How might we seal the interior of the 777X wing tank to prevent combustion due to electromagnetic energy?
Overview
The 777X is Boeing's second aircraft with composite wings and the first to feature a composite wing combined with a metal fuselage. Electromagnetic effects (EME) pose significant risks to aircraft, as the build-up of EME currents can lead to sparking—a critical concern near jet fuel that could result in combustion. Although fuel tank explosions are rare, they have caused 346 fatalities since 1989. To mitigate this risk, sealant is applied at potential energy build-up points and along all seams to prevent fuel leaks. Because composite and metal materials conduct electricity differently, the sealant application process for the 777X’s composite wings requires distinct procedures compared to traditional metal wings
Role
Industrial Engineer, System Design Lead
Skillset
System Design, Prototyping, Project Management, Usability Testing, Lean Manufacturing, & Process Improvement
Impact
Created a comprehensive production system for 777X composite wing assembly
Planned workflows for 550 tasks across 124 employees in three manufacturing shops
Achieved $1.1M in capital savings through precise equipment analysis
Reduced ergonomic risks by 50%, saving $240,000 annually
Designed shop layout and recovery plans to manage schedule deviations
Step 1: Technical Research
Production system design began in tandem with the final stages of product design. As such, numerous specifications had already been determined regarding the wing and the seal requirements. My role was to understand the product design requirements and be the advocate for the human component of the system. I began by understanding and capturing all existing product design decisions.
reviewed engineering drawings
technical interviews with subject matter experts and technical fellows
electromagnetism requirements and specifications
data analysis on historical data from the first 100 wings produced for the 777 and 787 production lines
technical interviews with Environment, Health & Safety
This is a good visual of the interior of a wing tank; it is not an ergonomically friendly environment.
source: Aviation Week Network
Step 2: User Research
I partnered with 6 dedicated subject matter experts to conduct data collection workshops in a week-long sprint format. Their knowledge and experience were essential to the success of the system’s design. The team worked diligently to capture the job data (job sequencing, time performance estimations, tooling needs, capital equipment needs, chemical needs, consumable product needs, and training requirements) provided as well as the pain point and frustrations with existing systems. I focused on understanding both their existing, recurring problems as well as problems encountered during startup.
Each sprint was followed by a data synthesis period for processing all data received. Data compilation visuals were then verified or altered before continuing with the next section of the wing. The process took three months and resulted in a vast volume of task performance data for all 50+ wing sections. At the end of this effort, we had a rough-cut understanding of the statement of work and the various integration points for disposable goods, tooling, capital equipment, quality inspections, and our people.
I participated in a new-sealer training to understand the talent required and the methods in place to educate new employees.
I then conducted field studies of existing, active seal application processes to capture a greater depth of understanding of pain points. By watching and speaking with sealers on the 777 (non-composite wing) I was able to understand the ergonomic concerns that they battled daily as well as the design failures in their daily work statement:
gathered their tools and then walked 15 minutes (in the world’s largest building) to their work station
twisted and contorted their bodies to enter into the outboard wing tank sections
artistry required to apply seal to the specific dimensions required in the engineering drawings
rubbed their shoulders after several hours of overhead work
squinted to see their work within the wing tank cavity
Example of the process required to enter the access interior of an airplane wing tank. source: youtube
Step 3: Define System Framework
All of the information collected to data was incorporated into 9 manufacturing operation planning deliverables:
· ergonomics score
· value stream map of integration points (tooling, capital equipment, etc.)
· wing map capturing all job data for each wing tank
· job sequencing outline for each wing tank
· employee placement map (in accordance EHS maximums)
· risk and opportunity registrar
· pain-points registrar
· crew cycling plan
· shop budget
Building airplanes is complicated, hard, and FUN work. This image gives you an idea of the organized chaos of the production environment. Find a person or car to give you an understanding of the scale of the building.
source: The Boeing Company
Step 4: Prototyping
Three prototypes were created:
To-scale wing box out of plywood to represent a section of the outboard wing which was lifted to working height
3D renderings of the wing were modeled in CAVE virtual reality software
Crew cycling model which incorporated job data utilizing Aurora modeling software
Step 5: Usability Testing
The team collected a selection of available ergonomic tools such as robotic arms, tool jigs, backpack shoulder support, step stools, and lifts. Seal mechanic subject matter experts replicated seal operations within the prototype wing box, and I captured critical information such as completion time, ergonomic pain points, and ergonomic tool viability.
A similar test was conducted using the CAVE virtual reality software to investigate sections of the wing not produced in the to-scale mock-up. We focused heavily on wing tank sections where fixtures altered the typical form of the wing tank.
The crew cycling model allowed me to determine where the statement of work exceeded that of the planned headcount.
All three usability tests resulted in the finding of numerous pain points which were added to our pain-point registrar. The job data collected allowed the team to convert assumption-based decisions into evidence-based decisions for the basis of our production system.
