Knows well the chemistry of the dreamliner battery. Boeing chose the most powerful there is but also the most volatile they went to lithium. Which is why here is our danger look so stepped down to secure a plane president just before the fire he started a new company to make lithium ion batteries for business jets. Bugs i was a true believer in the technology. Then he began testing 23. 3 m. Series. Battery that. Went beyond even the latest industry guidelines going so far as to fire bullets into batteries to see if they could be made safe military applications. You know you could run the test that you feel that you need to meet the requirements to be safe but. You also need to have a conscience thats going to tell you i want to do the extreme. In the end testing with a conscience couldnt make the batteries meet the requirements is new company failed. We became professional and destroying batteries and and in the more we learned about it the worse it got i mean with home i got him to give in to him and we were saying i wonder what the rest of the guys are doing well i guess we knew why. By the rest of the guys he means boeing. And they were testing too weak a standard one written by the f. A. A. Specifically for the dreamliner. Its the f. A. A. Is job to regulate safety but when it comes to building airplanes the f. A. A. Delegate service side almost completely to the aircraft manufacturers. When it comes to the battery and beyond boeing largely polices itself the batteries passed boeings tests in line with the f. A. A. Rules boeing said the 787 batteries would virtually never catch fire on board an aircraft then they failed twice in just 9 days. Boeing has not uncovered the root cause of the failures. It found a work around. A strong steel case morning too late. And in exhaust the no interest fuels any fire will be a hospital because theres not enough oxygen to support combustion but several leading scientists have their doubts i dont think its a sufficient fix even inside that steel box with all of its fortifications all the elements are still there for fire. Despite not knowing the root. Americas safety regulator the f. A. A. Was satisfied. And in april 2013 the dreamliner was back. But this story goes far beyond a burning battery it begins at boeing itself. Is it the 1st american commercial jet capable of economical Transatlantic Service the boeing 707 jet. Since its creation in seattle nearly a century ago boeing had developed a reputation as a world class engineering company. But in 1970 boeing changed. In merged with competitor mcdonnell douglas. 2 companies with 2 very different Business Models. The merger was all about transforming our successful culture and Business Model into the same business while the doll dogs had used unsuccessfully you basically insure g. G. Miriam is stop doing aggressive new product go into your other business for cash. The new boeing moved its headquarters from seattle the only home the company had ever known to chicago. It began slashing investment in research in order to cut costs. And maximize wall street returns. I felt was wrong i felt the company was going to come in the wrong direction and. I thought that quality would suffer and the integrity of the product would suffer. The feel that that legacy and now history in a clump of time. Has been hijacked. By a bunch of course. By 2003 it was time to launch a new plane. But boeings new board was reluctant to invest the billions needed. The board made it clear that. They wanted this plan made for less money they wanted it made for 5000000000. 00. They wanted parkers the command to pay the rest. Its expensive so how do you make that happen well you promised them that you can do it for words and then worry about the consequences later. Boeing came up with a plan to save itself money. It would push the costs on to its major suppliers. Boeing would call them pumice. And they would design and pay for the parts they built. Boeings job would be to assemble the plane. It was almost as if at times you thought boeing executives believed well maybe they could sit in chicago and have other companies do things they would just rake in the money somehow by putting it all together putting a boeing sticker on it at the end. Right on show jewel boeing rolled out the dreamliner on sunday july the 8th 2007. 787. Their alliance with us today have made a big commitment to boeing out of this airplane so far they have ordered 600 and 77th birthday. To you a lot of ways enjoy 2007 it was one of the more magical moments seen in the industry watching us live around the World Broadcasting im told in 45 countries in mind languages for the fear of this very exciting new boeing 787 dreamliner. We were all inside the factory with artificial lighting big stage tom brokaw huge screens. I. Then open the doors of this giant assembly bay a new roles this beautiful beautiful. There it is sitting in the sun and we all stream outside and well touch it. And none of us know that. And im reassured by all the executives involved that its going to fly within 2 months. What i realized Walking Around it is that you could you know. Look up in the wheel well and you can see daylight. We learn that the whole thing was shot. Beautiful isnt absolutely beautiful. They roll like this fish airplane. I realize the doors are made of plywood this plan that we were admiring was completely a shell inside none of this would be possible of course without Exceptional Leadership theres only 2 conclusions you can draw you have executives there who are either in which case theyre clueless because theyre going to get caught in 2 months or you have a complete disconnect between the people who are working on the play and the engineers and the executives who are saying this and so to each and every member of the sudden