NYC777 From United States of America, joined Jun 2004, 5160 posts, RR: 49 Posted (6 years 6 months 2 weeks 3 days 21 hours ago) and read 9624 times:
+ Completed first step of converting the line to a moving line.
+ Only final assembly if production process has been converted.
+ Entire production process to be converrted to moving line by 2008.
Leelaw From , joined Dec 1969, posts, RR: Reply 1, posted (6 years 6 months 2 weeks 3 days 19 hours ago) and read 9428 times:
Boeing Begins Use of Moving Assembly Line for 777 Jetliners
SEATTLE, Nov. 08, 2006 -- The Boeing Company [NYSE: BA] has started using a moving assembly line for the first time to build its market-leading 777 jetliner. For now, the moving assembly line is used only during final assembly positions for the airplane, moving it at a steady pace of 1.6 inches per minute during production...
To make its 777 assembly line move during final assembly, 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.
NYC777 From United States of America, joined Jun 2004, 5160 posts, RR: 49 Reply 2, posted (6 years 6 months 2 weeks 3 days 19 hours ago) and read 9397 times:
Is Boeing supposed to increase the production rates of the 777? If so from what rate to what rate?
Does the moving line help increase the production rate?
Revelation From United States of America, joined Feb 2005, 10470 posts, RR: 20 Reply 4, posted (6 years 6 months 2 weeks 3 days 19 hours ago) and read 9369 times:
Quoting NYC777 (Reply 2): Is Boeing supposed to increase the production rates of the 777? If so from what rate to what rate?
NYC777 From United States of America, joined Jun 2004, 5160 posts, RR: 49 Reply 5, posted (6 years 6 months 2 weeks 3 days 19 hours ago) and read 9336 times:
Lemurs From United States of America, joined Mar 2005, 1439 posts, RR: 4 Reply 6, posted (6 years 6 months 2 weeks 3 days 18 hours ago) and read 9248 times:
It's not such a joke though really...increasing the speed of the moving line at that rate would increase montly production by 20%. That's not a small number folks, even if it's not going to beat any slugs in races.
There are 10 kinds of people in the world; those who understand binary, and those that don't.
NYC777 From United States of America, joined Jun 2004, 5160 posts, RR: 49 Reply 7, posted (6 years 6 months 2 weeks 3 days 18 hours ago) and read 9210 times:
Ok but what is the monthly 777 out going to be eventually. Right now it seems to be about 5 to 6 per month but are they going to increase it something like 7 to 8 per month?
I think they would have to with the increasing 777 backlog.
Beech19 From United States of America, joined Jul 2006, 936 posts, RR: 4 Reply 8, posted (6 years 6 months 2 weeks 3 days 18 hours ago) and read 9168 times:
Actually yes... 2in/min is the proposed speed for the moving lines when they were being talked about. I beleive that is the speed of the 737 lines. So they COULD speed it up 20% as was mentioned and increase production by A LOT.
There has been talk of speeding up the 777 line to faster than 5 days.
Quoting NYC777 (Reply 7): I think they would have to with the increasing 777 backlog.
I think they should leave it at 5 days myself. It will keep a good backlog yet customer can still get aircraft within 18 months of ordering. Unless they got some massive order (or a few) they should probably leave it alone.
Beech19 From United States of America, joined Jul 2006, 936 posts, RR: 4 Reply 10, posted (6 years 6 months 2 weeks 3 days 15 hours ago) and read 8861 times:
Quoting Gr8Circle (Reply 9): A question here.....does Boeing (and Airbus too) have production work round the clock in shifts, or do the plants shut down at night...?
I can't speak for Airbus but at Boeing its 24/7. Day shift, swing and graveyard (only 6 hours long).
They only shut down twice a year... Family Day (in August usually) and for the Christmas-New Years break (1 - 2 weeks).
Stitch From United States of America, joined Jul 2005, 26720 posts, RR: 83 Reply 11, posted (6 years 6 months 2 weeks 3 days 15 hours ago) and read 8856 times:
Quoting NYC777 (Reply 7): Ok but what is the monthly 777 out going to be eventually. Right now it seems to be about 5 to 6 per month but are they going to increase it something like 7 to 8 per month?
The primary limit to the 777 production rate right now is the ability of suppliers to get parts to PAE, I believe.
Quoting Gr8Circle (Reply 9): A question here.....does Boeing (and Airbus too) have production work round the clock in shifts, or do the plants shut down at night...?
787atPAE From United States of America, joined Oct 2006, 143 posts, RR: 4 Reply 12, posted (6 years 6 months 2 weeks 3 days 12 hours ago) and read 8670 times:
Boeing may build the aircraft all day, but only the cool stuff happens at night. Stuff like moves of the fuselage sections, wings, etc, over other planes and through the factory. Even the doggone airplane itself goes to the paint shop at night. I've only heard riveting during the day.
