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Boeing | Industrial Engineering Implementing Paint Automation in an Aerospace Company Christine Shanks ([email protected]) Copyright © 2014 Boeing. All rights reserved. 7/18/2015 1 Boeing | Industrial Engineering Implementing Wing Paint Automation: Benefits of implementing automation 777 Wing Paint Manufacturing Process Boeing Lean Overview Development & Implementation with cross- functional team Automation is key to 777 rate increase Copyright © 2014 Boeing. All rights reserved. 7/18/2015 |2 Boeing | Industrial Engineering Wing Paint Automation Benefits Quality: +25% WIP: 2 booths (1 wing set) (-4 booths/1 turn position) (-2 wing sets) Shop Supplies: -30% (Masking, Tape, etc.) Paint use: -25% Floor Space: 29000 sq. ft. (-60%) Safety & Ergonomics: -20% Rate: Facilitates future rate increase Weight: - 459 lbs. (380 lbs. drag equivalent, 79 lbs. actual) per wing set Cranes: -92% (30 moves to 2 moves ) Copyright © 2014 Boeing. All rights reserved. (Injury risk reduction) Environmental: -70% (Hazmat) Labor: -40% (Wing paint) Flow: -40% (5 days to 3 days ) 7/18/2015 |3 Boeing | Industrial Engineering Paint Laydown 2 Day Flow Wing Paint Product - Process & Flow Prep & Abrade surfaces Wash Current State Conversion Coating Paint Building Rinse Blow Dry Overhead Crane Mask Spars Tooling & Crane Hang Curtains 2 2 Overhead Cranes Prime front & rear spars 3 Paint front & rear spars 5 Cure 1 4 6 7 11 Mask Leading edge Hang Curtains 8 9 10 Prime Leading Edge Paint LE Teflon Cure 12 Unmask Decals & Stencils 15 Turn Position 13 QA shake Mask Leading edge for VPB 14 Vertical Paint Booth (VPB) – 1.5 Day Flow Corrosion Application – 1 Day Flow Processes: Processes: Abrade Mask Mask OW Walkway Mask Reg Letters Paint poly Mask runway Alignment Hang Curtains Spray CIC Cure Unmask Wash Cure Rinse Paint Runway Alignment Conversion Coating Cure Rinse Hang Curtains Dry Prime Unmask Mask “Blackline” and “no step stencils Paint “Blackline”, “no step stencils, and Safety Line attach point Copyright © 2014 Boeing. All rights reserved. 7/18/2015 |4 Boeing | Industrial Engineering Single Piece Flow Factory Vision 777 Program| Boeing Production System Value Stream Map Value Stream Map Paint 2 Day Capability Paint Value Stream Map Value Stream Map The 9 Tactics 1 Tactic1 Value Stream Map 5 Tactic 5 Point of Use 2 Tactic 2 Balance the line 6 Tactic 6 Feeder Lines 3 Tactic 3 Standard Work 7 Tactic 7 Break Through Processes 4 Tactic 4 Visual Controls 8 Tactic 8 Pulse the Line 9 Tactic 9 Moving the line Value Stream Map Value Stream Map 5S + Safety Copyright © 2014 Boeing. All rights reserved. Sorting, Simplifying, Sweeping, Standardizing, Self Discipline 7/18/2015 |5 Boeing | Industrial Engineering Road Map to Automation: Development phase 2004 737 team studies automation for the Wing Paint processes 2005 737 Team presents automation concepts to the 777 wing paint team. 2006 - 2009 777 Wing Paint Automation team formed to study and develop new paint process 2011 2010 Leadership approves Wing Paint Automation for the 777 2.5 day cycle. Implementation team was formed to manage 1. Construction Schedule 2. Leadership gives go ahead for further investigation and development of wing paint automation 3. 4. Process Development 5. Work around plans 6. Copyright © 2014 Boeing. All rights reserved. Permits Contracts Booth designs 7. Daily Managment 2011 2013 Construction management through August Programming continues for the following processes Load first wing into to Automation booth started online programming in September Wash Prime & Paint Spars Corrosion application for Spars At 2.5 day cycle automation was painting the Upper panel of the wing. 7/18/2015 |6 Boeing | Industrial Engineering 777 Wing Paint Improvement Strategies – Lean+ Tactics 1-6 Manual Processes POU kitting, standard work, balanced line Tactic 7 (Breakthrough Technology) Manual Processes Optimize NVA tasks (masking, washing, etc) POU kitting, standard work, balanced line Reduce variation with training Eliminate NVA tasks Improve safety and ergo through work hardening and job rotation