Technology Discoveries in A Changing Boeing Environment

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Technology Discoveries inA Changing Boeing
Environment

• Steven C. Johnson
• Director, Fabrication Division Computing
• Boeing Commercial Airplane Group
• February 2, 2000

OMAC PresentationFebruary 3, 2000/sjc-jh
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Design Anywhere, Build Anywhere,Support
Anywhere Think Globally - Act Locally
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Boeing Facts

• Boeing builds 60 of the worlds jetliners
• Boeing is the worlds largest military aircraft
  maker and Americas largest NASA contractor
• Boeing has 200,000 employees world wide

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Boeing Facts

• Boeing has 100 types of manufacturing control
  systems and machine tools
• Our manufacturing sites are primarily in Wichita,
  St Louis, Puget Sound, Southern California and
  our part subcontractors are world wide (25 from
  Europe)

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BCAG Components Sites
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Design Anywhere, Build Anywhere,Support
AnywhereMain Landing Gear Forward Trunnion
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Welcome toBoeing Commercial Airplanes
Fabrication DivisionAuburn Site
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Auburn Site Components

• Fabrication Division
• Major supplier of airplane components, detail
  parts, sub assemblies, and assemblies
• Aircraft Systems Interiors (ASI)
• Major supplier of electrical wiring and duct
  systems and interior floor and wall panels
• Wing Responsibility Center (WRC)
• Major Supplier of wing components and empennage
  structures

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Challenges

• We have 286 class CPUs running multimillion
  dollar machines
• We pay premium prices for proprietary machine
  controllers
• We have multiple factory network protocols

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Challenges

• Culture and tradition. Weve built it this way
  for decades. We know it works.
• It is easier to keep rolling than to stop and
  change
• It costs money to upgrade and then support an
  upgrade.

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Challenges

• Production rate has to be maintained during
  upgrading process
• Computing software and hardware cycles provide
  upgrades every eighteen months. Factory machines
  last from 10-30 years. How do we reconcile this
  difference?
• Our parts, processes and final product have to be
  FAA certified.

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Configuration of Machining Cell
Probe Data Storage
FAB DNC
Cell Control Cell HMI Process
Database Scheduler Resource Manager NC Program
Mgmt. Pallet Transportation Production
History Using HP-UX 10.20 Unix
OS X-windows/Motif TCP/IP Ethernet FTP NFS Front
End PC (PC B) Cell Control Messaging NC
Program Transfer Machine Tool HMI Probe Data
Collection Probe Data Analysis Spindle Monitor
HMI Using NT Workstation 4.0 TCP/IP
Ethernet FTP High Speed Serial Bus
Boeing Enterprise Network
Router/Switch
TCP/IP Factory Network
Cell Control Processor HP-UX Unix
Work Setup Tooling Terminals
Ethernet Hub
Front End PCs (x4)
Fanuc HSSB
10BaseT Ethernet
Lantronix Terminal Server
Tool Presetter
Dual Vehicle Controllers
RS232C Serial Communications
MC1816 Mills with Fanuc 160MC Controls ( x4)
Factory Automation ComputingEnvironment.ppt B.
Ross 10/9/98
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Design Anywhere, Build Anywhere,Support
Anywhere Goals

• More flexible factory systems that support
  changing manufacturing processes.
• Effective integration and use of people,
  machines, and information systems.
• Seamless information delivery among people,
  machines and information systems.

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Design Anywhere, Build Anywhere,Support
AnywhereManufacturing Data Format Standards -
STEP
As-Is Applications, Hardware and Method
To-BeCommon Data Format
CATIA and Custom Applications, (80 currently)
PC CAD for NC - ESPIRIT and VIRTUAL
GIBBS UNIGRAPHICS-ANC Application - implemented
AP203, AP219 STEP for Mfg. I
- to implement AP224
Define Process
CUSTOM BOEING Built Applications
OPTIMAL/ISO 14649 INTERCIM - Wichita, ICAM - St.
Louis STEP-NC
Translate
GE FANUC, ALLEN BRADLEY,
OPTIMAL/ISO 14649 SIEMENS - preferred
controllers. STEP-NC,
AP219
Execute
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Design Anywhere, Build Anywhere,Support
AnywhereSeamless Data Transfer
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Design Anywhere, Build Anywhere,Support
AnywhereNC Machine Controller Evolution
Processing Power
1960
1970
1980
1990
2000 and Beyond
1955
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Design Anywhere, Build Anywhere,Support
AnywhereRequirements and Tactics

• Plug-n-Play Controller Architectures and
  Modules (Java, COM, Wireless, IEEE 1394 etc.)
• COTS Networking products
• Minimal or No Product Definition
  Transformations between Design and Manufacture
  (XML, STEP, NURBS, etc.)
• Integration of B2B Opportunities
• Commodity Technologies used throughout the
  factory

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Factory Floor to Top Floor Integration
Enterprise Systems
Facilities
Build Definition

ERP
Ethernet Connectivity
Factory Management Communications
Digital Manufacturing MCDs

• HMI/PC Architecture
• Web Capabilities
• Enterprise-level Data Access
• Object Oriented

• GNC
• NURBS
• Simulation

Monitor Machine Performance
Measure Analyze Quality
Controller
Machine Tool/ Device

• Maintenance
• Diagnostics
• Predictive Maintenance

• Process Control
• CMM Conformance to Specs Measurement
• Machine Tool Accuracy

Factory Floor
Sensors
Enterprise Systems
Factory Spt.
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Boeings Expectation of Open Architecture
Seamless CAD to NC
Airplane Engineering Design (CAD)
CAM Feature-based Attributes
Assembly-Build Integration Planning (Simulation)
Direct CAD to CNC Feed
Post Process Execute Locally on Factory
Computing Environment

• Enhance Product Quality with Process Acceptance.
• Improved Production Readiness.
• Reduced Cost of Parts Assemblies.

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Partnerships

• Teaming Relationship among OEMs, Controller
  Manufacturers, Equipment suppliers...
• OMAC provides the industry leadership and forum

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Outcome

• Common Factory Floor
• Integrated Manufacturing Environment
• Reliable Support Environment