WEIGHT CONTROL RESPONSIBILITY, AUTHORITY, and ACCOUNTABILITY (RAA)

Presentation at the 67th Annual Conference of the Society of Allied Weight Engineers, Inc.

Seattle, Washington 17-21 May, 2008 Kenneth LaSalle 787 Weight Engineering The Boeing Company

Weight Control RAA Agenda

 Importance of Weight Control  Weight Derivation Ingredients  Roles & Responsibilities  Weight Control Engineering Attribute Overview  Summary

Weight Control RAA

 Q: Why is weight efficiency important to airlines?

 A: Weight affects 2/3 of the airplane operating cost

Weight Control RAA

How is the airplane weight, at Entry Into Service, derived & improved through design process (structural perspective)?

Product Development “Design Sensitive” Tools/Parametrics Firm Concept Parametrics + LCPT Initial Sizing Detail Design Fully Released MBDs / Actual Weights Weight = f Configuration + Aerodynamics + Loads • Mission req’ts • 3-View • Airfoil Type • Sweep • External + Stress • Strength + Design • Producibility • Preliminary • Fatigue • Layouts • Planform • T/c • Design • Stiffness • Ply maps • Integration • Aspect ratio • MLA • Criteria • Buy to Fly • Functionality • Span • Internal • Min Gage • Detailed Part Modeling • New Technology • Etc.

• Thermal • MS • Integration • Etc.

• Combined • Etc.

• Noise • Etc.

• Design Growth • Etc.

Weight is the result of the released design. To influence the airplane weight, the weight control engineer must influence the design process.

Weight Control RAA Roles and Responsibilities (or RAA)

 Ensure the weight efficiency & weight compliance of our company’s products     Provide airplane weight estimates given “any” level of design definition Documented weight estimations w/all assumptions defined Articulate differences between new design concept and existing fleet Proactive design influence (must integrate ourselves into the design community)  Lead airplane weight optimization effort (New, Derivative, or Sustaining)  Company leadership’s “primary” resource for weight efficient project planning   Provide technology & weight optimization roadmap (Chart the course w/ R&D Team) Lead weight reduction planning activities (Idea collection thru implementation)

Required Weight Control Engineering Attributes

    Big Picture / Vision / Strategy Focus Teamwork Technical Competence Personal Attitude / Challenge / Development

Big Picture / Vision / Strategy

   Commercial Airplane Business Unit (Investment in enhanced performance?)  Conditions affecting airlines   High fuel prices?

Passenger expectations (more comfort or direct flights)   Company fleet condition (aging or gaps in family?) Launched Programs (competing resources)   787 Family, 777 Freighter, 747-8 A380, A350 Airplane Performance Organization (How Do We Balance Risk?)  Engine Performance (SFC) vs. Weight (OEW) vs. Aero Performance (L/D) Weight Engineering Organization  Communicate frequently to the design team     What is the airplane weight level (understand all assumptions) Where the airplane level is going (forecasting) Why we are pursuing target weight level How we are going to achieve target weight level

Teamwork (Establish Trust & Dependability)

    Establish Network         Leadership (First-line to program level) Configuration & Engineering Analysis (C&EA) Design Stress Loads Manufacturing Finance Global Supplier(s) Build Relationships… More than just requesting information Provide Data   On time (meet commitments) Accurate (fidelity required, list & discuss all assumptions) Team Player   Ask trade study team to request missing disciplines’ participation Represent airplane level interests, not just Weight Engineering

Technical Competence

Determine Mission Requirement Design Impacts

            Range (wing planform & loft size, fuel capacity, low speed devices) Passenger count (fuselage length & diameter, wing center section width) Passenger Accommodations (higher humidity, lower cabin alt pressure, large windows) Speed (wing sweep, airfoil depth, etc.) Take off & landing performance (i.e. icy runway conditions, field length) Family plan (weight impacts due to commonality) Interior architecture (New vs. Derivative vs. Existing Fleet)    Interior flexibility impacts Overhead space utilization (Crew rest compartments, OCAS, etc.) Option strategy (what to make basic vs. options) Cost (NR & Recurring) Noise - Environmental & Passenger Maintenance and reliability enhancements Aviation authority requirements (FAA or EASA) Entry into service goal

Technical Competence Understand Schedule & Key Design Gates

Weight Reduction Opportunity

1000’s of pounds             Product Development Firm Concept Systems Architecture Initial Loads Preliminary Loads Aerodynamic Lines Freeze Firm Configuration Firm Interior Architecture Detail Design Phase Final Loads Flight Testing Entry Into Service (EIS) 10’s of pounds

Technical Competence Understand Work Package Definition

 Structures– Ensure clear understanding of:   Part-level definition Primary vs. secondary structure    Integration structure (splices, sealant, fastener type & size, etc.) Attachments (composite – bolts in lieu of rivets) Interfaces (systems to structures, eccentricities, etc.)    Systems – Ensure clear understanding of:  Systems architecture definition (fuel, high lift, hydraulic, electrical, etc.)    Systems separation Bomb blast Engine/APU blade off/rotor burst Loads (determine which ones are critical, how close is next condition)   External (static – 2.5G flaps down, dynamic – gust) Internal (buckling, combined loading, thermal, etc.)  Systems (fan blade out, voltage, heat, power, , flow, rpms, psi, etc.) Materials     Allowables (A-basis vs. B-basis, criteria effects, etc.) Density (areal weight, density, etc.) Sizing criteria (choose most efficient material, i.e., for fatigue or strength or durability) Application (CFRP… ply orientation/optimization, etc.)  Cost (Titanium vs. Aluminum)

Technical Competence Understand Weight, Cost, Schedule Relationship

 Determine significant technical weight drivers           Material selection Planform (Wing & Empennage) Body cross-section Airfoil technology High lift systems Load alleviation Architecture Integration Supplier base System’s performance requirements (Temp, flow, power, pressure, etc.)  Determine large cost drivers (typically compete with large weight drivers)    Advanced materials (procurement cost, manufacturing, etc.) Advanced build technology (new facilities, tooling, etc.) New Technology (high-pressure hydraulics, fiber optics, advanced magnetics, etc.)  Balance weight vs. performance vs. cost vs. schedule

Technical Competence Ask Questions / Challenge Decisions

 Ask questions & compare existing fleet data    What requirements and objectives guide the design?

What advisories are circulating that affect the design?

Study or create “Tops Down” charts to compare fleet data  Challenge decisions and criteria     Requirements Commonality designs Material selections Production Constraints    Inspectable Preferred materials and standard parts Handling constraints (envelope, weight, robustness)    Assembly techniques & tooling Architectural or layout arrangement Loads, stress and design assumptions (Conservative?)  Provide Feedback   Positive & negative Say “thank you”

Personal Attitude/Challenge/Development

 Having a positive and optimistic outlook and approach enables:    Strong design team working relationships - trust, integrity, ethics More cross-functional participation resulting in accumulation of known and unknown information Mentoring & friendship opportunities  Developing weight control attributes takes repetition working through new designs  Learning to be inquisitive, while providing appropriate support, is necessary  Communication skills are an essential asset  Implementation of short- and long-term career development plans needs to occur early

Summary

 Weight Engineering is a diverse and technical field  Weight control engineering is proactive  Roles and responsibilities change as program progresses through design cycle  Communication, both verbal and written, are key  It takes a lengthy period to become an adept weight control engineer