Since first rolling off the assembly line in 1967, the Boeing 737 has been in continuous production, with more than 12,000 airframes sold. It has shaped modern air travel, influencing how airports are designed and the business models of airlines. The 737 now comprises entire fleets for some carriers and forms the backbone of others, including Qantas and Virgin's domestic operations in Australia.
In recent years, however, the aircraft has been tainted by design defects and quality control failures, most notably highlighted by the crashes of two 737 MAX 8 jets in 2018 and 2019. Those disasters led to a worldwide grounding and direct oversight of production by the US Federal Aviation Administration.
Despite the crisis, airlines remain hungry for new, more efficient 737 MAX airframes. Boeing says the MAX uses 20 per cent less fuel than previous versions, averages 7 per cent lower operating costs, and offers up to 14 per cent lower maintenance costs. The company describes the MAX line as offering airlines greater profit potential.
The 737 begins its life as a fuselage, shipped in by train from Kansas, where it is made. At the Renton factory, which has been the home of 737 production since 1970, each fuselage arrives in the distinct green colour of its protective primer. It is then rolled and lifted into position in an elevated part of the facility, where it is inspected before insulation, electronic, hydraulic, and mechanical parts are installed.