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Utilizing a Process Engineering Tool to Manage Workplace Safety, Health, Environmental and Ergonomic Risk in Commercial Airplane Production

Steven Magasis, CIH787 SHEA Representative

Boeing 787 Airplane ProgramSafety Health and Environmental Affairs

6/6/07

COPYRIGHT © 2007 THE BOEING COMPANY

Setting New Levels of Leadership

Less fuel usedLower emissionsQuieter for communities, crews, and passengersFewer hazardous materialsLess waste in production


Composites Serve as Primary Structural Material

Composites50%

Aluminum20%

Titanium15%

Steel10%

Other5%

Carbon laminateCarbon sandwichOther compositesAluminumTitaniumTitanium/steel/aluminum


Global Structures Team

41434446

4748

1145

Fixed Trailing Edge (KHI)

Main Landing Gear Wheel Well (KHI)

Forward Fuselage (KHI)

Forward Fuselage (Spirit)

Wing Box (MHI)

Leading Edge (Spirit)

Moveable Trailing Edge (HdH)

Wing-to-Body Fairing (Boeing-Winnipeg)

Horizontal Stabilizer (Alenia)

Center Fuselage(Alenia)

Center Wing Box (FHI)

Vertical Fin (Boeing-Fredrickson)

Wing Tips(KAL-ASD)

Aft Fuselage(Vought)


Joined Section 43-46

Charleston, SCto Everett, WA

JoinedSection47-48

Charleston, SC to Everett, WA

Section 41Wichita, KS to Everett, WA

DreamlifterRoute Structure

Section 46Grottaglie, Italy

to Charleston, SC

Section 44Grottaglie, Italy to

Charleston, SC

Horizontal StabilizerFoggia, Italy

to Charleston, SC

WingNagoya, Japanto Everett, WA

Section 43Nagoya, Japan

to Charleston, SC

Section 11/45Nagoya, Japan

to Charleston, SC


Dreamlifter


Dreamlifter and DBL


Separated at Birth?


787 Final Assembly Factory FlowEverett, WA

Everett, WA factory is certified with ISO 14001

12

4365

40-26


787 Final Assembly Factory FlowEverett, WA


International Team at Work


Standard Work (Background): SHEA Documents

HECP Hazardous Energy Control Plans HCIS Hazard Communication Information Sheets

FPWP Fall Protection Work PlansACSP Airplane Confined Space Permits


EaseLevelData Delivery

ME-Push3D or2D

Velocity-based "Shop Order Instance" (SOI)

787 SHEA "SHEA Wizard“XML-based (ME-Pull)

EaseLevelData Source

ME-Push2DExcel-Workbook based "Operations Library" SHEA Note used to populate Installation Plan" (IP), pushed to Velocity-based "Shop Order Instance" (SOI)

ME-Push3DDELMIA Process Engineer"SHEA Work Instruction Library Item" used to populate Installation Plan" (IP), pushed to Velocity-based "Shop Order Instance" (SOI)

STANDARD WORK

EaseLevelData Source

MT-Pull1DWeb-Based access to full listing of 787SHEA documentation.


Standard Work: SHEA Work Instructions and Documents

HCIS (24) Hazard Communication Information Sheets

FPWP (60) Fall Protection Work Plans

HECP (114) Hazardous Energy Control Plans

ACSP (13) Airplane Confined Space Permits

IP Installation Plan

MT Manufacturing Technician (ultimately must implement these work instructions)


The SHEA Wizard is designed to assist Manufacturing Engineers (MEs) in the performance of two required functions:

Adding SHEA library Work Instructions (and associated Resource Objects) to a 787 Installation Plan (IP).

Creating a SHEA verification report for each 787 IP as a means of compliance with Program requirement to ensure a safe build process.

Who Uses the SHEA Wizard and Why?