a sudden global team i say thank you. Congratulations and keep up the great work more than any other single event. It was a good line and it was a statement that the boeing company is now poem about the big lie. The day off to the roll out wall street pushed boeing stock to a 10 year high. But it was all about one rival as revealed in boeings investor calls. Car. Around. September 2007 boeing announces its 1st delay. The all your audi airplane goes to gather. Really complicated. Oct 2007 the 3 month delay becomes 6 months we wish we didnt have to do this. Kind of Innovation Challenges there were doing our best to meet. The target 20096 months becomes 2 years of delays. We know we can and must do better and im confident that despite our setbacks we will get 787 through the Flight Test Program and into the hands of our cause. It just kept getting worse and worse and it seems unbelievable you have to understand this is all the president there never been a boeing to land a boeing program the sequence of events which is awful on like a catastrophe rather then just a manageable series and away as. The dreamliner a Business Strategy was backfiring. Designed to save so much money it was costing boeing billions. The outsourcing plan failed very badly all these different suppliers who were going to build these major sections couldnt actually do it. To fix the dreamliner boeing dispatched hundreds of Quality Inspectors to struggling supply is around the globe including to its partner and linea in southern italy ringback. We are just looking through a day on a part of the full office. Ready would take on the topic of constructing the body of the plane not without a minion panels but with composite plastic barrels. The Main Objective to lose weight. Saving fuel and making the 707. 00 cheaper to run. But no one had ever made anything like this before not boeing and especially not in linea that is not the home of all of that on the market and nothing else like that. Boeings Quality Inspectors have one overriding priority to make sure the job is done correctly. In 2009 when inspectors found fools in parts made in this a lenny a plant. They would work to stop. A year later in a linear as other factory they again found Serious Problems and again they wanted work to stop. But this time manages overruled the Quality Inspectors. This internal boeing document from 2010 reveals executives ordered a linea to continue with fabrication without delay we follow all of the time the proceeded to stall but with the help of a boring specialist at the time there was a word in this prove it condition they took responsibility for approving the quality and we would continue to warfare engine and the product. In a separate memo obtained by aljazeera boeing states that she may required deviations to the preferred quality process. We received the memos from an engineer who like many we spoke with was afraid to appear on camera so he answered my questions by email. The quality engineer told us deviating. In the process compromised safety. A lineage boeing said it did not. So i brought the memo to the former president of boeings Engineers Union so my name is cynthia kohl c y n t h a last name c o l e since your cold spent 32 years at the company but never on the Dreamliner Program ringback. So she had never seen this memo before ready. The Program Schedule may require deviation to the preferred process see that was says right there that one fragment of the sounds you know you dont you dont change your quality process for schedule you make quality happen in the schedule. Theyre short changing the engineering process to meet a schedule and theyre not even allowing Quality Control to do their job and theyre telling them this is how its going to be i dont see how these people who write these things and agree to these things honestly if you hear how they how they sleep at night i just dont get it how can you do that. As an engineer i find that reprehensible. How does it make you feel as a fly. Oh yeah i know fire so is though and. It just makes you know because ive been kind of avoiding finalists only and seeing this i would definitely avoid fire. On counting the cost this week were on patrol off the coast of west africa as nations deployed naval forces to counter the scourge of piracy. Off the 6 years of treading water gold prices are on the rise plus how iraq plans to cut its. Counting the cost on aljazeera the latest news as it breaks. With details coverage no one is willing to return home to me on my own without. Papers and security guarantees from around the world the talent is facing the new Prime Minister and negotiate a new bricks that day a deal the e. U. Says cannot be renegotiated. America is divided like never before each side is so convinced that they are absolutely correct that the other side is dangerous people in power investigates how partisan politics are writing the civil norms vital to american democracy every indicator shows america to be the least well functioning democracy of any established democracy. One of the strange death of american civility on aljazeera. I was raised in france. These are my grandparents. These are my parents and this is mean. By them both isis and us on. The 1st of a 2 part epic tale of a remarkable family. The father the son and the jihad part one on aljazeera. Oh i Maryam Namazie in london just a quick look at the headlines now months of deadly bombardment have come to a pause in northwest syria after the government announced a conditional cease fire as strikes have halted in italy province which is syrias last rebel stronghold the truce was announced during peace talks in kazakhstan the opposition says they will abide by the deal as long as the government doesnt violate it there are fears the latest Ebola Outbreak in the democratic