dak l&e processes and tools 010326 boeing-lean engineering public release control no. 00-080...

DAK L&E Processes and Tools 010326 Boeing-Lean Engineering Public Release Control No. 00-080

Boeing Phantom WorksLean and Efficient Processes and Tools

Dave KoshibaProgram ManagerLean and Efficient Define and Produce(314) 233-7754


Lean Enterprise Thrusts

Lean Engineering•Parametric 3D Solids•Dimensional Management•Virtual Manufacturing•Model Based Definition (Int/Ext)• Single Source of Product Data•Virtual Collaboration

Lean Engineering•Parametric 3D Solids•Dimensional Management•Virtual Manufacturing•Model Based Definition (Int/Ext)• Single Source of Product Data•Virtual Collaboration

Lean Supplier Management

• Supplier Base Reduction• Certified Suppliers• Suppliers as Partners• Electronic Commerce/CITIS• IPT Participation

Lean Supplier Management

• Supplier Base Reduction• Certified Suppliers• Suppliers as Partners• Electronic Commerce/CITIS• IPT Participation

Lean Manufacturing

• Throughput Studies• Variability Reduction/SPC• HPWOs• AIWs• Advanced Technology Assembly• Operator Verification

Units

Traditional

Lean

Cos

t


Based on Changes After Initial Release (REV’s, EO’s, DCN’s, etc)Based on Quality Tags per 1000 Std Hours

Explicit Recognition that 80% of Product Cost is Locked-in by Product Definition

Goals and MetricsBased on 2nd Generation Experience

Non-Recurring Development

First Unit Fab & Assy (T1)

Recurring (Production)

Support (O&S)

50%

66%

50%

50%

ReduceCost

ReduceCycleTime

ImproveQuality

1

2

1

2

50%

50%

50%

-

90%

90%

90%

-

2

BoeingImprovement Goals


Development in theVirtual Factory

Production Units

T1

Virtual Manufacturing Reduces Rework and Improves Learning

Savings in Rework andProduct Definition Changes

Savings

Assembly/Tooling Validation• Tooling Interference Checks• Part to Part Interference Checks• Optimized Sequence Flow• Incorporates TUI’s

Mfg. Cost

Traditional

T1

Affordable, Low RiskDeployment in the Real Factory

Boeing-Lean Engineering Public Release Control No. 00-010


Virtual Fabrication

Virtual Assembly

Virtual Process

Validation of NC ProgramsElimination of Machine CollisionsReduction of PTO’sReduced/Eliminated Rework

Enhanced Work InstructionsWorkforce FlexibilityLower Assembly Hours

Increased Factory ThroughputImproved Asset Utilization

Virtual FactoryVirtual Factory

Production Factory Production Factory

Virtual Manufacturing Tools Support Lean Manufacturing

Virtual Manufacturing Validates the Product Definition, Optimizes the Manufacturing Plan and Costs, and Simplifies Worker Training and Work Instruction Quality

Simulation BasedWork Instructions

Validation of Assembly ProcessOptimized Assembly SequencesProduct Improvement Changes w/o Line Disruption


for Effective, Low Risk Deployment in the Real World

Supportability ToolsSignificantly Reduce Operations and Support Costs

• Early Support Concept Assessments• Eliminates Physical Mock-Ups• Reduces Personnel Requirements• Safety Evaluations• Improved System Integration• Maintenance Rehearsal/Training

Development in the Virtual World,



Months from End ofConceptual Design Phase

StaffingLevel

Forward Fuselage DevelopmentTotal IPT Labor

Prototype3D SolidRelease

PrototypeWireframeRelease

EMD Wireframewith 2D Drawing

Release• Modern Programs Are Using:

• 3D Solid Model Master Definition - No Drawings

• Detail Available Much Earlier to Support Full, Data-Driven IPT Decisions

• Daily VR Reviews

• Virtual Manufacturing

• Improved Supplier Coordination and Concurrent Procurement

Lean Engineering Product Definition Process SignificantlyReduce NonRecurring Cost and Cycle Time

Prototype3D SolidRelease - 2000 *

* Indicates results from vehicle of approximate size and work content of forward fuselage


Summary

• Significant Progress Made in Reducing Design Cycle Time and Personnel

• Early Redesign Efforts Demonstrated Manufacturing Benefits

• Simulation-Based Work Instructions Emerged as an Enabler for Improving Realization Factor

• Tools Have Been Developed That Facilitate Meaningful Up-Front Supportability

• Prototype Forebody Demonstrated the Full Potential of Lean Engineering Tools

• Simulation Has the Potential to Significantly Reduce Certification Cost and Cycle Time

Modeling & Simulation Applications Have Resultedin a Paradigm Shift in Product Development


dak l&e processes and tools 010326 boeing-lean engineering public release control no. 00-080...

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