How ME’s Utilize the SHEA Wizard

Wizard Demo


SHEA Input to Standard Work Operations and Resources


Standard Work; Shop Floor Info


Standard Work;ME Ergonomic Checklist Identifies Risk

Current Checklist

6 Ergo Risk Categories

LiftingHand/ArmOverheadPush/PullBendingKneeling

Cumulative

All total against a standard limit as defined by requirements incorporated in DELMIA

* Copyright Auburn Engineers

*

*


787 Master Dispatch Display –Task Assignment Display

Medical Restrictions

Assignable SOIsTitle

SOI: Load & Lock L/H Blade Seals

Qualified MT’s Assign Ergo

Elapsed Time

Y

Y

Tieks, Susan

Anthony, Kyle

Mar, John

Hale, Mark

Norlin, Rob

Yee, Sonny15 Min

15 Min

MTs required: 2 GFever:

ETA5 Min

Available

13 Min

54 Min

1.62 H

2.42 H

2

1

3

2

2

3

Hrs Today

Pre-Assigned

Install Dorsal Fin

Initial Torque RH Tension

Final Torque RH Tension N -------

MASTER DISPATCH DISPLAY

Available

Available

13 Min

----------

----------

2

1

3

0

0

0

----------

----------

----------

----------

----------

0

0

0

0

0

A

A

A

A

A

A

A

A

A

A

U

U

U

C

W

V

V

Control Station:190

L/N:35

Team:ALL

Thu. Sept 18, 2008 Boeing M-day: 453 17:45 PST

Sellers, Donny

Clemins, Jackie

Sawyer, Thomas

Scotts, Darrell

Newton, Paula

Tawnson, Henry

Wilson, Caleb

Daniels, Tyler

Kenyon, Farris

Dierks, Paul

Fisher, Karri

5

0

8

1

1

4

OT Hrs in Pay Period

4.5

0.75

0

12

0

0

2

6

3

1

2

787 SUMMARY STATUS

Click to send Assignment

Refresh

MT Status Category:A – Available (Clocked In)U – Not Clocked InV – VacationS – Scheduled Appointment (Dentist, etc)W – Workshop / Lean ActivityC – Training (Class, OJT, etc)J – Jury DutyE – Extended Absence (LOA, etc)

FAD01PAP0300

Production schedulers will make informed decisions to help reduce ergonomics risk exposure to production personnel. The “black”dot here indicates that this person will exceed a recommended exposure level should the assignment be made.

*Noti

onal*

*Noti

onal*


SHEA Input to Standard Work Operations and Resources


EMERGENT WORKEaseData Delivery

MT-PushVelocity-based, SHEA-type “Emergent Event” is

submitted

EaseResponse

SHEA -Pull

787 SHEA Representativeresponds.

Manufacturing Technician MT


Emergent Work; Logic Mapping


Emergent Work; Shop Floor Information


Progressing on Schedule

20052002

787-8FirstFlight

787-8 Enters Service

AirplaneAnnouncement

Firm Configuration

Program Launch

Authorityto Offer

2003 2004 2006 2007 2008 2009 2010

787-3Enters

Service

787-9EntersService

Start of Major

Assembly


Utilize your customer’s core systems as much as possible,

…while retaining as much independent control of content as possible.

Don’t confuse the “model” with “reality”.

All this stuff is really cool, but it will not help your customer to reduce injury and illness if the instructions are not implemented.

Key Concepts

You customer will undoubtedly tell you “Safety is my number one priority”.

That’s great. But just for good measure, find out what your customer’s number 2, 3, 4 and 5 priorities are; see if your safety program facilitates them reaching those goals too...

Focus on your end user, and make sure that he/she has ready access to your program information, can understand it, and can let you (the Safety Professional) know when you’ve screwed up.


Innovation AwardIntegrating Safety and Ergonomics into the 787 Life Cycle787 Safety, Health and Environmental Affairs

L-R: Vincent Martinis, Tony Blackner, Wade Wheeler, Brenda Fukai-Allison, Jeff Hawk, Rich Gardner, Chuck Eggleston, Steve Magasis, Dave Smith

Boeing principles for Safety, Health and the Environment have been incorporated early in the 787 design phase. The integration of safety, environmental and ergonomics professionals in the product design process will have lasting benefits throughout the 787 life cycle, resulting in:

An Airplane that is Better for People

• Integrated philosophy for worker safety and the environment through design

• Focus on leading indicators and proactive intervention

• Ergonomics and Safety considerations incorporated in Tooling and Facility Designs

• Engineering tools and processes adopted/used by SHEA professionals

• >75 SHEA design requirements and objectives in six key areas of risk

• Ergonomics evaluations of 2000+ Installation Plans (IPs)

• Safe Work Instructions included by process in Installation Plans (IPs)

• Incorporated into Everett Site ISO14001 certification

• 787 2007 LWDCR Target = 1.0

Questions ?