Large Scale Human Factors
Design Integration
- Maintainability on the Boeing 787 Dreamliner
Dwaine Carvan
The Boeing Company
Oct, 2008
The 787 Family
787-8
787-3
210-250 passengers (three-class)
8,000 – 8,500 nmi | 14,800 – 15,700 km
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
Innovative
systems
technologies
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© 2005
2007 THE
THE BOEING
BOEING COMPANY
COMPANY
Composite
primary
structure
Large cargo
capacity
Overhead
crew rests
Enhanced
flight deck
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
HF
== Fuselage & Interior
== Final Assembly & Delivery
== Services
== Certification
*** Co-ordinate Human Factors across all organizations ***
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HFE Discipline Federated Across
Various Organizations
Visual and auditory perception
Anthropometry
Ergonomics
Aviation
Services
Maintainability
Factory
Ergonomics
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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© 2008
2007 THE
THE BOEING
BOEING COMPANY
COMPANY
HF/E Engineer Becomes Part of the Design Team
Manufacturing
Engineer
3D
Industrial
Engineer
Manufacturing
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Maintenance
HF/E Engineer
Service
Design Engineer
Designing Worker Safety into Products,
Factory Tools, and Assembly Processes
Identified Risks
Historical Data
Hourly-All Recordables
Hourly-Ergo Recordables
35
Other
30
777/767/747
25
65%
20
58%
62%
15
56%
73%
71%
58%
68%
55%
66%
10
Supplier
5
737/757
0
1995
1996
1997
1998
1999
2000
2001
2002
2003
Jun04*
717
36
747 46/48 Sec
777 Wings
32
777 Body
Structures
747 Wings/
WBJ
777
FA/FBJ
767 Wings
747 FA
25
20
767 J&I
767 Body
Structures
20
30
747 41/42 Sec
777 SI
15
Manufacturing
Support
16
Flight Ops
& DC
12
10
QA
5
8
767 FBJ
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
4
0
0
2
4
6
8
10
12
14
16
18
20
22
24
Re
pe
t
itiv
e
Us
Lost Workday Case Rate
Ot
he
r
Sq
ua
tti
ng
Im
pa
ct
Recordable Case Rate
747 SI/
FBJ
24
767 FA
777 STP
767 STP
28
777 WBJ
Employee Safety Designed-In
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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2007BOEING
THE BOEING
COMPANY
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© 2005©THE
COMPANY
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
 HF’s 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.
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Solution: 787 has overhead rail system
designed in.
Design for Accessibility and
Manufacturability
Overhead Rail
Hoist
Problem: 767 landing gear actuator is
difficult to install because its trapped
under wing structure.
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Solution: The 787 has designed in a
removable panel to enable hoisting from
above.
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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