MGMT 580 – FINAL PROJECTCesar A. Marrero

AGENDA

Introduction Popularity of the Boeing 737 Reliability Program Failures of the Boeing 737 Evaluation: Defective Wiring (TWA Flight 800) Conclusion

INTRODUCTION

Boeing 737 – the workhorse for low-fare airlines around the world Easier and less expensive to maintain Fewer parts than older models Quick turnaround at the terminals

BOEING 737 – POPULARITY

Over 7,500 aircraft delivered to date Record-breaking orders of any model in a

single year 1,124 net orders of the next-generation version

(models 700, 800, and 900) in 2012 914 orders for the 737 MAX version

RELIABILITY PROGRAM

Entire System Common components reused in all airframes Unchanged fuselage

Changes primarily to wing structure and engines Airframe is quite cost-efficient Redesigning fuselage would not provide much

improvement Increased costs with two separate production lines

RELIABILITY PROGRAM

Humans in the System Commonality of airframes promotes familiarity Training costs are significantly reduced Employees use a common set of tools and

procedures

RELIABILITY PROGRAM

Maintenance of the System Interchangeable parts Standard technical documentation Longevity efforts

RELIABILITY PROGRAM

Simplicity of Design Greater turnarounds for airline carriers Maximize the use of their fleet Low stance on the ramp

Easier to maintain and load Servicing can be done at ground level Baggage can be loaded from the ground

Last minute cargo/luggage additions

RELIABILITY PROGRAM

Redundant and fail-safe features Two engines per aircraft, even though only one is

needed to fly Two electrical systems Two fuel systems Emergency Oxygen system Triple Rudder system

RELIABILITY PROGRAM

Manufacturing Methods and Purchasing Requirements Assembly line production, similar to the

automotive industry Accelerated production Reduced production costs Fewer order backlogs and customer waiting

times

RELIABILITY PROGRAM

Maintenance of complete product or system performance records Production and maintenance logs

Records failures, replacements, repairs, warnings, field tests, and operating conditions

Influences changes in the airframe Improves manufacturing methods Modifies quality checks Identifies most reliable components

Extensive field testing before components are fielded

RELIABILITY PROGRAM

Communication Valuable collaboration between customers, chief

mechanics, and field service reps Efforts ensure new version of 737 continues the trend

of simplicity, reliability and low cost. Airlines can choose a version of 737 with latest cockpit

displays or commonality with older models

FAILURES OF THE BOEING 737

Events influenced dramatic changes in the inspection and maintenance process TWA Flight 800 – Exploded, killing all on board Southwest Flight 812 – Peeled exterior skin

TWA FLIGHT 800

Exploded 12 minutes after take off Boeing Model 747, not 737 230 on board killed

Cause determined to be faulty wiring Spark caused ignition of fuel fumes FAA ordered Boeing to inspect all airframes,

especially the older 737 model

SOUTHWEST AIRLINES FLIGHT 812

Loss of cabin pressure, caused crew to perform emergency landing

Cause determined to be manufacturing flaws on the fuselage skin Rivet joints not aligned or overlapped, causing

fatigue on external skin Skin peeled off, causing a rapid loss of cabin

pressure Not first time skin peeled-off

EVALUATION OF DEFECTIVE WIRING

Cause and effect diagram:

Aircraft Explodes

PeopleMachinery / Equipment

MaterialsMethods

Different fuel mixture

Failure to detect defective cables

Substandard cables

Insufficient quality control

Missing inspection steps

Inexperienced maintainers

Insufficient testing tools

Inadequate testing tools

MACHINERY / EQUIPMENT

Insufficient testing tools NO tools available to detect fuel leaks

Inadequate testing tools NO tools to detect electrical shortages

METHODS

Missing inspection steps NO instructions on how to inspect for fuel leaks

around electrical wiring

Insufficient quality control NO formal QC oversight when inspecting the

areas where fuel cells and electrical wiring are combined

PEOPLE

Failure to detect defective cables NO training Unable to physically view defective cables

Inexperienced maintainers NO experienced workers/mentors

MATERIALS

Substandard cables Outsourced cables delivered by sub-contractors

Different fuel mixtures Lack of standard fuel operations at airfields

world-wide

CORRECTIVE ACTIONS

FAA ensure corrective actions are complied with

Boeing ensures employees receive immediate maintenance notices

Boeing consider redesigning electrical wiring near fuel systems

Boeing consider improving fuel leak detectors

CONCLUSION

“Reliability, or quality over the long term, is the availability of a product to perform its intended function over a period of time and under prescribed environmental conditions.” (Summers, 2010). Based on this definition, the Boeing 737 has

exceeded these conditions Surpassed their intended function by extending

its lifespan beyond the prescribed maximum of 75,000 flights.

REFERENCESBoeing Website (2013). The Boeing Next-Generation 737 Family --

Productive, Progressive, Flexible, Familiar. Retrieved August 16, 2013 from http://www.boeing.com/boeing/commercial/737family/background.page

Dummeyer, D. (2013). Boeing Quarterly Reports (2Q13). Retrieved August 16, 2013 from http://www.boeing.com/commercial/aeromagazine/articles/2013_q2/pdf/AERO_2013q2.pdf

Brady, C. (1999). Boeing 737 Production. Retrieved August 15, 2013 from http://www.b737.org.uk/production.htm

Irving, C. (2012). Is Boeing’s 737 an Airplane Prone to Problems? - Newsweek. Retrieved August 17, 2013 from Newsweek Magazine at http://www.thedailybeast.com/newsweek/2012/03/19/is-boeing-s-737-an-airplane-prone-to-problems.html

Spicer, K., Angers, S. (2002). Boeing: The Secret Behind High Profits at Low-Fare Airlines. Retrieved August 15, 2013 from Boeing website: http://www.boeing.com/commercial/news/feature/profit.html

Summers, D. (2010). Quality. New Jersey: Prentice Hall