S.R. LUTHRA INSTITUTE OF MANAGEMENT

Productions and Operations Management

MBA SEM 2GROUP NO :- 1(A2)

PRIYANKA BACHKANIWALA-4RAKSHIT BHAVSAR-13KOSHA DOSHI-24AANCHAL JAIN-37SONAM LALWANI-51

TOPIC : Making of Boeing

04/08/2023

THE MAKING OF BOEING

NEED FOR BOEING 777

EXPERTS OPINION

Experts questioned the need for a new model existing 747 was running successfully

Unnecessary spending huge amount on development of Boeing 777 ( whose attributes are roughly similar to the existing 747.

Developing a new aircraft is highly complex affair. They can improve efficiency for operators and convenience in existing. Cost would be cheaper than developing a new one.

BOEING COMMENT

Why do auto manufacturers keep improving their latest models to suit customers, need. Because they are dynamic and market driven and want stay in business without hanging on old models.

They want to survive in the competitive world.

Boeing Comment … (contd.)

To cut costs on designing and devdeloping the new 777 model, Boeing adopted a unique process.

They adopted collaborative designing and development process that involved customer, air carriers, technicians , finance experts, computer experts an even other manufacturers of aircraft.

Boeing 777 was first aircraft to be digitally designed by computers and was expected to be best in efficiency and quality in its class.

BACKGROUND Boeing was founded in 1916 by William Boeing and

George Westervelt and was initially called the Pacific Aero Products Company. The company’s name was changed to Boeing in 1917.Boeing began manufacturing aircraft for the US military during World War 1.

Boeing Air Transport (BAT) was formed to run airmail services. BAT also trained pilots, set up airfields and provided maintenance staff for the services.

The management than realized that to accelerate the company’s growth it needed to design, mass produce and sell its own aircraft. After World War 2, the company shifted its focus from the defense industry to commercial jets.

In 1962, Boeing manufactured Air Force One for the American President’s use. In late 1969, Boeing entered the field of spacecraft manufacturing by contributing to the Apollo program.

BACKGROUND …(Contd.)

Boeing and its subsidiaries operated in six key business segments:

1.Commercial Airplanes2 Aircraft and Weapon Systems3. Network Systems4. Support Systems and Launch5. Orbital Systems(collectively ,Integrated Defense Systems)6. Boeing Capital Corporation(BCC) The commercial aircraft division contributed around 60% of

the total revenues. Boeing’s manufacturing plants were located at :

1. Everest(Washington)2. Wichita(Kansas)3. Long Beach(California)

DESIGN AND DEVELOPMENT OF BOEING 777

The aircraft was built at the Boeing plant Everett, USA. Production process involved “collaborative product design and development. Boeing aimed at achieving three specific goals when it built the aircraft.

Goals are : Reduce aircraft development time

significantly Meet customer customer requirements

better by involving them without in the development process

Avoid costly modification

Development process of Boeing 777 was substantially different from that previous Boeings

Company actively sought suggestion from major carrier including United airlines, Nippon airlines, British Airlines, Japan airlines, Cathay airlines to develop configuration

They focused on operations with different routes, traffic loads and service frequency.

1st time customer played important role in making of an aircraft. Private engineers of airlines and other officials came on site to assist in making by Computer Aided Design (CAD) and Computer Aided Manufacturing (CAM).

Boeing has invested in CAD-CAM in 1980 to develop software to manufacture Boeing 777.

Studies at Boeing showed that part interference and difficulty in properly fitting the parts together in the aircrafts final assembly were the most common problems in manufacturing aeroplanes.

That CAD/CAM technology used to digitally pre-assemble the aeroplane on a computer to overcome these problems. That improves accuracy in design and assembly of parts and instantaneous communication that helps in their improvement of quality and that also reduces cycle time to introduce new aeroplane in market.

Company organized its workers into 238 cross functional staff design teams, each responsible for specific activity. Over 75 design teams collaborated directly over a combination of private and secure public network. The team used 2200 computer terminals during the development process.

The major team involved in this process included designers, manufacturing, representative, tooling staff, engineers, finance personnel, suppliers and customers and each and every one connected with sophisticated computers linked by the largest mainframe installation of its kind in the work consisting of 8 IBM mainframe computers.

Boeing 777 was termed the 1st ‘paperless airplane’ it was design by Computer aided three dimensional interactive application (CATIA) system.

A moving assembly line kept production moving at a steady pace, allowing employees to gauge status at a glance and reduce the amount of work –in progress inventory. The use of a moving line allowed the 777programme to improve quality and reduce costs and at the same time shorten the time taken to final aircraft.

DISTINGUISHING FEATURES

Fly-By-Wire(FBW) Advanced technology glass flight

deck. Overhead space solution. Lightweight and economical

material. Advanced wings. Enhanced Ground Proximity

Warning System(EGPWS)

Fly-By-Wire

Fly-By-Wire is where all mechanical linkages between the controls and movable surfaces are removed and instead carried out automatically.

Where pilot’s control are processed by a computer and send to the flight control surface actuators with electrical rather than mechanical signals.

Advanced technology glass flight deck.

The 777 flight deck was designed in horizontal format and the navigation and engine information appeared on six large display screens.

The display arrangement saved space, weighted less, required less power and generated less heat thus did not required air conditioning at all.