republic of congo could last for 2 to 3 years countries about a Response Team says the government there is only identifying about 50 percent of all the cases authorities are trying to trace anyone who came into contact with the latest victim of the virus in the congolese city of goma they say the man who died on wednesday had a large family and infected several people. U. S. President donald trump has announced a deal to sell more american beef to europe his government says its a modest win as washingtons trade war with china escalates exports to the bloc will increase by more than 40 percent in the 1st year but the deal still needs to be approved by the e. U. Parliament. The agreement today will lower trade barriers in europe and expand access for American Farmers and ranchers in year one duty free american beef exports to the e. U. Will increase by 46 percent over 7 years there will increase by another 90 percent the e. U. Has chosen book areas christina caregiver as its candidate to lead the International Monetary fund a 65 year old is the current chief executive at the world bank the i. M. F. Twin organization for my i. M. F. Chief Francis Christine legarde resigned in july after e. U. Leaders chose at her place mario draghi as the European CentralBank President under a convention with the u. S. A european usually leads the i. M. F. And an American National head to the well bank. And u. S. Rapper asap rocky has been released from custody pending a verdict in his assault trial in sweden prosecutors have asked judges to impose a 6 month prison sentence the lawyers say asap israel name is ricky myers should be sentenced harshly because they believe he threw a bottle at the alleged victim during a street fight on june 30th why is denies using the bottle in the scuffle but admits he acted in self defense judges will hand down the verdict on aug 14th rewind now continues but i will be back with the news hour 2100. 00 g. M. T. In about half an hour from now do join me then. If the dreamliner represents boeings future. And ive come to the place where that future will be built. In this Assembly Plant in charleston South Carolina. Ive been called to a meeting with a man who works inside the plant. Hes taking a huge risk even talking to me. Its been eating me alive to know what i know and i have no appetite no venue to say anything. At his request we used a different voice. 300 souls on the plane their lives its bigger than me. We had seen reports of bad workmanship in the plot. But the man claimed the problems of falling deeper. With all the problems reported on the 787 theres 90 percent its get swept away hushed up. Its an iceberg. The people that actually work on it are the biggest problem there isnt an educated under skilled and uncaring staff that are building these planes and im not the only one that feels that way and he was prepared to prove it wearing a camera inside the plant to record what some workers said about the dreamliner. So. You cant have somebody from mcdonalds do heart surgery thats trusting someone with your life thats what were doing here. Ive seen a lot of things that should not go on at an airplane plant people talking about doing drugs looking for drugs. Like in a plane. Like this someone right now i could just walk up to this. You know put your. When boeing 1st announced a 787 back in 2003 nobody ever dreamt it would have been assembled anyway but washington state. The one place boeing to always made its commercial aircraft. But new boeing was playing by new rules so it did something into never done before. Final assembly to the highest bidder. They were going to hold a competition for a steer against a nationwide competition were to build this plant. Iran to my editor after i put the phone down i think it was 5 oclock and i said youre going to believe this theyre going theyre not necessarily going to go here. Washington state one but only by giving boeing what was then a record 3000000000. 00 in tax breaks. 5 years later owns machinists would go off the job after contract because you should install. The strike cost boeing billions and added to the dreamliner has delays. Boeing stock was in freefall a major Global Economic crisis. That strike really enraged the top executives at boeing. So early in 2 sides in the night they made it very clear that they wanted a 2nd assembly made somewhere else. That turned out to be South Carolina the state offered cheap land and labor. Close to 1000000000. 00 in support found no unions. The decision to build the 2nd 77 Assembly Line in charleston South Carolina was made because of the strike in 2000 it they want to do it there because they wanted to weaken the union and they did. But for boeing leaving behind a world class Union Workforce for the Greener Pastures of a nonunion charleston would come at a price. Work in the plant is significantly behind and plagued by production areas. I know of one customer no longer except planes from charleston due to quality issues. They will only accept final Assembly Done in everett washington. Every day when you go to work not only are you doing your job but youre looking at the previous job to see if someone has messed Something Else up on that and chose not to tell me. To be sure everything is done correctly and the plane is safe boeing has Quality Assurance inspectors painstakingly check every step of the work but in South Carolina this inspector says he only saw ends off on finished. You think everything better. My name is john woods. Space engineer. To know their true. Going. Join the woods spent a career in the highly specialized field of everest base compass its. Boeing hired woods knowing he had qualified psychiatric conditions. Attention Deficit Disorder obsessive compulsive disorder and mild depression his job was to write instructions o