Lean Boeing
Boeing Everett * Introduction * Lean Efforts * 777 Floor Grid Component Delivery Improvements * 747 Line Side Supply and Simplified Ordering System * Chemical Point of Use Stations * 767 & 747 Wing Seal Moving Lines * 747 Horizontal Stabilizer Project
Introduction
Boeing is implementing Lean projects in various ways throughout its Everett Plant. The Company created an overall Lean Group to assist in the development and implementation of Lean initiatives throughout the plant. Programs invite the Group to participate in specific Lean projects if desired. The different airplane programs and organizations have also created their own Lean offices to focus specifically on Lean efforts within the particular program. For example, the 777 program has developed its own office, Critical Process Reengineering (CPR), to look for opportunities within the 777 line.
Throughout the Everett plant, Lean initiatives have yielded measurable results. Larger efforts, like some of those described below, have resulted in substantial resource productivity gains and savings. Smaller efforts have also produced significant benefits. For example, the development and implementation of an alodine pen to be used prior to primer touch up, has reduced hazardous waste generation by approximately 36, 55-gallon drums per year. As part of a small tool recycling and reconditioning program, the 777 Wing Majors shop is recycling plastic spatulas used to apply sealant, reducing hazardous waste generation by approximately 90 percent (only the scraped sealant residue and velcro pad are disposed of, not the spatula itself).
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Lean Efforts
To illustrate in greater detail the affect of Lean Manufacturing efforts at the Everett plant, five Lean projects were selected for closer examination. The initiatives selected and detailed below are the 777 Floor Grid Component Delivery Process, the 747 Line Side Supply and Simplified Ordering System, Chemical Point of Use
Introduction
Boeing is implementing Lean projects in various ways throughout its Everett Plant. The Company created an overall Lean Group to assist in the development and implementation of Lean initiatives throughout the plant. Programs invite the Group to participate in specific Lean projects if desired. The different airplane programs and organizations have also created their own Lean offices to focus specifically on Lean efforts within the particular program. For example, the 777 program has developed its own office, Critical Process Reengineering (CPR), to look for opportunities within the 777 line.
Throughout the Everett plant, Lean initiatives have yielded measurable results. Larger efforts, like some of those described below, have resulted in substantial resource productivity gains and savings. Smaller efforts have also produced significant benefits. For example, the development and implementation of an alodine pen to be used prior to primer touch up, has reduced hazardous waste generation by approximately 36, 55-gallon drums per year. As part of a small tool recycling and reconditioning program, the 777 Wing Majors shop is recycling plastic spatulas used to apply sealant, reducing hazardous waste generation by approximately 90 percent (only the scraped sealant residue and velcro pad are disposed of, not the spatula itself).
Top of page
Lean Efforts
To illustrate in greater detail the affect of Lean Manufacturing efforts at the Everett plant, five Lean projects were selected for closer examination. The initiatives selected and detailed below are the 777 Floor Grid Component Delivery Process, the 747 Line Side Supply and Simplified Ordering System, Chemical Point of Use