Case Study: Impact of Decisions on Development of Boeing 737 Max

Essential Idea:

Design decisions can unforeseen impacts

Introduction

The airplane manufacturing industry is dominated by two large companies: Boeing and Airbus. The two companies have been in fierce competition since the 1990s for dominance of the market. Early on, Airbus took the lead by implementing advanced technologies to improve performance and lower costs. Airbus was the first to introduce 2-person cockpits, the use of composite materials to lower weight and increase strength, and the development of fly-by-wire (digital) controls.

Recently, the energy efficiency of aircraft has become an important focus for aircraft manufacturers and airlines. Here, Airbus was the first to start using the CFM Leap engine, which boasts a 15% reduction in fuel production. This revolutionary engine was first used on the Airbus A320neo. The success of the design, and the fuel savings, saw Airbus grab a large market share. In response, Boeing developed the 737 Max which uses the same engine.

On October 29, 2018, a Lion Air Boeing 737 Max 8 crashes after takeoff. On March 10, 2019, an Ethiopian Airlines 737 Max8 crashes soon after take off. Upon examination of the airplane black boxes, similarities in the possible causes of the crash are identified.

The VOX video below, "The real reason Boeing's new plan crashed twice," goes into detail about the decisions and possible causes of these two catastrophes.

Who makes the CFM Leap Engine?

The Leap engine is manufactured by a CFM, joint venture between Safran Engines and General Electric (GE). The engine is 15% more fuel efficient and 40% quieter than other engines.

The engine features several technological advances and composite materials to achieve its high performance. In particular, its woven carbon fiber blades play a key role:

each engine is 500kg lighter
carbon fiber allows for an larger diameter blade, which results in greater propulsion
blades are more resistant to corrosion, temperature changes, and damage from impact and are

Questions and Reflection

1. Discuss whether the development of the A320neo is an example of market pull or technology push.

2. Identity and describe the category of innovation that best describes Airbus's introduction of the A320neo.

3. Outline the benefits of upgrading the engine on the A320neo.

4. Discuss two types of modelling might Boeing have used to determine that the high placement of the engine on the wing was feasible.

5. As outlined in the video, the Boeing designers were faced with two possible options to respond to Airbus's new plane: improve the existing 737 design, or develop a new plane.

5a. List the benefits and drawbacks of each approach.

Reflections Questions

Looking back on the history of decisions described in the video, identify what you believe to be the root cause of the problem with 737Max. What might the designers have done differently to prevent the error?

In what ways can designers predict, avoid or reduce the potential harm of their designs?

Resources

VOX: The Real Reason Boeings Plan Crashed Twice