Stitch From United States of America, joined Jul 2005, 26720 posts, RR: 83 Reply 13, posted (6 years 6 months 2 weeks 3 days 12 hours ago) and read 8660 times:
I did see one of EK's 773ER, in full colors, in front of the hanger one morning on the way into work a month or so ago. Fortunately, traffic was not too snarled.
Lightsaber From United States of America, joined Jan 2005, 10690 posts, RR: 100 Reply 14, posted (6 years 6 months 2 weeks 3 days 12 hours ago) and read 8617 times:
As others noted, so true. The whole point of a moving line is to add a pace to the production. By doing so, workers get motivated to finish before passing a litteral "inchstone." Same number of workers, greater number of airframes. Boeing customers are happy (they get their 777's on time), stockholders are happy (more profit) and the workers should be happy (believe it or not, it improves job security).
Quoting Stitch (Reply 11): The primary limit to the 777 production rate right now is the ability of suppliers to get parts to PAE, I believe.
They'll be able to ramp up. A 25% increase isn't major. (My math. 25% of 1.6 is 0.4. 0.4+1.6 is 2.0.
SlimChance From United States of America, joined May 2006, 62 posts, RR: 0 Reply 15, posted (6 years 6 months 2 weeks 3 days 11 hours ago) and read 8573 times:
Quoting Beech19 (Reply 8): Unless they got some massive order
You mean like if some cargo operator suddenly put in an order for 15+15?
Lokey123 From Barbados, joined May 2006, 138 posts, RR: 0 Reply 16, posted (6 years 6 months 2 weeks 3 days 11 hours ago) and read 8537 times:
I was down at BFI today and I'm heading up to Everett tomorrow. It should be interesting to get a look at this newly implemented moving assembly line. Will let all know what I see.
777MechSys From United States of America, joined Apr 2006, 350 posts, RR: 2 Reply 17, posted (6 years 6 months 2 weeks 3 days 10 hours ago) and read 8417 times:
Quoting Stitch (Reply 11): The primary limit to the 777 production rate right now is the ability of suppliers to get parts to PAE, I believe.
Quoting Beech19 (Reply 8): There has been talk of speeding up the 777 line to faster than 5 days.
I believe they under 5 right now. 4 to be technical. LOL I can't let you be right all the time.
Toiletboy99999 From , joined Dec 1969, posts, RR: Reply 18, posted (6 years 6 months 2 weeks 3 days 9 hours ago) and read 8325 times:
Quoting NYC777 (Reply 2): Does the moving line help increase the production rate?
This is actually very beneficial to Boeing. My degree is essentially doing things like this.
If anyone has ever seen those older photos of the boeing assembly process, it is a nightmare moving around all the planes to where they need to be. It was a real life game of Tetris. By having it set up this way, Boeing moves the plane down an organized chain, and moves the plane to each station.
Additionally, Boeing can better predict production times, and better fill in orders of new planes, because there is a more organized time slot system.
Yesterday, I spoke to a Boeing recruiter, and he told me that they are able to produce 28 737's a month using 2 moving assembly lines. I wont bore anyone with the details, but this concept has worked so well for Boeing, and has dramatically reduced production time of what it used to be.
Beech19 From United States of America, joined Jul 2006, 936 posts, RR: 4 Reply 19, posted (6 years 6 months 2 weeks 3 days 9 hours ago) and read 8141 times:
Quoting 777MechSys (Reply 17): I believe they under 5 right now. 4 to be technical. LOL I can't let you be right all the time.
Still talks of a 3 day rate.
Well... you COULD...
I thought they were at 5 and talking about going to three. My informant must have been wrong.
Theweave33 From United States of America, joined Jan 2006, 40 posts, RR: 0 Reply 20, posted (6 years 6 months 2 weeks 3 days 7 hours ago) and read 7668 times:
Vorticity From United States of America, joined May 2004, 337 posts, RR: 5 Reply 21, posted (6 years 6 months 2 weeks 3 days 6 hours ago) and read 7461 times:
The moving assembly line is part of Boeing's "Lean" efforts. It's intended to eliminate waste, and improve quality. If you really want to know more about it (the details)... read this article..
Cobra27 From Slovenia, joined exactly 12 years ago today! , 989 posts, RR: 0 Reply 22, posted (6 years 6 months 2 weeks 3 days 5 hours ago) and read 7173 times:
I think moving assembley line has only pyhcological advantages for workers, they get more into getting the job done. I see no other benefits from. The planes are to big to be put on conveyor line.
Does Airbus have a production line? I am not sure, but I think they don't have and at the same time have lower production cost for A320 family than Boeing 737
It does sound funny, but it's true - you increase throughput by increasing the pace.
Simple eh?
NOT!
The pace will be governed by the slowest operation (bottleneck).