Pilot preferred this arrangement because the flat panel display remained clearly visible under all conditions including direct sunlight.

Contd..

Large flat-panel displays present flight information in a readily accessible form, allowing pilots to quickly optimize flight parameters for schedule, passenger comfort, and economy.

Electronic checklists, which airlines can customize with airline-specific information and procedures, speed pre-flight checks and save valuable minutes that can buffer departure schedules.

Adding the electronic flight bag significantly reduces the need for paper on the flight deck and uses airplane-to-ground connectivity to deliver more critical information to the appropriate departments.

Overhead space solution

The design of 777 with a larger diameter and circular shape provided more space in overhead area of the plane.

This area can save up to four passenger seats and four cargo containers thus this free space result in additional revenue potential.

Even extra space could be used as crew rest station, for storage and to increase passenger seating or cargo capacity in the lower decks.

Lightweight and economical material

Advanced 7000 and 2000 series aluminum alloys, damage tolerant composites and advanced titanium alloys enabled reduction in weight by over 5800 pounds.

Improved aluminum alloy offered greater compression strength and enabled designer to save weight and improved corrosion and fatigue resistance.

Thus, this lightweight and powerful engines contributed to lower cost, easier to maintain and better fuel efficiency and lower emissions making 777 environment friendly.

Advanced wings. In 777 wings were considered

one of its best features. They were efficient and had

wings with longer span and increased thickness.

This advanced wings enhanced 777’s ability to achieve higher cruise speed, climb quickly and cruise at higher altitudes.

Also it allowed the plane to carry full passenger payloads at high elevation and high temperature airfield.

Enhanced Ground Proximity Warning System (EGPWS)

EGPWS is an independent monitor of an aircraft fitted into the cockpit and displays picture of geographical terrain surrounding the airplane.

It displays and give audible alert for a minute before any problem with terrain arose to pilot and it is faster by 10-15 seconds than any other systems.

BENEFITS

Elimination of over 3000 assembly interfaces, without physical prototyping

Reduction in engineering change requests, cycle time for engineering requests and material rework

Improvement in assembly tolerances for fuselage by 50 times

BENEFITS ..(Contd.)

Superior design Operational efficiency & spacious interiors

Comfort to customers Bright interiors Economic advantages to non-stop

rides which were not available earlier

Boeing 787 Dreamliner

ACHIEVEMENTS In June 2007,Boeing 777

achieved the top position in the manufacturing category of the Annual Computerworld Smithsonian Awards

In 1995, It won the Robert J. Collier Trophy, awarded by

the US National Aeronautic

Association

5 New models

By December 2004, the 777 was availablein the following 5 models:

777-200 777-200ER 777-200LR 777-300 777-300ER

QUESTION/ANSWER

Why the Boeing Company did launched the 777 model in spite of the existing 747 doing extremely well? Describe the distinguishing features of Boeing 777 as compared to other models manufactured by Boeing and its competitors?

Just like auto manufacturing keep improving their models to suit customers needs, because they are dynamic and market driven and don’t want to be out of business by hanging out to old models, Boeing also felt the same and so to survive in the competition they had to keep innovating new airplane models . Thus, Boeing Airplane company announced the development of a new airplane model- Boeing 777 – in late 1980s.

Distinguishing features:-1) Unique fuselage cross section.2) Boeing’s 1st application of Fly- By –

Wire.3) An advanced technology glass flight

deck with five liquid crystal displays.4) A comparatively large scale use of

composites.5) An extremely powerful engines.6) Efficient wings with longer span and

increased thickness.7) Enhanced ground proximity warning

system.

Que:2

Critically examine and comment on the collaborative and development process of

Boeing 777? And what could be the possible drawbacks of such

process?

According to the building process of Boeing, its quite difficult whe company is working with various teams on particular project where approximate 233 different designing teams working together for the making of 1 aircraft.

In previous models They have used to prepare plan on papers and share all the designing details as well as fixing planouts accordingly.

In which they found problems in fitting and fixing parts of aircraft while they are assembling the whole aircraft by different parts

Answer:

So that, In Boeing 777, Boeing collaborated with :

CAD/CAM

CATIA

IBM Mainframe computers

That will help them to fix the problem of fitting and designing of the aircraft. Also to identify 3D model in assembling and designing of a aeroplane. Also, they treduced cycle time of making of same.

QUESTION 3 :Illustrate the role of computer based technologies in the design and development process of the 777. Do you think the use of computers in aircraft designing/manufacturing is a complicated and expensive exercise? Comment.

ANS :

Boeing used Computer aided Design (CAD) and Computer Aided Manufacturing (CAM).

Boeing had invested in CAD/CAM technologies in 1980 by the late 1980’s the company had evolved a single strategy for applying the technology for manufacturing activities after numerous pilot programs

The CAD/CAM technology was used to digitally pre-assemble the aeroplane on computer to overcome problem.

It improved accuracy in design and assembly of parts as ell as instantaneous communication. It helped in improving aeroplane design and reduce the cycle time.

The major team involved in this process included Designer’s manufacturing, major representatives,tooling staff engineers,etc.

At the center a main frame of IBM 8 units were installed.

Boeing-777 was termed the first paperless aeroplane. It was 100% digitally designed aircraft using Computer-Aided 3-D interactive application.

Data management,user prodctivity and visualisation.

3-D, view upto 500 parts,corrections are possible.