Optimizing Line Balancing to Achieve Rate 7 Efficiency at Boeing

Abstract

This project addresses the production bottlenecks in the Moving Bin Buckets Line at Boeing South Carolina with the goal of achieving a production Rate 7 for the Boeing 787 program. Through time studies and lean analysis, inefficiencies were identified, and an optimized layout with resource reallocation was proposed. The study applied takt time principles, identified a critical bottleneck, and introduced a dedicated 'runner' role to improve process flow. The implementation of these changes resulted in meeting the takt time target of 9.2 minutes per unit. These improvements showcase the effectiveness of lean tools in real-world aerospace manufacturing challenges. Key Terms ⎯ Boeing 787, bottleneck analysis, lean manufacturing, takt time.