Problem in Boeing 787 assembly

From WSJ, We found an article talked about Boeing 787 assembly,

"The first Dreamliner to show up at Boeing's factory was missing tens of thousands of parts, Boeing said."
"When mechanics later opened boxes and crates accompanying the fuselage sections, they found them filled with thousands of brackets, clips, wires and other items that already should have been installed. In some cases, officials say, components came with no paperwork at all, or assembly instructions written in Italian, requiring translation."
"Boeing officials thought they could work through this unexpected twist in a couple of weeks. Instead, they had to put the plane up on jacks and remove its engines and tail to get to tight spots."
"Boeing set up this global supply chain and chose the suppliers. Now, they seem to be dumping on the suppliers, saying how they wouldn't use some of them again. "

I have some analysis of the problems according to lean concepts as belows,

1. Production Preparation (2P) was not working properly. Even, the PFMEA was executed the same situation as 2P. If the 2P was worked out in proper way, most of the problems in real assembly process can be simulated and prevent their happenning before actual running, otherwise, it was totally impossible to have many tens of parts missed to assemble to the plane. The purpose of 2P or product production preparation (3P) is going to eliminate the problems in the first mass production, Although, it is impossible to kick out all the process issues, but at least the process can reach a specified level. The concept is "do it right at the first time", consider about the 787, it is talking about 10 million and 6 months of process time. If the situation liked the article shown, how much lost in the business?

2. Mistake-proofing was absented in the process of assembly. If the mistake-proofing (poka-yoke) was consider in the process, it is also impossible to have parts missed. It should has a checking or testing before the next parts installation, and if it was a parts missed, the line should be stopped and clear the problem before the next process. We must remember that Poka-yoke is not only a checking, in other words, it is a very important concept and element in whole quality control system. Only one screw missed on tle plane will cause a disaster, even many tens parts missed?

3. In order to cost reduction and global supply chain system, same as A380, we found the parts came from every corners in the world. It is no needed to talk about the pull system, even if the assembly process will be affected by such kind of parts suppling. Some of the instruction in German, italian and Japanese, how can the workers to work for? Are they having the language knowledge liked James Bond?? In way of pull system to consider this problems, the final assembly process was easily to stop the parts supply chain and make the line and workers idle by the issue.

It is a good negative example for lean manufacturing implementation. We can have more understandings through the case study from other industries, because the issues were the same. Let me know if you have any comment on this, thanks! BTW, the video shown above is not the original video showing the real assembly process. The video disappeared in youtube already.