Detailed Narrative
Commercial Production Ramp-up and Quality
Boeing methodically increased commercial production in 2025, delivering 600 airplanes, the highest since 2018. The 737 production is stabilizing at 42 airplanes per month, with plans to increase to 47 later in the year, supported by a new North Line in Everett for rates above 47. The 787 program is stabilizing at rate 8 per month, with a target to reach 10 airplanes per month later this year, backed by factory expansion in Charleston. These ramps are guided by a safety and quality plan, including simplifying over 5,100 work instruction documents and reducing 787 rework hours by nearly 30% in 2025.
Development Program Progress
The 737-10 recently gained TIA2, expanding flight testing for avionics, propulsion, and auto flight. Certification for both 737-7 and 737-10 is still anticipated in 2026, pending FAA approval of design changes for engine anti-ice issues. The 777-9 received TIA3 approval, focusing on avionics and environmental control systems, with first delivery planned for 2027 despite a potential durability issue identified in a recent engine inspection.
Defense Business Stabilization
The defense business secured a transformational win for the U.S. Air Force's sixth-generation fighter and achieved key milestones like the MQ-25's inaugural engine run and the delivery of the first operational T-7A Red Hawk. Despite a $565 million charge on the KC-46A Tanker program in Q4 FY25 due to higher production support and supply chain costs, operational performance trends are encouraging, with 14 tankers delivered in 2025 and 19 planned for 2026. The PAC-3 seeker program increased output by 33% in 2025 due to prior capacity investments.
Spirit AeroSystems Acquisition and Integration
The acquisition of Spirit AeroSystems was completed before year-end, reinforcing efforts to improve safety and quality across the supply chain. This integration is seen as crucial for guiding capacity growth, particularly for the 737 program's rate ramps, and is expected to contribute to productivity and higher quality performance over time⏳. The acquisition is expected to have an unfavorable impact of roughly $1 billion on FY26 free cash flow.
Cash Flow Outlook and Legacy Issues
Boeing expects positive free cash flow of $1 billion to $3 billion in FY26, with a long-term target of $10 billion. This outlook is influenced by temporary impacts from delayed 777X certification (higher cash burn until 2029), customer considerations and excess advances from prior 737/787 delivery delays, and the cash impact of running off prior BDS charges. Capital expenditures are expected to increase to $4 billion in 2026 to support growth and production stability.