3.1 Essence of this stage

Testing of an aircraft means checking of how it will work during regular expluatation. It includes checking of its’ aerodynamic flight characteristics, chacking of its’ safety for passengers and crew etc.

3 .2 The initial assembly of the 737 was adjacent to Boeing Field (now officially named King County International Airport) because the factory in Renton was at capacity building the 707 and 727. After 271 aircraft, production was moved to Renton in late 1970. A significant portion of the fuselage assembly is in Wichita, Kansas previously by Boeing but now by Spirit AeroSystems, which purchased some of Boeing's assets in Wichita. The fuselage is joined with the wings and landing gear, then moves down the assembly line for the engines, avionics, and interiors. After rolling out the aircraft, Boeing tests the systems and engines before its maiden flight to Boeing Field, where it is painted and fine-tuned before delivery to the customer. An early-production Boeing 737-100 of Lufthansa, the type's launch customer, at Hannover Airport (1968).

The first of six -100 prototypes rolled out in December 1966, and made its maiden flight on April 9, 1967, piloted by Brien Wygle and Lew Wallick. On December 15, 1967, the Federal Aviation Administration certified the -100 for commercial flight, issuing Type Certificate A16WE. The 737 was the first aircraft to have, as part of its initial certification, approval for Category II approaches.[25] Lufthansa received its first aircraft on December 28, 1967, and on February 10, 1968, became the first non-American airline to launch a new Boeing aircraft. Lufthansa was the only significant customer to purchase the 737-100. Only 30 aircraft were ever produced.

The 737-200 had its maiden flight on August 8, 1967. It was certified by the FAA on December 21, 1967,[24][27] and the inaugural flight for United was on April 28, 1968, from Chicago to Grand Rapids, Michigan.[23] The lengthened -200 was widely preferred over the -100 by airlines.

3.3 The cost of testing phase is the cost of ground test aircraft. Prior to aircraft ground tests must be completed laboratory, bench and flight testing of its engine , the basic onboard systems and equipment. Flight tests are divided into the factory and government . Tests carried out at the factory for standalone and integrated working reliable operation of the airframe, powerplant , the definition of basic flight performance data. To calculate the total cost of the testing phase - takes into account the cost of flying time , the cost of salaries collective value of computer simulation station to the cost of software.

This stage is quite expensive taking into account that all elements should be tested somehow, most significant parts are subjected to different loads and tested at different temperatures, different analysis for determination the service life of each element is made, prototypes are made, so it involves cost of staff, cost of pilots, etc., taking into account that FAA signs the date, if the test fails the whole procedure is repeated once more, and this is additional cost, so it is quiet difficult to predict this one. I can tell you only about such parameter as fuel cost per nautical mile of Boeing 787-8 --- $24.39. I will need 2 pilots so I will spend approximately $20,000

Stage 4

Production

4.1 Production The first 271 737s were built in Seattle at Boeing Plant 2, just over the road from Boeing Field, (BFI). However, with the sales of all Boeing models falling and large scale staff layoffs in 1969, it was decided to consolidate production of the 707, 727 and 737 at Renton just 5 miles away. In December 1970 the first 737 built at Renton flew and all 737s have been assembled there ever since.

However not all of the 737 is built at Renton. For example, since 1983 the fuselage including nose and tailcone has been built at Wichita and brought to Renton by train. Also much of the sub-assembly work is outsourced beyond Boeing.

Production methods have evolved enormously since the first 737 was made in 1966. The main difference is that instead of the aircraft being assembled in one spot they are now on a moving assembly line similar to that used in car production. This has the effect of accelerating production, which not only reduces the order backlog and waiting times for customers but also reduces production costs. The line moves continuously at a rate of 2 inches per minute; stopping only for worker breaks, critical production issues or between shifts. Timelines painted on the floor help workers gauge the progress of manufacturing.