Utilizing a Process Engineering Tool to Manage Workplace Safety, Health, Environmental and Ergonomic Risk in Commercial Airplane Production
Steven Magasis, CIH787 SHEA Representative
Boeing 787 Airplane ProgramSafety Health and Environmental Affairs
6/6/07
COPYRIGHT © 2007 THE BOEING COMPANY
Setting New Levels of Leadership
Less fuel usedLower emissionsQuieter for communities, crews, and passengersFewer hazardous materialsLess waste in production
COPYRIGHT © 2007 THE BOEING COMPANY
Composites Serve as Primary Structural Material
Composites50%
Aluminum20%
Titanium15%
Steel10%
Other5%
Carbon laminateCarbon sandwichOther compositesAluminumTitaniumTitanium/steel/aluminum
COPYRIGHT © 2007 THE BOEING COMPANY
Global Structures Team
41434446
4748
1145
Fixed Trailing Edge (KHI)
Main Landing Gear Wheel Well (KHI)
Forward Fuselage (KHI)
Forward Fuselage (Spirit)
Wing Box (MHI)
Leading Edge (Spirit)
Moveable Trailing Edge (HdH)
Wing-to-Body Fairing (Boeing-Winnipeg)
Horizontal Stabilizer (Alenia)
Center Fuselage(Alenia)
Center Wing Box (FHI)
Vertical Fin (Boeing-Fredrickson)
Wing Tips(KAL-ASD)
Aft Fuselage(Vought)
COPYRIGHT © 2007 THE BOEING COMPANY
Joined Section 43-46
Charleston, SCto Everett, WA
JoinedSection47-48
Charleston, SC to Everett, WA
Section 41Wichita, KS to Everett, WA
DreamlifterRoute Structure
Section 46Grottaglie, Italy
to Charleston, SC
Section 44Grottaglie, Italy to
Charleston, SC
Horizontal StabilizerFoggia, Italy
to Charleston, SC
WingNagoya, Japanto Everett, WA
Section 43Nagoya, Japan
to Charleston, SC
Section 11/45Nagoya, Japan
to Charleston, SC
COPYRIGHT © 2007 THE BOEING COMPANY
787 Final Assembly Factory FlowEverett, WA
Everett, WA factory is certified with ISO 14001
12
4365
40-26
COPYRIGHT © 2007 THE BOEING COMPANY
Standard Work (Background): SHEA Documents
HECP Hazardous Energy Control Plans HCIS Hazard Communication Information Sheets
FPWP Fall Protection Work PlansACSP Airplane Confined Space Permits
COPYRIGHT © 2007 THE BOEING COMPANY
EaseLevelData Delivery
ME-Push3D or2D
Velocity-based "Shop Order Instance" (SOI)
787 SHEA "SHEA Wizard“XML-based (ME-Pull)
EaseLevelData Source
ME-Push2DExcel-Workbook based "Operations Library" SHEA Note used to populate Installation Plan" (IP), pushed to Velocity-based "Shop Order Instance" (SOI)
ME-Push3DDELMIA Process Engineer"SHEA Work Instruction Library Item" used to populate Installation Plan" (IP), pushed to Velocity-based "Shop Order Instance" (SOI)
STANDARD WORK
EaseLevelData Source
MT-Pull1DWeb-Based access to full listing of 787SHEA documentation.
COPYRIGHT © 2007 THE BOEING COMPANY
Standard Work: SHEA Work Instructions and Documents
HCIS (24) Hazard Communication Information Sheets
FPWP (60) Fall Protection Work Plans
HECP (114) Hazardous Energy Control Plans
ACSP (13) Airplane Confined Space Permits
IP Installation Plan
MT Manufacturing Technician (ultimately must implement these work instructions)
COPYRIGHT © 2007 THE BOEING COMPANY
The SHEA Wizard is designed to assist Manufacturing Engineers (MEs) in the performance of two required functions:
Adding SHEA library Work Instructions (and associated Resource Objects) to a 787 Installation Plan (IP).
Creating a SHEA verification report for each 787 IP as a means of compliance with Program requirement to ensure a safe build process.
Who Uses the SHEA Wizard and Why?
