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Author Swanstrom, Fred M. Hawke, Tom.
Source International SAMPE Technical Conference. v 31 1999. p 101-113.
Abstract This is a case study documenting cost reduction efforts on the Boeing 767-400ER Raked Wing Tip (RWT) structure. The 767 Integrated Product Team combined Concurrent Product Definition (CPD), digital design, Design For Manufacturing and Assembly (DFMA) and determinant (tool-less) assembly techniques with a year long lean manufacturing pre-production workshop. Cost saving product design improvements were implemented during early concept stages based on information gained from factory assembly simulations using inexpensive mockups and rapid prototypes. Utilizing DFMA techniques, baseline part count was reduced by 65% per ship set, resulting in significant cost savings. In addition, assembly shims were minimized using Variation Simulation Analysis (VSA), a statistically based tolerance management software program. Determinant assembly techniques using coordinated fastener holes were utilized to simplify the assembly process as well as reduce assembly tooling. Compared to similar assemblies in productio n at Boeing, the 767-400ER RWT composite fabrication and assembly labor was reduced approximately 50%. Non-recurring tooling cost savings are estimated to be near 70%. Overall cost figures indicate a 30% reduction in total cost on unit one production, with projected cost reduction potential of 50%. (Auth abstract) [References: 1] XX