The Boeing plant on the outskirts of
Toronto boasts a long and rich history. That history
includes several name changes that reflect previous owners
and involvement in some of the most important and some of
the most unusual aerospace programs of the last 65 years.
The National Steel Car Corporation of Malton, Ontario, built
the plant in 1938. When Great Britain needed an aircraft
factory out of reach of German air attack during World War
II, the plant was declared a Crown Corporation and renamed
"Victory Aircraft." During the war, its employees turned out
430 Lancaster bombers and more than 3,000 Anson utility
aircraft for the Royal Air Force.
In late 1945, A.V. Roe of Canada Ltd.
acquired the facility from the British government.
In 1949 the plant produced the first
commercial jet transport to fly in North America—the Avro
XC-102 Jetliner. Although the plane had a successful
flight-test program, pressure to increase production of
military aircraft during the Korean War forced the
commercial jetliner off the production line.
The plant quickly moved into high gear to
build the Avro CF-100 Canuck. A twin-engine all-weather
interceptor, the CF-100 made its first flight in 1950 and
entered service with the Royal Canadian Air Force in 1952.
Over eight years, the plant produced 692 Canucks in five
major versions.
As CF-100 production declined, A.V. Roe's
plant designed and built two prototypes of one of the most
unusual experimental aircraft ever to fly: the VZ-9AV
Avrocar. This flying-saucer-shaped vehicle promised a major
breakthrough in vertical takeoff and landing technology. But
after two years of tests, the Avrocar proved they could
hover only two feet (61 centimetres) off the ground and move
forward and backward at 35 mph (56 kilometres per hour).
Because they were aerodynamically unstable, the program was
cancelled in 1961.
Between the Canuck and the Avrocar, the
plant embarked on an ambitious project and the development
of one of the most technologically advanced aircraft of its
time.
After failing to find a suitable fighter
in the United States or Europe capable of defending Canada's
vast airspace, the Royal Canadian Air Force in 1953 awarded
Avro's Toronto plant the contract to develop the airframe
and engines for the CF-105 Arrow.
A twin-engine, long-range, all-weather,
supersonic interceptor, the Arrow featured a large
delta-shaped wing. It flew with a crew of two and could
carry eight Hughes Aircraft Falcon infrared-guided or four
radar-guided Sparrow air-to-air missiles in its huge
internal weapons bay.
After four years of development, the
Arrow made its first flight in 1958. The plane placed the
plant at the forefront of supersonic flight technology and
became a source of Canadian national pride. Chief design
engineer Doug Moore was responsible for the structural
design of the forward fuselage of the Arrow. "The Arrow was
very sophisticated for its time," recalled Moore, now
retired. "We were doing things with that plane
aerodynamically that hadn't been done before."
Financial and military realities,
however, soon began working against the plane.
As modern military aircraft became more
technologically advanced, and thus more expensive, they
needed to be capable of carrying out multiple missions to
justify costs.
Unfortunately, the Arrow was designed and
built for one mission: to intercept Soviet bombers. As the
Arrow's development costs rose, Canadian military planners
decided the Soviet bomber threat could be more economically
countered by surface-to-air missiles, such as Boeing's
Bomarc, and by less expensive multi-mission aircraft that
were initially passed over in favor of the Arrow, including
the McDonnell F-101B Voodoo.
In 1959, after only one year of flight
tests and production, the Arrow program was canceled. Five
aircraft had been completed and had flown 66 flights; more
than a dozen were on the production line. All the Arrows
were scrapped. Only a single forward fuselage section and
one main landing gear remain; they're on display at the
National Aviation Museum in Ottawa.
Ironically, the decline of the Arrow
proved a boon for aerospace companies south of the Canadian
border. Many of the company's talented engineers accepted
jobs with Boeing, North American Aviation, Hughes and
McDonnell. More than 30 joined NASA and played key roles on
the Mercury, Gemini and Apollo space programs.
The opportunity to manufacture aircraft
components for Douglas Aircraft brought new life to the
plant in 1963. DeHavilland Aircraft of Canada, the fourth
owner of the facility, entered into a joint venture with
Douglas to manufacture wings and tail assemblies for the
DC-9 jetliner. Douglas Aircraft of Canada was formed in
1965, and in 1968 the company purchased DeHavilland's
buildings and surrounding property.
The plant was modernized extensively and
enlarged in 1970 to accommodate wing assembly for the DC-10.
The expansion made the Toronto plant the largest aerospace
manufacturing facility in Canada at that time.
In 1981 the plant became known as
McDonnell Douglas Canada (MDCAN) and expanded its production
to include KC-10 and MD-11 wings, MD-80 wings, empennage and
cabin floors, and F/A-18 side panels and pylons.
During this time, MDCAN was at the
forefront of change as it developed several continuous
improvement process programs. One program decentralized the
fabrication shop, dividing it into product groups composed
of self-managed employees who were individually responsible
for performing most of their tasks. Other programs involved
the formation of strategic business units and a
"just-in-time" inventory system. Many of these innovations
later served as models for similar programs at other
McDonnell Douglas locations.
The plant became Boeing Toronto Ltd. in
1997, after the merger of McDonnell Douglas and Boeing. As
Boeing Toronto, it was the sole provider of 717 wings. The
facility also fabricated parts for the Delta rocket, the
C-17 airlifter and 737 jetliners.
Now, the plant's 42-year history with
heritage Boeing companies is ending. The plant will cease
operations as a Boeing facility following shipment of the
last 717 wing.
"The accomplishments of the people here
have had a significant impact on the world we live in
today," said Stephen J. Fisher, president of Boeing Toronto.
"From wartime production, to the pioneering development of
supersonic flight and the building of wings and assemblies
for one of the most successful commercial jet families, the
people at this facility faced immense challenges and
opportunities. A lot of people can be very proud of the job
they have done here."
Stolen with thanks from the Boeing website