The world’s first Boeing 747-400 LCF rolled out amidst fanfare and festivities at a ceremony staged by the two companies in a sparkling EGAT hangar at Chiang Kai-Shek International Airport in Taiwan.  Mr. David Wang, Chairman of EGAT, and Mr. Scott Strode, Vice President, Airplane Development and Production, 787 “Dreamliner” Program, Boeing Commercial Airplanes, co-hosted the event. An impressive list of VIPs, including Taiwan’s Ministers of Transportation, County Governer, officials from Ministers of Economic Affairs, American Institute in Taiwan, and Dr. Chang Yung-Fa, Group Chairman, the Evergreen Group, participated in the red-carpet event.  A thank-you tribute recognizing the talent and hard work of approximately 300 specially invited Boeing and EGAT LCF team members and performances by the Evergreen Wind Band highlighted the program.  The band, a 28-member ensemble of classically trained musicians, wore uniforms with blue shirts and caps designed by Dr. Chang to evoke traditional marine-captain attire. Especially for the elegant cap of the female members which caught everyone’s attention.

"It's hard to believe it's been only 18 months since we announced that EGAT would modify this unique fleet of airplanes," said Scott Strode, 787 vice president of Airplane Development and Production, Boeing Commercial Airplane Groups.  "This team has set a new standard for partnership, performance and achievement while working to a very aggressive schedule."

"It's difficult to overstate the important role the LCF plays in the 787's success," Strode said. "Transporting the large composite structures by air is the foundation of the lean global production system we've designed for the 787."

Competition for the specialized airframe conversion assignment was stiff and included a selected pool of the world’s aviation maintenance, repair and overhaul (MRO) industry leaders.  EGAT’s success with the work establishes it as a global MRO player, and creates a springboard into the aircraft conversion market for Taiwan’s burgeoning aviation industry.

“We are confident our remaining two conversions will be completed on time and will be in use when they are needed to get ‘Dreamliner’ production off to a smooth start,” said Wang.  “We are proud that Boeing selected EGAT to perform these conversions.”

The World’s First Large Cargo Freighter

The enormous airplane is the first of three specially modified jets that will be used to transport major assemblages back to the Boeing factory in Everett, Wash. for final assembly of the all-new Boeing 787 “Dreamliner.”  A modified Boeing 747-400 passenger aircraft, the LCF can haul more cargo by volume than any other airplane in the world.  With a volume of 65,000 cubic feet (1,845cubic meters), the LCF can carry loads that are three times the size of those accommodated by the original Boeing 747-400 freighter, which has a capacity of 24,900 cubic feet (115 tons).  The new Boeing 747-400 LCF also incorporates an original “swing tail” design that allows fast, easy loading and unloading of the huge composite assemblages.

High-Tech Aircraft Modification

The LCF conversion project demonstrates the highest technology available for aircraft modification.  Implementing required modifications was more difficult than producing a brand-new Boeing 747-400 or converting a passenger model of the aircraft into a standard freighter.  Boeing led a global team of experts to design the LCF, its various components and systems. In addition to conducting ground tests and test flights, the Boeing team has overseen the large-scale integration effort and maintains daily program management. EGAT transferred the design into working plans for engineers and orders for technicians, and transformed the original airframe to meet LCF specifications, in addition to installing and testing new, upgraded operating systems.  EGAT began work on the first Boeing 747 LCF conversion in June 2005 in Hangar No.2 where the unveiling event was staged.  Executed with surgical precision, the first steps required cutting away the upper portion of the fuselage and tail sections of the Boeing 747-400, lengthening and heightening the airframe, and building the swing tail to facilitate ease of uploading and unloading of the of the large composite sections for the 787 Dreamliner.

The Boeing 747-400 LCF Building Process

The world’s first 747-400 LCF took 375 working days and more than 500,000 hours by 450 engineers, technicians, mechanics, construction specialists, quality control experts, ground-support personnel and more. The new aircraft has over 20,400 square feet (1,836 square meters) of skin held in place by more than 850,000 rivets.  Together, EGAT and Boeing skillfully managed two shifts that worked a combined 16 hours a day to complete the first LCF.  EGAT’s successful roll-out of the huge conversion assignment demonstrates the company’s abilities and effective use of technology, in addition to setting a major MRO-industry milestone.

Future Development

EGAT started building the second LCF in November of 2005 and currently, 65 percent of the conversion has been completed. The third one is expected to be modified in 2007. EGAT has confidence in completing the rest of the task and will still cooperate closely with Boeing to help ensure the program is working smoothly.

EGAT Introduction

EVA Air and GE Aircraft Engines, the world’s largest engine manufacturer, formed Evergreen Aviation Technologies Corporation (EGAT) as a joint venture in September 1998.  The marriage of EVA’s airline experience with GEAE’s leading-edge aviation technology proved to be ideal and produced a world-class maintenance operation equipped to both respond to individual carrier’s requirements and provide top quality maintenance services.  

EGAT’s technologically advanced facility includes two massive aircraft hangars, onefully equipped engine shops and one 120,000-pound engine test cell plus storage for spare parts and equipment.  A third hangar is under constructed and scheduled for completion in April 2007.  EGAT has 1,700 dedicated employees, and serves approximately 30 airlines in addition to providing spare part and maintenance services for GE Aircraft Engines and The Boeing Company.

Since the 787 launch in April 2004, 32 customers have logged 420 orders and commitments, of which 377 are firm orders valued at $59 billion at current list prices, making the Dreamliner the most successful commercial airplane launch in history.