Boeing is reorganising the lean manufacturing process designed for its 787 programme in a bid to expedite assembly on its much-delayed twinjet project.
According to programme sources, a system of "super mechanics" who hold all the necessary certifications to self-check work to appropriate airworthiness standards is being abandoned in favour of a traditional quality-assurance system. The sources say over the past year of assembly the self-certification process had become an impediment to progress rather than an enabler of efficiency.
They attribute the slow pace of assembly work to what are known as "rejection tags". Each rejection tag identifies a "non-conformance" in the design that must be checked through a quality-certification process.
For example, during the normal manufacturing process, holes are drilled to install fasteners. In some instances, those holes have to be drilled a second time if an issue arises with the first hole. As a result, the hole is considered to be "non-conforming" requiring a larger diameter fastener and must be checked through a quality-certification process.
As a result, the 787 programme has begun to shift from a system of self-certifying manufacturing staff to a more traditional system of quality assurance similar to Boeing's legacy programmes. The revised system is first being implemented for out-of-sequence travelled work and is expected to be expanded to the entire final assembly process.
The revised system is a "positive step," says one person working with the aircraft.
By using its traditional quality-assurance system, Boeing is able to better control and group the number of rejection tags to reduce paperwork and solution time. For example, under the original system, four non-conforming holes in the same area of the aircraft were filed as four individual issues rather than just one. The new system would streamline the process by grouping these rejection tags together, cutting paperwork significantly.
Boeing unveiled the 787 in July 2007 and originally intended to deliver the first aircraft to launch customer All Nippon Airways in May this year. Earlier this year the airframer said it expected to make its first delivery in early 2009, but in recent weeks there has been widespread speculation that another extensive delay is set to be announced by Boeing.
Now, its biggest 787 customer, International Lease Finance (ILFC), is reportedly anticipating a further delay of around six months before first delivery as a result of a design change needed to the wing box.
ILFC chairman Steven Udvar-Hazy reportedly said at a JP Morgan investor conference in New York that he does not expect the first delivery to occur until the third quarter of 2009 as a result of structural design changes that are needed to the centre wing box. The comments were reported by a JP Morgan analyst in a note to clients, according to widespread reports.
Source: Flight International
