PROBLEM STATEMENT


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MISSION STATEMENT:

We aim to produce a Lean Manufacturing Trim station for thermoplastic parts that are produced by the new 250 Ton press at Boeing Spokane.

PROBLEM STATEMENT:

Currently Boeing is using a 3-axis CNC router station to trim the thermoplastic panels used for ventilation ducting in the 777- 300 E.R. planes.  The panels are produced from a 250- ton press and require some trimming before they are ready for use.  The current trimming technique is an arduous and time intensive process that doesnt coincide with Boeings goal of utilizing the principles of Lean Manufacturing.  We will provide a product that will trim the panels to specified tolerances.  We will incorporate the principles of lean manufacturing as applicable, as well as make the device simple enough for anyone to use.  The major improvements over the current 3-axis router process will be, increased productivity, decreased cost, and increased compliance with lean manufacturing principles.

         PPROJECT DELIVERABLES:

     A simple right sized product that satisfies all customer needs

     Prototype test results

     A current website to track team progress

     Team poster for Design Expo

     Final Report / Documentation / Drawings

     DFMEA to assess risk of the design

     Provide Users manual with safety guidelines

 

ENGINEERING SPECS:

MATERIAL SPECS

     Trim Polytherimide BMS8-353 Type I Class 99 Grade 3A and 4A panels to tolerances of +/- .030

     Use table IV in Section of 11.1 in PSDS for part acceptance requirements

     Comply with all aspects of PSDS

     Surface finish and flaw requirements are outlined in table IV of PSDS and will be met

OPERATION AND SIZE SPECS

     Noise level limit of 85 db for safe operation

     Use 110 volt power ideally (220 max)

     Fit within a 10 x 10 section in a 4 wide L configuration

     Trim the panels to a net shape with tolerances of +/- .030

     Be robust and adaptable to many configurations for various parts

     Users will prefer this machine over current method

     Training manual will be visual so anyone could run the machine

     All tools and parts located within the workcell 

PROCESS IMPROVEMENT SPECS

     Complete a net trim in under 2 minutes (excluding set up time)

     Not take longer than 30 minutes to change part configuration

     Surface finish and flaw requirements are outlined in table IV of PSDS and will be met

     Will be movable by one person (on wheels)

     Reduce labor costs by enabling any operator to run machine

     Process will be continuous flow

 

 

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