Large Scale Human Factors Design Integration

- Maintainability on the Boeing 787 Dreamliner

Dwaine Carvan The Boeing Company
Oct, 2008

The 787 Family

787-8
210-250 passengers (three-class) 8,000 8,500 nmi | 14,800 15,700 km

787-3
290-330 passengers (two-class) 3,000 3,500 nmi | 5,500 6,500 km

787-9
250-290 passengers (three-class) 8,600 8,800 nmi | 15,700 - 16,300 km
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Configured for Success

787 Design Features

Breakthrough passenger cabin Advanced wing design

Overhead crew rests

Enhanced flight deck

Innovative systems technologies

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Composite primary structure

Large cargo capacity

Advanced engines and nacelles

An Airplane for Global Users

Pilots Flight Attendants Airline Mechanics Ground Service Crews

Passengers

Factory workers
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BCA Human Factors & Ergonomics Team Mission

Ensure that humans can build, operate, maintain, and enjoy Boeing products in a safe and efficient manner by providing consistent and reliable human factors support via requirements, test and evaluation, research, and consultation.

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Impacted Groups Getting on the VIP List

== Airplane & Services *** Human Factors *** == Systems Integration == Propulsion == Wing & Empennage == Fuselage & Interior == Final Assembly & Delivery == Services == Certification *** Co-ordinate Human Factors across all organizations ***
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HF

HFE Discipline Federated Across Various Organizations

Visual and auditory perception Ergonomics Aviation Services Factory Ergonomics Anthropometry

Maintainability

Flight Deck Airplane Interiors Airplane Configuration Cognition Test, evaluation & usability Statistical analysis
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787 Airplane Integration

787 Airplane Integration

The 787 program included Human Factors as an integral aspect for all design decisions from initial configuration concepts including general airplane layout and provisioning, to the final design stages which encompasses design for production, operational use, and serviceability in the field. How did we do it?

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HF/E Engineer Becomes Part of the Design Team

Design Engineer HF/E Engineer

Manufacturing Engineer
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Industrial Engineer Manufacturing

Service

3D

Maintenance

Designing Worker Safety into Products, Factory Tools, and Assembly Processes
Historical Data
35 30

Identified Risks
777/767/747

Hourly-All Recordables Hourly-Ergo Recordables

Other

25 20 15 10 5 0
36 777 Wings 32 767 STP 28 747 Wings/ WBJ 747 SI/ FBJ 767 Wings 20 Manufacturing Support 777 FA/FBJ 777 Body Structures 747 46/48 Sec 777 WBJ 767 FA

65% 58% 62% 56% 55% 68% 58%

73%

71% 66%

Supplier

737/757
1995 1996 1997 1998 1999 2000 2001 2002 2003 Jun04*

717

777 STP

30 25 20 15 10 5 0
eo fP ow er To ols Aw Lif kw tin ar g d Po st ur e Kn ee lin g Ov er he ad Be nd Pu ing sh in g/P ull in g Ot he r Sq ua tti ng Im pa ct

747 41/42 Sec 777 SI 767 J&I

Recordable Case Rate

24

747 FA

767 Body Structures

16

12

Flight Ops & DC

QA

8 767 FBJ 4

0 0 2 4 6 8 10 12 14 16 18 20 22 24

Lost Workday Case Rate

Employee Safety Designed-In

Re

pe t

itiv e

Us

New Processes & Tools

Ergonomics Design Requirements Checklists for Engineers Risk Analysis Tools

Design for Assembly

Interactive Design Workshops Human Modeling Simulations Shop Floor Information Management Reduced Risk

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Designing for Factory Mechanics

Approx. 1000 Assembly Technicians 3 shifts Joining Together Large Assemblies Engine & Landing Gear Installation Interiors Commodity Installations Exterior Painting Testing and Delivery
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Focus on Maintainability
What is Maintainability? Also referred to as Design for Maintenance/Maintainers the relative ease and economy of time and resources with which an item can be retained in, or restored to a specified condition when trained personnel have performed maintenance on it Human Factors Engineer addresses this design element Significant parameter in airline maintenance cost and schedule reliability

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Maintainability
HFs 2 pronged approach Evaluate maintainer as system component and gauge their effectiveness

Represent maintainer with respect to workload, comfort, safety, ease of operation, etc.

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Maintainability
Implementation Primarily via Maintainability Evaluation of Design (MED) process/tool. Prioritized list of systems/components mechanics will frequently interact with Requirements delivery tool Interactive excel format that delivers a rating Digital Human Modeling CATIA human modeling software for verification and validation

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MED

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MED

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Final Assembly Production Line Everett, WA

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Digital Human Modeling

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Assist Features Integrated into Structure

Overhead Rail

Hoist

Problem: Installing heavy power panels caused injuries.

Solution: 787 has overhead rail system designed in.

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Design for Accessibility and Manufacturability

Overhead Rail

Hoist

Problem: 767 landing gear actuator is difficult to install because its trapped under wing structure.

Solution: The 787 has designed in a removable panel to enable hoisting from above.

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Providing for training using Simulation tools

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New Technology enables inclusive Design Assessments

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Flight Deck

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Cabin Environment

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Questions?

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