The Birth of the 787 Dreamliner by Edgar Turner

Author:Edgar Turner
Language: eng
Format: epub
ISBN: 9781449442088
Publisher: Andrews McMeel Publishing, LLC
Published: 2010-04-16T04:00:00+00:00

Lean and Mean Manufacturing

The 787 assembly program is built on “lean” principles. Lean manufacturing is based on eliminating waste, using common processes, and building a supply chain that moves smoothly and steadily. Key to its success is a moving line and on bringing parts, tools, and people to precisely when and where they are needed. Tools, parts, and other materials are often collected together or “kitted” for a specific installation, including all the fasteners needed for the job, and are ready for the mechanics at the point of use.

Lean manufacturing also focuses on communication up and down the supply chain, continuous vigilance for inefficiencies, and employee involvement, which encourages solutions and innovations from the design and production engineers, the mechanics who build the parts and assemble the airplane, the inspectors, and the representatives from supplier companies who work daily at the Boeing facility.

Visual cues are another part of lean manufacturing. Clearly marked zones along the line indicate where parts and tools should be delivered; colored lights tell everyone on the factory floor whether or not the airplane is progressing down the line according to plan; and a giant scoreboard provides an overview of how the line is functioning.

These lean techniques have historical roots that go back to World War II, when a Boeing workforce that included many women new to industry responded to wartime urgency by developing a streamlined system for building the B-17 bomber that eliminated scrap and waste, rework, and bottlenecks. In its modern form, lean manufacturing draws on processes pioneered in Japan.

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