COPYRIGHT © 2007 THE BOEING COMPANY
Standard Work;ME Ergonomic Checklist Identifies Risk
Current Checklist
6 Ergo Risk Categories
LiftingHand/ArmOverheadPush/PullBendingKneeling
Cumulative
All total against a standard limit as defined by requirements incorporated in DELMIA
* Copyright Auburn Engineers
*
*
COPYRIGHT © 2007 THE BOEING COMPANY
787 Master Dispatch Display –Task Assignment Display
Medical Restrictions
Assignable SOIsTitle
SOI: Load & Lock L/H Blade Seals
Qualified MT’s Assign Ergo
Elapsed Time
Y
Y
Tieks, Susan
Anthony, Kyle
Mar, John
Hale, Mark
Norlin, Rob
Yee, Sonny15 Min
15 Min
MTs required: 2 GFever:
ETA5 Min
Available
13 Min
54 Min
1.62 H
2.42 H
2
1
3
2
2
3
Hrs Today
Pre-Assigned
Install Dorsal Fin
Initial Torque RH Tension
Final Torque RH Tension N -------
MASTER DISPATCH DISPLAY
Available
Available
13 Min
----------
----------
2
1
3
0
0
0
----------
----------
----------
----------
----------
0
0
0
0
0
A
A
A
A
A
A
A
A
A
A
U
U
U
C
W
V
V
Control Station:190
L/N:35
Team:ALL
Thu. Sept 18, 2008 Boeing M-day: 453 17:45 PST
Sellers, Donny
Clemins, Jackie
Sawyer, Thomas
Scotts, Darrell
Newton, Paula
Tawnson, Henry
Wilson, Caleb
Daniels, Tyler
Kenyon, Farris
Dierks, Paul
Fisher, Karri
5
0
8
1
1
4
OT Hrs in Pay Period
4.5
0.75
0
12
0
0
2
6
3
1
2
787 SUMMARY STATUS
Click to send Assignment
Refresh
MT Status Category:A – Available (Clocked In)U – Not Clocked InV – VacationS – Scheduled Appointment (Dentist, etc)W – Workshop / Lean ActivityC – Training (Class, OJT, etc)J – Jury DutyE – Extended Absence (LOA, etc)
FAD01PAP0300
Production schedulers will make informed decisions to help reduce ergonomics risk exposure to production personnel. The “black”dot here indicates that this person will exceed a recommended exposure level should the assignment be made.
*Noti
onal*
*Noti
onal*
COPYRIGHT © 2007 THE BOEING COMPANY
EMERGENT WORKEaseData Delivery
MT-PushVelocity-based, SHEA-type “Emergent Event” is
submitted
EaseResponse
SHEA -Pull
787 SHEA Representativeresponds.
Manufacturing Technician MT
COPYRIGHT © 2007 THE BOEING COMPANY
Progressing on Schedule
20052002
787-8FirstFlight
787-8 Enters Service
AirplaneAnnouncement
Firm Configuration
Program Launch
Authorityto Offer
2003 2004 2006 2007 2008 2009 2010
787-3Enters
Service
787-9EntersService
Start of Major
Assembly
COPYRIGHT © 2007 THE BOEING COMPANY
Utilize your customer’s core systems as much as possible,
…while retaining as much independent control of content as possible.
Don’t confuse the “model” with “reality”.
All this stuff is really cool, but it will not help your customer to reduce injury and illness if the instructions are not implemented.
Key Concepts
You customer will undoubtedly tell you “Safety is my number one priority”.
That’s great. But just for good measure, find out what your customer’s number 2, 3, 4 and 5 priorities are; see if your safety program facilitates them reaching those goals too...
Focus on your end user, and make sure that he/she has ready access to your program information, can understand it, and can let you (the Safety Professional) know when you’ve screwed up.
COPYRIGHT © 2007 THE BOEING COMPANY
Innovation AwardIntegrating Safety and Ergonomics into the 787 Life Cycle787 Safety, Health and Environmental Affairs
L-R: Vincent Martinis, Tony Blackner, Wade Wheeler, Brenda Fukai-Allison, Jeff Hawk, Rich Gardner, Chuck Eggleston, Steve Magasis, Dave Smith
Boeing principles for Safety, Health and the Environment have been incorporated early in the 787 design phase. The integration of safety, environmental and ergonomics professionals in the product design process will have lasting benefits throughout the 787 life cycle, resulting in:
An Airplane that is Better for People
• Integrated philosophy for worker safety and the environment through design
• Focus on leading indicators and proactive intervention
• Ergonomics and Safety considerations incorporated in Tooling and Facility Designs
• Engineering tools and processes adopted/used by SHEA professionals
• >75 SHEA design requirements and objectives in six key areas of risk
• Ergonomics evaluations of 2000+ Installation Plans (IPs)
• Safe Work Instructions included by process in Installation Plans (IPs)
• Incorporated into Everett Site ISO14001 certification
• 787 2007 LWDCR Target = 1.0