1998-06-02

Simulation Enhanced Work Instructions for Aircraft Assemblies 981861

The Boeing Company is developing and implementing the tools for the 21st Century for product development with their Design Manufacturing and Producibility Simulation (DMAPS) program. DMAPS combines the best of people, hardware and software tools commercially available to develop product and process simulation applications. The DMAPS toolset enhances the process of preparing concept layouts, assembly layouts and build-to-packages. Comprised of an Integrated Product and Process Team (IPPT), DMAPS produces products faster and with higher quality. The result is a process that eliminates costly changes and rework, and provides all IPPT's the tools and training necessary to perform their tasks right the first time.
Boeing applies DMAPS tools to a variety of existing and new programs to build more affordable products. Savings goals set forth by the program are shown in Figure 1. Goals include reductions in design development, cycle time, and staff, as well as tooling, manufacturing labor, cycle time, and staff. Other goals include improved operator training and performance.
To realize savings in manufacturing, an improvement in the quality of data delivered to shop mechanics was needed. It has been demonstrated that higher quality build-to-packages can eliminate up to 80% of engineering and tooling rework. The data contained within the build-to-package is the key for developing an electronic build plan that accelerates mechanic learning and improves quality on the shop floor. This paper addresses the effort to produce simulation enhanced work instructions and the tools needed to deliver them to the shop.
DMAPS expanded the use of graphic simulation by taking it from the engineer's desk and delivering it to the shop floor. Mechanics are now using simulation enhanced work instructions for building aircraft assemblies as a part of DMAPS' effort to bring Virtual Manufacturing to Production.

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