Reducing the Wing Body Join (In-Tank Systems) Cycle Time

Abstract

Due to increased demand, The Boeing Company decided to reduce the cycle time of the 777/777x Airplane Program from 10-day to 7-day. This project impacts the position of the Wing Body Join (In-Tank Systems). The goal was to have a bar chart with zero conflicts and correct precedence and duration time; these would positively improve bar load and jobs completed on time. The D.M.A.I.C. methodology was used in this project. A workshop was performed as a starting point to build the new bar chart with the personnel related to the process. Time studies were conducted, starts and completes were eliminated, and the job's time duration was adjusted, increasing the bar load by 22% and reducing by 50% jobs with more than two hours. After the time studies, analysts worked on two champion recipes to minimize conflicts between sealers and in-tank mechanics and reduce inspections. These efforts increased the jobs completed on time by 16%, comparing the last airplane used with a 10-day cycle and the third airplane on a 7-day cycle. Key Terms ⎯ D.M.A.I.C., Do What's Due (D.W.D.), Bar chart load, Precedence, Bar chart, In-Tank, Budget, Bar time, Time Studies, Champion Recipes.