Determining the optimal set of solutions for storage and conveyance of tools in a highly variable manufacturing environment

Abstract

In November 2013, Boeing launched a derivative of the 777 airplane, known as the 777X, which will be the largest and most efficient twin-engine jet in the world when it enters service in 2020. In parallel with new airplane development, Boeing is transforming its existing 777 production system through an initiative known as FPS, or Future Production System (FPS), in order to create a more safe, flexible and productive manufacturing environment that accommodates the 777 and 777X. This will require upgrades to be made to the existing 777 manufacturing process. FPS requirements include the need for a system to better support the mechanic by implementing "final stage tool kitting." My project scope was to plan, design, and implement a tool kitting process for the Service Ready Wing (SRW) area of 777 Manufacturing. The first part of this thesis evaluates the prescribed solution of tool kitting and attempts to evaluate its potential cost and benefit to 777 SRW Manufacturing. The thesis then systematically approaches the problems for which tool kitting is trying to solve, rather than the solution itself. The result is a set of solutions discussed in Chapter 7 that focuses on reducing tool inventory, floor space, and non-value added time of the mechanic. This thesis is intended to serve as a model for all areas of 777 and 777X Manufacturing as teams continue to work towards understanding how to improve tool management. By providing a systematic approach to evaluating the current-state tool usage in a specific manufacturing area, and focusing proposed solutions on actions that solve a defined problem set agreed to by key stakeholders, this work will help guide other groups towards creating successful, sustainable tool conveyance solutions.