One factor I didn’t fully appreciate until getting into aerospace engineering was the cost of “production tooling”. Contrary to the name this isn’t wrenches and screwdrivers, it’s massive scaffolding and steel beam Assembly Jigs - the biggest ones being Final Assembly Jigs or “FAJs” which hold all the individual parts of an assembly together while they’re drilled and fastened. These FAJs have to be extremely stiff and strong because the dimensional tolerance requirements are often extremely tight, on the order of thousandths of an inch (that’s 0.001”). As a result you get assembly tooling that looks like this (yellow is the wing, silver is the final assembly jig tooling):
View attachment 65349
Another example from the 787 line. Everything in blue is an assembly jig:
View attachment 65350
Elon Musk has a quote I really like, “Designing the rocket is easy, designing the rocket factory is hard.” This stuff represents an astronomical up front cost to design and produce to create an assembly line. Rewind to 2004, as the “lost decade” was ramping up and Boeing cancelled the 757 program and threw away all their production tooling. No doubt this was some beancounter thing wanting to make floor space in Everett for something else, not wanting to pay rent on some warehouse to store it all, etc, but in my opinion it was terribly short sighted.
By scrapping the production tooling they abandoned their capability to ever produce another 757 without starting from scratch, and put all their eggs in the 737 basket. Any future request for a modified or updated 757 would have to result in essentially standing up a new program and that aforementioned astronomical cost in manufacturing tooling development.
To use a Hollywood analogy, Boeing is playing it safe by sticking to making sequels and comic book movies. They could take a risk and do something brand new and innovative but the up front cost and uncertainty of return on investment is antithetical to their model of making the most profit for their shareholders. I personally think this is foolish though, as you can’t keep stretching an airplane forever and eventually no amount of bandaids will be enough to let you get away with it. And the modify and bandaid approach vs designing the right airplane for the mission will always result in a crappier product, but the bet they’re making is whether the crappier airplane is still “good enough.”