implementing paint automation in an aerospace company
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Implementing Paint Automation in an Aerospace Company. Christine Shanks ( [email protected] ). Implementing Wing Paint Automation:. Benefits of implementing automation 777 Wing Paint Manufacturing Process Boeing Lean Overview - PowerPoint PPT PresentationTRANSCRIPT
Copyright © 2014 Boeing. All rights reserved.
Boeing | Industrial Engineering
04/19/2023 1
Implementing Paint Automation in an Aerospace Company
Christine Shanks ([email protected])
Boeing | Industrial Engineering
Copyright © 2014 Boeing. All rights reserved.
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
04/19/2023 | 2
Boeing | Industrial Engineering
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Wing Paint Automation Benefits
Quality: +25%
WIP: 2 booths (1 wing set) (-4 booths/1 turn position) (-2 wing sets)
Floor Space: 29000 sq. ft. (-60%)
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 )
Shop Supplies: -30% (Masking, Tape, etc.)
Paint use: -25%
Safety & Ergonomics: -20% (Injury risk reduction)
Environmental: -70% (Hazmat)
Labor: -40% (Wing paint)
Flow: -40% (5 days to 3 days )
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Wing Paint Product - Process & Flow Current State
Paint Building
Paint Laydown 2 Day Flow
Prep & Abrade surfaces
Wash
Conversion Coating
Rinse
Blow Dry
Mask Spars
Hang Curtains
Prime front & rear spars
Paint front & rear spars
Cure
Mask Leading edge
Hang Curtains
Prime Leading Edge
Paint LE Teflon
Cure
Unmask
Decals & Stencils
QA shake
Mask Leading edge for VPB
Corrosion Application – 1 Day Flow
Processes:
Mask Hang Curtains
Spray CIC Cure Unmask
15
4
7
10
12
1513
14
8911
Turn Position
Vertical Paint Booth (VPB) – 1.5 Day Flow
Processes:
Abrade Wash Rinse Conversion Coating Rinse Dry
Mask OW Walkway Mask Reg Letters Hang Curtains Prime
Paint poly Cure Mask runway Alignment Unmask
Paint Runway Alignment Cure Mask “Blackline” and “no step stencils
Paint “Blackline”, “no step stencils, and Safety Line attach point
2
6
3
Overhead Crane
Tooling & Crane
2 Overhead Cranes
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777 Program| Boeing Production System
Single Piece Flow Factory Vision
Standard Work
5S + Safety
Paint
Sorting, Simplifying, Sweeping, Standardizing, Self Discipline
Tactic1 Value Stream Map
Tactic 2 Balance the line
Tactic 3 Standard Work
Tactic 4 Visual Controls
6
5
7
8
9
3
4
2
1
The 9 TacticsTactic 5 Point of Use
Tactic 6 Feeder Lines
Tactic 7 Break Through Processes
Tactic 8 Pulse the Line
Tactic 9 Moving the line
Paint
Value Stream Map
Value Stream Map
Value Stream Map
777 Final Assembly100% Movement
Date
Time
Jobs
Behind
Value Stream Map
Value Stream Map
Value Stream Map
2 Day Capability
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Road Map to Automation:Development phase
04/19/2023 | 6
Programming continues for the
following processes
Wash
Prime & Paint Spars
Corrosion application for Spars
2013
Construction management
through August
Load first wing into to Automation booth
started online programming in
September
At 2.5 day cycle automation was
painting the Upper panel of the wing.
2011
Implementation team was formed to
manage
1. Construction Schedule
2. Permits
3. Contracts
4. Process Development
5. Work around plans
6. Booth designs
7. Daily Managment
2011
Leadership approves Wing
Paint Automation for the 777 2.5 day
cycle.
2010
777 Wing Paint Automation team
formed to study and develop new paint
process
2006 - 2009
737 Team presents automation
concepts to the 777 wing paint team.
Leadership gives go ahead for further
investigation and development of wing
paint automation
2005
737 team studies automation for the
Wing Paint processes
2004
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777 Wing Paint Improvement Strategies – Lean+
04/19/2023 | 7
Tactics 1-6 Manual Processes
POU kitting, standard work, balanced line Optimize NVA tasks (masking, washing, etc) Reduce variation with training Improve safety and ergo through work hardening and
job rotation 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
Tactic 7 (Breakthrough Technology) Manual Processes
POU kitting, standard work, balanced line
Eliminate NVA tasks
Eliminate duplicated processes
Eliminate detectable variation
Eliminate employee exposure and repetitive tasks
Combine cure times with subsequent processes
Process Specific Booths
Mitigate access constraints
Eliminate positions
Overhead cranes transportation
Eliminate unnecessary handling and tools
Flow
Reduce days
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Development Overview
04/19/2023 | 8
777 Wing Paint Automation
Development Phase
2. Develop
Manufacturing processes
3. Develop
Facilities Layouts & Robot
configuration
4. Simulate
Processes & Application
5. Evaluate
6. Recommend
Business Case Analysis
1. Learn &
Understand
Assess & Determine
Feasibility
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Road Map to Automation:Implementation Phase
04/19/2023 | 9
Programming continues for the
following processes
Wash
Prime & Paint Spars
Corrosion application for Spars
2013
Construction management
through August
Load first wing into to Automation booth
started online programming in
September
At 2.5 day cycle automation was
painting the Upper panel of the wing.
2012
Implementation team was formed to
manage
1. Construction Schedule
2. Permits
3. Contracts
4. Process Development
5. Work around plans
6. Booth designs
7. Daily Managment
2011
Leadership approves Wing
Paint Automation for the 777 2.5 day
cycle.
2010
777 Wing Paint Automation team
formed to study and develop new paint
process
2006 - 2009
737 Team presents automation
concepts to the 777 wing paint team.
Leadership gives go ahead for further
investigation and development of wing
paint automation
2005
737 team studies automation for the
Wing Paint processes
2004
Boeing | Industrial Engineering
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Project Leader
Project IE Project Manager
Finance Business Operations
Research & Technology
Manufacturing
Manufacturing
Engineering
EHS & Environment
al
Automation Safety Quality Project
EngineeringEquipment
Engineering
Supplier Management
Robotic Supplier
Sub Supplier Sub Supplier
Tooling Site Services
Booth Desinger
Booth Contractor
Sub Supplier Sub Supplier
Implementation Overview
04/19/2023 | 10
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ASM Product and Process FlowFuture State
Paint Building
Automated Paint Booth – 3 Days
Processes:
Prep wing Wash
Sand upper and lower Inspar surfaces
Wash wing complete
Conversion coating wing complete
Rinse Wing complete
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
Spar Decals & Stencils
Apply CIC to spars
Unmask
QA shake
Available Capacity for new Work Statement
787
12
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Automation Created Capacity for 777By: 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).
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Copyright © 2014 Boeing. All rights reserved.