Eliminate duplicated processes Eliminate detectable variation Eliminate employee exposure and repetitive tasks Combine cure times with subsequent processes Accelerate cure to enable subsequent tasks Process Specific Booths Improvements limited by access due to product dimensions Overhead crane transportation Improve necessary and unnecessary handling and tooling Flow Reduce hours Process Specific Booths Mitigate access constraints Eliminate positions Overhead cranes transportation Flow Copyright © 2014 Boeing. All rights reserved. Eliminate unnecessary handling and tools Reduce days 7/18/2015 |7 Boeing | Industrial Engineering Development Overview 2. Develop Manufacturing processes 1. Learn & Understand Assess & Determine Feasibility 3. Develop Facilities Layouts & Robot configuration 777 Wing Paint Automation Development Phase 4. Simulate Processes & Application 6. Recommend Business Case Analysis 5. Evaluate Copyright © 2014 Boeing. All rights reserved. 7/18/2015 |8 Boeing | Industrial Engineering Road Map to Automation: Implementation Phase 2004 737 team studies automation for the Wing Paint processes 2005 737 Team presents automation concepts to the 777 wing paint team. 2006 - 2009 777 Wing Paint Automation team formed to study and develop new paint process 2011 2010 Leadership approves Wing Paint Automation for the 777 2.5 day cycle. Implementation team was formed to manage 1. Construction Schedule 2. Leadership gives go ahead for further investigation and development of wing paint automation 3. 4. Process Development 5. Work around plans 6. Copyright © 2014 Boeing. All rights reserved. Permits Contracts Booth designs 7. Daily Managment 2012 2013 Construction management through August Programming continues for the following processes Load first wing into to Automation booth started online programming in September Wash Prime & Paint Spars Corrosion application for Spars At 2.5 day cycle automation was painting the Upper panel of the wing. 7/18/2015 |9 Boeing | Industrial Engineering Implementation Overview Project Leader Project Manager Project IE Finance Research & Technology Business Operations Manufacturin g Manufacturin g Engineering EHS & Environment al Automation Safety Quality Project Engineering Equipment Engineering Tooling Supplier Management Robotic Supplier Sub Supplier Copyright © 2014 Boeing. All rights reserved. Site Services Booth Desinger Booth Contractor Sub Supplier Sub Supplier Sub Supplier 7/18/2015 | 10 Boeing | Industrial Engineering ASM Product and Process Flow Future State Automated Paint Booth – 3 Days Processes: Prep wing Wash Sand upper and lower Inspar surfaces Paint Building Wash wing complete Conversion coating wing complete Rinse Wing complete 2 1 Blow Dry wing Complete Mask Spars Prime front and rear spars, lower panel, upper panel and Leading edge Paint front and rear spars, lower panel, upper panel and Leading edge Teflon Mask & Paint Runway Alignment Stripe, Blackline, and no step stencils, Reg Letters & safety line attach point 787 Spar Decals & Stencils Available Capacity for new Work Statement Apply CIC to spars Unmask QA shake Copyright © 2014 Boeing. All rights reserved. 7/18/2015 | 11 Boeing | Industrial Engineering Automation Created Capacity for 777 By: Reduced Factory footprint: – Two paint positions – Opens up valuable floor space to be repurpose Labor – One operator for spray operations Flow – 2 days reduction Cost – Implementing new technology was less than the cost to build a duplicate booth of the old system. Robotics Apply soap, rinse, abrade, conversion coat, prime & paint Consistent and accurate Reduce time required to paint the wings by 40 percent. The technology brings a whole new set of skills Safer – Reduces the physical demands of painting wings vertically, and eliminates ergonomic issues and employee exposure to chemicals. Capacity Design the booths to accept a longer wings for future derivatives (777x). Copyright © 2014 Boeing. All rights reserved. 7/18/2015 | 12 Boeing | Industrial Engineering Copyright © 2014 Boeing. All rights reserved. 7/18/2015 | 13 Copyright © 2014 Boeing. All rights reserved.