Efficiently inching along
Published 9:00 pm Wednesday, November 8, 2006
EVERETT – Boeing Co.’s 777 jets have begun rolling down the assembly line – literally.
The company recently implemented a moving assembly line in which the airplanes creep ever so slowly down the factory floor as Boeing employees piece the 777s together. The new plane-making method is expected to increase productivity and quality.
“A moving line drives efficiency throughout the system because it makes problems visible and creates a sense of urgency to fix the root causes of those problems,” said Elizabeth Lund, director of manufacturing for the 777 program.
Over the lifetime of the 777 program, the 300 to 400 seat jets have wracked up 851 orders from 46 customers.
Boeing currently only uses the rolling line during 777 final assembly, where mechanics install seats and overhead stow bins. The plane moves at a rate of 1.6 inches per minute. Boeing intends to have the entire 777 production system moving by 2008.
To make the 777 assembly line move, Boeing uses a tug that attaches around the front landing gear of the airplane and pulls it forward. The tug has an optical sensor that follows a white line along the floor.
Earlier this year, Boeing began work to transform its 777 assembly line into a leaner and more efficient production system. But changing over to a moving line while still producing planes on the stationary system can be difficult, said Chuck Cadena, spokesman for the 777 program.
“It’s kind of like changing a flat tire while driving down the road,” Cadena said.
Boeing began a similar switch to a moving system on its Renton-built 737 in 2000. The line became fully operational in 2002.
The company already enjoys the benefits of several lean manufacturing techniques put in place on its 747 and 767 production lines, said Leslie Hazzard, a communications manager for airplane production at Boeing. However, Boeing doesn’t plan to convert those lines over to a moving system.
An advancing line fosters better support for the workers who are building the airplane.
“It’s similar to the team of people supporting a surgeon and ultimately the patient in an operating room,” Lund said.
