“The past five to seven years have been very hard on us personally,” Darrel Larson, a vice-president of operations, told me. Larson, who grew up on a farm in North Dakota, has a rangy frame and a folksy manner. We were standing on the floor of the building where the 777 is constructed—the largest factory in the world by volume. It’s a vast, open hangar, two-thirds of a mile long and a third of a mile wide, subdivided by rows of glass-walled offices. A system of tunnels runs beneath it, and a network of rails above, hung with gantry cranes that can lug an eight-ton engine across the floor. The factory runs around the clock, yet it was eerily quiet. The planes are mostly assembled from modules made at other sites nearby, and pieced together in a strictly orchestrated sequence. Shrink-wrapped airplane lavatories were clustered along the perimeter, next to carts full of bins with numbered parts. It was the world’s most sophisticated Lego set.
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