar Panel Factory: Los Angeles, CA

Discover the special piece of technology powering everything from the International Space Station to satellites that enable mobile phones, internet and weather forecasting here on Earth. Visit Boeing’s state-of-the-art Spectrolab where high-efficiency solar cells are created to support life on Earth and human exploration of space. Explore the history of satellites and find out how Spectrolab employees simulate the sun!

787 Dreamliner Factory: North Charleston, SC

Get an inside look at the Boeing facility where the energy-efficient Dream l iner airplanes are built. Watch as many diverse teams come together to create a finished product that lives up to Boeing’s principles of safety, quality, and integrity. Students will explore a sustainably powered, z ero waste - to- l andfill facility to see sustainable innovation up-close, then bring aircraft design to life with a fun paper airplane activity.

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Boeing Delivers First North Charleston-built 787-9 Dreamliner

Boeing has delivered the first 787-9 Dreamliner assembled at its North Charleston, S.C., facility to United Airlines. The airplane also marks a milestone for the 787 program as the 250th Dreamliner to be delivered.

“In 2012, we delivered our first South Carolina-built 787-8, and less than three years later, we’re celebrating another significant milestone – our first 787-9 delivery,” said Beverly Wyse, vice president and general manager, Boeing South Carolina. “This is an incredible achievement for Boeing, and I’m proud to be a member of the Boeing South Carolina team.”

In the first quarter of 2013, Boeing South Carolina teammates began fabrication, assembly and integration of the aft and mid fuselage sections for the first Boeing 787-9 and delivered them to Everett Final Assembly. In November 2014, work began on the first South Carolina-built 787-9 when the first aft and mid sections were delivered to Boeing South Carolina Final Assembly. The airplane rolled out to the flight line in January 2015 and completed its first flight last month.

“Our customers have told us they love flying on the Dreamliner, and we’re excited to mark yet another first for the aircraft with this delivery from Boeing South Carolina,” said United’s Vice President of Fleet Ron Baur. “We were the first North American carrier to fly the 787-8 in September 2012 and the first to fly 787-9s in September 2014. The Dreamliners have allowed us to fly longer distances with greater fuel efficiency and open new direct routes such as Los Angeles to Melbourne, while providing our customers and employees with a more comfortable flying experience.”

This is the fourth 787-9 for United Airlines, in addition to the 12 787-8s the airline already has in service.

The 787-9 complements and extends the 787 family. With the fuselage stretched by 20 feet (6 meters) over the 787-8, the 787-9 is designed to fly up more passengers and cargo farther with the same exceptional fuel and environmental performance: 20 percent less fuel use and emissions than the airplanes they replace.

• Boeing & Aerospace

Boeing plans for N. Charleston reveal doubling of facilities

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WASHINGTON — Boeing will more than double the number of parking slots for finished jetliners and add a second final-assembly line at its plant in North Charleston, S.C., according to a recent document that also suggests the newest version of the 787 Dreamliner may not be built in Everett.

The public filing details how Boeing will grow at its 265-acre campus next to Charleston International Airport, as well as on 468 acres of adjacent land the state bought this month to lease long term to the company.

Boeing outlined its plans in papers filed with the U.S. Army Corps of Engineers seeking approval to use federal wetlands. The disclosure was required because Boeing proposes to excavate or fill almost 154 acres of federal waters to level the ground for construction.

Included are nearly 20 acres of wetlands or upland buffers that were protected under a restrictive covenant when the Boeing plant was built in 2011.

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Most immediately, Boeing will expand its flight line — where finished jets are parked for engine and fuel testing before test flight — from seven stalls to 16. The plan also includes a previously announced paint facility so that finished Dreamliners can be delivered to customers in North Charleston without first being flown to Fort Worth, Texas, for final painting.

Starting in 2016 or after, the document says, Boeing will enlarge its existing final-assembly plant southward to fit in a second, parallel production line.

Analysts have speculated Boeing was making room for final assembly of the 787-10, the newest and longest derivative of the popular Dreamliner — or for perhaps even the 777X that’s the focus of a pending multistate competition.

The latest details of Boeing’s expansion plans reinforce indications that the 787-10 likely will get built in North Charleston, said Scott Hamilton, an aviation analyst with Leeham in Issaquah.

Boeing is expected to announce the final-assembly site for the 787-10 in March.

Currently, Boeing’s widebody plant in Everett assembles both the base 787-8 model and the stretch 787-9. North Charleston handles final assembly for the 787-8 and is to begin producing the 787-9 next fall.

At 224 feet, the 787-10 is 40 feet longer than the 787-8. The current North Charleston plant is nearly 1,100 feet long, according to scale maps in the public notice released by the Army Corps of Engineers and the South Carolina Department of Health and Environmental Control.

That’s room enough to fit four 787-10s in line. In Everett, Hamilton said, a nose-to-tail 787-10 assembly line would have to be at an angle, which is less efficient.

Boeing is proposing to replace North Charleston’s single U-shaped assembly line with two parallel lines by stretching the plant by about 800 feet.

Boeing’s long-term plan for North Charleston calls for adding 3.4 million square feet of manufacturing space to the west and south of the current plant, near the intersection of Michaux Parkway and International Boulevard. Also included are additional office space and parking.

Boeing recently gave up first right of refusal to buy an additional 488 acres of land west of the airport, saying it could always come back to it.

Jack Jones, general manager of Boeing’s South Carolina operations, had steadfastly declined to specify the company’s plans for all the available land.

Boeing is producing a total 10 Dreamliners a month from the two assembly lines in Everett and the single line in North Charleston but doesn’t break out each plant’s output. The combined rate is to quicken to 12 a month by 2016 and to 14 a month by 2019.

That scenario calls for seven Dreamliners a month to roll out of North Charleston by 2018-19. On top of that, Boeing is building a North Charleston plant to design and assemble engine inlets for the 737 MAX to be produced in Renton.

That might keep North Charleston too busy, Hamilton believes, to have a shot at landing the 777X if Puget Sound-area Machinists again reject Boeing’s contract offer Friday.

The 777X “is more than I think Charleston can handle,” Hamilton said. “But Boeing being Boeing, you never know.”

Connie Kelliher, spokeswoman for International Association of Machinists District 751, which represents Boeing’s Puget Sound-area assembly workers, said the union believes tooling Boeing installed in the Everett plant is equipped to handle the 787-10’s longer fuselage.

What’s more, Kelliher contends, analysts and Boeing workers think the only way the company can meet its accelerated production for the Dreamliner would be to keep the second “surge” line in Everett going permanently.

Kelliher said Everett is slated to ramp up to nine 787s a month in early 2014, far outpacing North Charleston.

“We are certainly producing more than our share of 787’s right now,” she said.

The public in South Carolina has until Jan. 20 to comment on Boeing’s expansion plan. In exchange for use of federal wetland near the Ashley River, Boeing has offered to preserve 3,618 acres of nearby Cooper River watershed as well as clean out 150 acres in another watershed to restore natural plants and animals.

Kyung Song: 202-383-6108 or [email protected]. Twitter: @KyungMSong

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• Mid-Level or Senior Manufacturing Technology Analyst Charleston, South Carolina 09/04/2024 Save for Later

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