Fri, Jan 28, 2005
Speed Before The Fact
Boeing's Next-Generation 737
airplane is making history again as the application of lean
manufacturing techniques gives it the shortest final-assembly time
of any large commercial jet.
The 737, the world's most popular commercial airplane model, is now
assembled in 11 days at the company's Renton, WA, facility. That's
a 50 percent reduction since lean techniques were introduced there
in late 1999.
"Speed is just one aspect of this remarkable achievement," said
Carolyn Corvi, 737/757 Programs vice president and general manager.
"With market conditions for airlines constantly changing, shorter
assembly times allow them to make decisions about interior
configuration and systems closer to delivery. That's a great
benefit to them."
"We're not going to stop at a 50 percent reduction, but
improving our production system isn't just about doing things fast.
It's about doing everything better, continuously enhancing the
quality of our products and the processes we use to design and
build them," Corvi added.
In addition to reducing assembly time, the 737 program has
reduced work-in-process inventory by 55 percent and stored
inventory by 59 percent.
The program's moving assembly line is the most compelling symbol
of the factory's lean improvements. That line moves products from
one assembly team to the next at the steady pace of two inches per
minute. Other lean techniques Boeing uses include just-in-time
delivery systems, point-of-use staging of tool and parts kits,
standardized work processes, and visual control systems.
The lean techniques, which Boeing is applying to other
production lines, enable a smooth, continuous production flow,
enhancing the quality and efficiency of production processes.
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