Boeing made the decision to outsource a significant portion of the 787 Dreamliner's design and manufacturing to external suppliers during the initiation phase of the project. This move was considered a bold and historic departure from traditional aerospace manufacturing.
While the exact date of the initial decision is not precisely stated, the program was officially launched in April 2004, indicating that the outsourcing strategy was in place around or before that time. It's mentioned that in January 2003, Boeing announced the 7E7 Dreamliner (later the 787), and by September 2005, the company was sending detailed design work to its global partners.
Boeing outsourced approximately 70% of the design, engineering, and manufacturing to over 50 strategic partners. This strategy aimed to: Cut costs,Accelerate development,Share risk,Leverage suppliers' expertise.
However, this extensive outsourcing led to various challenges, including supply chain disarray, costly delays, and difficulties with integration.
Stonecipher oversaw the launch of the Boeing 787 Dreamliner in order to challenge Airbus. Although not fully evident at the time, the results of major changes to Boeing's airplane program design, sourcing and financing made during Stonecipher's and Condit's tenures would later prove disastrous. The outsourcing and divestment decisions made 20 years earlier continue to cause Boeing serious problems.