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Implementing Paint Automation in an Aerospace Company Christine Shanks (christine.a.shanks@boeing.com)

Implementing Wing Paint Automation: • Benefits of implementing automation • 777 Wing Paint Manufacturing Process • Boeing Lean Overview • Development & Implementation with cross- functional team • Automation is key to 777 rate increase

Wing Paint Automation Benefits • Quality: +25% • WIP: 2 booths (1 wing set) • (-4 booths/1 turn position) (-2 wing sets) • Floor Space: 29000 sq. ft. (-60%) • Rate: • Facilitates future rate increase • Weight: - 459 lbs. • (380 lbs. drag equivalent, 79 lbs. actual) per wing set • Cranes: -92% • (30 moves to 2 moves ) • Shop Supplies: -30% • (Masking, Tape, etc.) • Paint use: -25% • Safety & Ergonomics: -20% • (Injury risk reduction) • Environmental: -70% • (Hazmat) • Labor: -40% • (Wing paint) • Flow: -40% • (5 days to 3 days )

Paint Laydown 2 Day Flow Prep & Abradesurfaces Wash Conversion Coating Rinse Blow Dry Mask Spars Hang Curtains Prime front & rear spars Paint front & rear spars Cure Mask Leading edge Hang Curtains Prime Leading Edge Paint LE Teflon Cure Unmask Decals & Stencils QA shake Mask Leading edge for VPB • Wing Paint Product - Process & Flow • Current State Paint Building Overhead Crane Tooling & Crane 2 2 Overhead Cranes 3 5 1 4 6 7 11 8 9 10 12 15 13 Turn Position 14 Vertical Paint Booth (VPB) – 1.5 Day Flow Processes: Abrade WashRinse Conversion Coating RinseDry Mask OW Walkway MaskRegLetters Hang Curtains Prime Paint poly Cure Mask runway Alignment Unmask Paint Runway Alignment Cure Mask“Blackline” and “no step stencils Paint “Blackline”, “no step stencils, and Safety Line attach point Corrosion Application – 1 Day Flow Processes: MaskHang Curtains Spray CIC Cure Unmask

Value Stream Map Value Stream Map Value Stream Map Value Stream Map Value Stream Map Value Stream Map Paint 2 Day Capability Paint The 9 Tactics Tactic1 Value Stream Map Tactic 2 Balance the line Tactic 3 Standard Work Tactic 4 Visual Controls Tactic 5 Point of Use Tactic 6 Feeder Lines Tactic 7 Break Through Processes Tactic 8 Pulse the Line Tactic 9 Moving the line 1 5 2 6 777 Final Assembly Date 3 7 Behind Time Jobs 4 100% Movement 8 9 Standard Work 5S + Safety Sorting, Simplifying, Sweeping, Standardizing, Self Discipline Single Piece Flow Factory Vision 777 Program| Boeing Production System

Road Map to Automation:Development phase • 2013 • 2011 • 2011 • 2010 • 2006 - 2009 • 2005 • 2004 • 737 team studies automation for the Wing Paint processes • 737 Team presents automation concepts to the 777 wing paint team. • Leadership gives go ahead for further investigation and development of wing paint automation • 777 Wing Paint Automation team formed to study and develop new paint process • Leadership approves Wing Paint Automation for the 777 2.5 day cycle. • Implementation team was formed to manage • Construction Schedule • Permits • Contracts • Process Development • Work around plans • Booth designs • Daily Managment • Construction management through August • Load first wing into to Automation booth started online programming in September • At 2.5 day cycle automation was painting the Upper panel of the wing. • Programming continues for the following processes • Wash • Prime & Paint Spars • Corrosion application for Spars

777 Wing Paint Improvement Strategies – Lean+ Tactics 1-6 • Manual Processes • POU kitting, standard work, balanced line • Optimize NVA tasks (masking, washing, etc) • Reduce variation with training • Improve safety and ergo through work hardening and job rotation • Accelerate cure to enable subsequent tasks • Process Specific Booths • Improvements limited by access due to product dimensions • Overhead crane transportation • Improve necessary and unnecessary handling and tooling • Flow • Reduce hours • Tactic 7 (Breakthrough Technology) • Manual Processes • POU kitting, standard work, balanced line • Eliminate NVA tasks • Eliminate duplicated processes • Eliminate detectable variation • Eliminate employee exposure and repetitive tasks • Combine cure times with subsequent processes • Process Specific Booths • Mitigate access constraints • Eliminate positions • Overhead cranes transportation • Eliminate unnecessary handling and tools • Flow • Reduce days

Road Map to Automation:Implementation Phase • 2013 • 2012 • 2011 • 2010 • 2006 - 2009 • 2005 • 2004 • 737 team studies automation for the Wing Paint processes • 737 Team presents automation concepts to the 777 wing paint team. • Leadership gives go ahead for further investigation and development of wing paint automation • 777 Wing Paint Automation team formed to study and develop new paint process • Leadership approves Wing Paint Automation for the 777 2.5 day cycle. • Implementation team was formed to manage • Construction Schedule • Permits • Contracts • Process Development • Work around plans • Booth designs • Daily Managment • Construction management through August • Load first wing into to Automation booth started online programming in September • At 2.5 day cycle automation was painting the Upper panel of the wing. • Programming continues for the following processes • Wash • Prime & Paint Spars • Corrosion application for Spars

Automated Paint Booth – 3 Days Processes: Prep wing Wash Sand upper and lower Inspar surfaces Wash wing complete Conversion coatingwing complete Rinse Wing complete Blow Dry wing Complete Mask Spars Prime front and rear spars, lower panel, upper panel and Leading edge Paint front and rear spars, lower panel, upper panel and Leading edge Teflon Mask & Paint Runway Alignment Stripe, Blackline, and no step stencils, Reg Letters & safety line attach point Spar Decals & Stencils Apply CIC to spars Unmask QA shake ASM Product and Process FlowFuture State Paint Building 2 1 787 Available Capacity for new Work Statement