Increasing the line pace usually requires a re-engineering of the bottleneck process.
It may even require a re-engineering of the product around the bottleneck process.
(If you're ever bored, ask me what I learned about product re-engineering from watching the guys at Nissan, Sunderland, installing engines/transmissions in Bluebirds.. )
The beauty, though, is a clear visibility as to the overall benefit to the product and the line
Quoting Lightsaber (Reply 14): . The whole point of a moving line is to add a pace to the production
It's well worth a read, for all you guys out there
Quoting Cobra27 (Reply 22): I think moving assembley line has only pyhcological advantages for workers
I have to strongly disagree with that, Cobra27.
The moving assembly line imposes a discipline to the production process whose effect is felt right down the supply chain and back into design.
Vorticity's link scratches the surface. I'd strongly suggest reading it (if you haven't already).
The moving assembly line will re-engineer just about the entire business focussed around that product.
It's also much more prone to being disrupted by problems/issues, but that's actually the point of it.
You HAVE to have disciplines that a non-moving line allow you to get away with.
Those disciplines are invariably beneficial to the business.
Leelaw From , joined Dec 1969, posts, RR: Reply 24, posted (6 years 6 months 2 weeks 3 days 2 hours ago) and read 6666 times:
Boeing spurs 777 output
New system makes production toe the line
By JAMES WALLACE
P-I AEROSPACE REPORTER
...For now, a tug moves the 777 along a 275-foot line during final assembly. The tug, which has an optical sensor that follows a line on the floor, is attached to the front landing gear and pulls the plane forward about 1.6 inches per minute. The tug stops if there is a problem.
During this part of final assembly, mechanics install seats, overhead bins and other interior parts. In addition, functional testing is performed on various systems, and the two engines are installed.
Eventually, Boeing could be building the 777 at record rates. Boeing will not talk about the production rate for a specific jet, but the company is boosting production of the 777 to seven jets a month, according to people on the program. Boeing has studied the feasibility of raising rates even more, to perhaps 10 planes a month...
25 Cobra27: That is what I said. Other benefits? Something from engineer's (not psychology of workers) maybe? Or not?
26 Astuteman: For fear we have a misunderstanding, I believed you to have said that the moving line has "only psychological advantages for workers". My words "disc
27 UAL747-600: With regards to monthly/anual deliveries see below. Fair use excerpt from Seattle PI Eventually, Boeing could be building the 777 at record rates. Boe
28 Revelation: Indeed. In fact, the only way the overall production rate can increase is to do so. It's just not the answer I imagine the poster was after! If I did
29 777MechSys: No talk... 777 will be on a 3 day rate by the end of the year.
30 NYC777: So are you saying they'll be putting out 1 777 every three days? Is that what it means? If so, that's pretty damned good!!!
31 Beech19: Good to hear. Then my "informant" was only half wrong. LOL Whats crazy to think is pushing out both 777's and 787's at 3 days a peice! Thats a lot of
32 WestWing: Just a quick request for clarification. According to earlier posts, Everett operates 24/7 and 777MechSys says they will achieve a 3-day rate for 777s
33 Lightsaber: But if you've read any history about mass production, you realize that unless you push the limit, the company is throwing away productivity. If Boein
34 DZ09: what's that green stuff you see on airplanes during assembly. Is that an aluminum primer or some sort of protective plastic film?
35 Beech19: Yes, every 3 days (on average, weekend work isn't as quick) a 777 would leave the factory, dragged across Highway 526 and into one of the paint shops
36 NYC777: Wow then we're talking about 10 777/month. Have the suppliers already been turning out their pieces to support this rate? Seems like quite a bit.
37 Beech19: Plastic film. When you pull it all off and polish it up you get a AA aircraft.
39 AirbusCanada: here is an article comparing production process at airbus and boeing. http://courses.washington.edu/samcrs/Howtheotherhalfbuilds.pdf
40 Beech19: No... The green is not a primer as i already mentioned. It is a plastic-based coating (film was the wrong word) that is on the metal peices that are
42 KELPkid: Ah, thanks for the correction. I never knew about the plastic before...and primer is quite green (just a lot more yellowish green than the plastic!).
43 Beech19: Yeah... the plastic is cool to see. Definitly not your average white plane jane airliner. (plastic green is how the BBJ's are delivered to the custom
44 Toiletboy99999: Sorry, all of this was in a convo. i had with a Boeing Project Engr.
45 Astuteman: Me too Me too It does ask a lot of the design community, though. I genuinely hope that you meant "defer". I'd hate to "differ" with you on this subje
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As others noted, so true. The whole point of a moving line is to add a pace to the production. By doing so, workers get motivated to finish before passing a litteral "inchstone." Same number of workers, greater number of airframes. Boeing customers are happy (they get their 777's on time), stockholders are happy (more profit) and the workers should be happy (believe it or not, it improves job security).
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