Here is an example of the CAVE Virtual Reality system being used to model capital equipment. The tool is very helpful in creating rapid, high fidelity prototypes to take the guesswork out of production system design. The tool can place VR mechanics into the environment with a variety of different ergonomic specifications.
source: Auganix.org
Step 6: Design Iteration
The job data was incorporated into our manufacturing operation plans.
For our pain points, there were some quick wins (such as delaying a fixture installation until after the sealing operations) which were easily incorporated into the system design.
Other pain points required technical solutions. These were delegated to research and development groups with product design authority.
While managing the completion of all complementary design improvement efforts, I led a sub-team through an ergonomics review to evaluate our primary ergonomics risk associated with performing overhead work for long durations. Our solution was multifaceted and included the use of numerous ergonomic support tools, migrating as much work from overhead to working level, and a creative crew cycling program to ensure that day-to-day people were working extended periods overhead. The team’s efforts resulted in a reduction of shop ergonomic risk by 50%.
Step 7: Prototyping II
Once again, the team created three prototypes:
table-top replica of the production system including 3d printed wings and support structure as well as Lego people
the R&D sub-team created mock-up test pieces for the purpose of verifying the design solutions
crew cycling model using Aurora Modeling Software
Aurora modeling software allowed us to create complex precedence networks to better understand and validate our crew cycling plans. source: Stottler Henke
Step 8: Usability Testing II
For the first usability test, the team painstakingly conducted hour-by-hour movements of people and parts in accordance with our operating plans. We documented missing facility layout details such as capital equipment storage locations and computer locations for review drawings as we proceeded. We captured part delivery requirements. We found even more pain points. All were documented with a written script of movement as well as with photos of each hour and populated into a formal log.
For the second usability test, the new technical solutions created by research and development sub-teams were also tested and approved by the seal mechanic subject matter experts.
For the third usability test, the crew cycling model once again allowed me to determine where the statement of work exceeded the capacity of my planned headcount.
Step 9: Design Iteration II
Once again the team worked to include the quick wins and formed sub-teams to resolve the larger issues.
I performed quantity and capacity assessments of the capital equipment and tooling requirements which resulted in $1.1M in capital expenditure avoidance.
These improvements were incorporated into the manufacturing operation plans.
Step 10: Prototyping and Usability Testing
A to-scale replica wing was created. This effort tested all processes inclusive of the wing tank seal on a to-scale wing in real-life conditions prior to production.
Step 11: Design Iteration
Quantitative data highlighted that the seal mechanic set-up process (which included collecting tool kit, shoe covers, bibs, consumables, refrigerated seal, parts, and understanding their jobs for the day) was a source of nonvalue added work and contextual interviews highlighted that this was a frustration point for the seal mechanics. I conducted a Six Sigma assessment to validate that this was a critical factor in production variability for the 777X system as well as that of the 787 and 777. I led the team through another 5-step problem-solving effort to create a resolution. The team determined that by creating a u-shape flow for collecting all requirements, we could reduce the burden on the employee which would reduce frustration as well as reduce the time spent not performing core job. The resulting $240,000 annual savings pleased both the team as well as my budget-conscious leadership.
Step 12: Final Design Implementation
Due to the efforts to prototype, test, and improve the system design numerous times before implementation on the production airplane, the first production wing was completed within budget and on time. This did not stop the team from capturing pain points and frustration for further improvement.
Impact Analysis
• Designed production system for 777X composite wing assembly and seal.
• Created robust operating plans for 550 jobs, 124 employees, and 3 manufacturing shops.
• Saved over $240,000 per year by utilizing multidisciplinary technical expertise to investigate problems, determine root cause, and implement corrective actions.
• Developed and implemented a trimodal learning curve into production system design.
• Improved headcount utilization by 11% by simulating 777X wing production system in Aurora Modeling Software and investigating alternate crew cycling methods
• Saved $1.1M in capital expenditure avoidance through equipment quantity analysis.
• Translated operating plans into manufacturing shop aids and metrics which provided technical and non-technical support to 8 different internal organizations.
• Performed risk and opportunity analysis and management for $1.3M budget.
• Designed facility layout in support of 777X Wing Production.
• Created recovery plans to correct schedule deviations due to part shortages, labor loss, and quality issues.
• Reduced overall ergonomic risk of shop overhead work environment by 50% through crew cycling.
I am so proud to have participated in the creation of this stunning aircraft. source: Boeing
Reflections
The inclusion of subject matter experts was essential to the successful production system design.
The workshop format allowed the integrated project team to complete intense sessions of rapid improvement which greatly facilitated the project timeline.
Project management is an essential role in any design process.
While the team could have accepted a status quo effort, the intentional consideration of the human needs allowed the team to create a system that exceeds expectations.
The bond created by a team working together for a joint goal is powerful. When it came time to depart from this role, I felt as if I was leaving a family. We celebrated each other’s birthdays and mourned each other’s losses.
There are few moments at Boeing quite as special as a first flight. source: youtube