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Increased emphasis on standardizing processes and controlling variability in production operations includes validating perishable tools used in daily operations. Even though dealing with reputable manufacturers, many factors including communication, custom specifications and personnel turnover can lead to the perpetuation of mistakes if errors are not discovered and corrective action implemented. However, inspection is costly and inspection costs far outweigh many item costs unless considering product defects. A beneficial balance may be obtained by employing statistical sampling techniques similar to ISO 2859 [1] to verify the quality of incoming tools.

Decades ago our innovative grandfathers developed the first automated riveting machines based on hard automation using kinematics and tools attached to a C-frame. The C-frame serves multiple functions: First, it holds the upper and lower tools in fixed positions relative to each other; second, it translates upper active tooling forces to the lower tool; and third, it embraces the part placed between the upper and lower tool. C-frames and newly developed yoke, ring and gantry machines, used for low level (first, second) fuselage and wing assembly are growing in size to exorbitant proportions to satisfy requirements of larger and larger structures. High costs are dictated by massive kinematics and complex controls that provide stability, precision, and process speed. All this is mainly needed because we have to carry mechanical forces around the part, from upper to lower tool along the C-frame, gantry, yoke, bridge, etc.

The introduction of a new derivative to an existing aircraft model poses many decisions regarding old versus new. In the case of the introduction of the extended range 767 (the 767-400ER), an entirely new wing design prompted the examination of the then current assembly processes and tooling. The hesitation to build new drill templates for use in the traditional method of second stage wing spar assembly inspired Tool Engineering Management to request the investigation of a low cost automated drilling apparatus. As a result, the Boeing Automated Tools Group and Advanced Integration Technology, Inc. (AIT) developed and implemented mobile numerically controlled mini-drilling machines for post-ASAT I assembly-drilling operations.

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.

Out-of-round holes are formed as a result of tool motion during drilling. Tool vibration is driven by radial and tangential forces on the primary and secondary cutting edges. These forces in turn depend on the chip loads on each cutting edge, which in turn depend on the position of the tool at the current time and at the time of the previous tooth passage. A preliminary analysis based on balancing the cutting forces and the bending forces on the tool, shows that the characteristic frequencies of motion of the tool in the tool frame are near 3/rev, 5/rev, 7/rev etc. (corresponding to 2/rev, 4/rev, 6/rev) in the workpiece frame. These motions are consistent with the tool motion and hole form errors commonly observed on the shop floor. We will describe procedures for measuring the dependence of cutting forces on chip load, the development of simple equations for lateral motion of the tool, and solutions for the tool's behavior.

Power quality has become a subject of increased attention for electrical power systems on both commercial and military aircraft. Several power quality guidelines and specification documents exist that govern today's power system operation and the contributing characteristics of electrical load equipment. This paper presents power quality requirements for future Boeing commercial airplanes, driven by advances in aerospace applications of power electronic equipment, increased load demand and complexity, as well as new power system architectures. The influence of new equipment types on electrical system power quality is described including the effects of motor controllers, AC power converters, and large dynamic loads. The impact of power type classifications such as variable frequency AC power and multiple DC voltage levels is also discussed. Simulation results are presented to develop and validate these power quality requirements.

Trace chemical contaminants produced by equipment offgassing and human metabolic processes are removed from the atmosphere of the International Space Station's U.S. Segment by a trace contaminant control subassembly (TCCS). The TCCS employs a combination of physical adsorption, thermal catalytic oxidation, and chemical adsorption processes to accomplish its task. A large bed of granular activated charcoal is a primary component of the TCCS. The charcoal contained in this bed, known as the charcoal bed assembly (CBA), is expendable and must be replaced periodically. Pre-flight engineering analyses based upon TCCS performance testing results established a service life estimate of 1 year. After nearly 1 year of cumulative in-flight operations, the first CBA was returned for refurbishment. Charcoal samples were collected and analyzed for loading to determine the best estimate for the CBA's service life.

The Portable Fastener Delivery System or PFDS, has been developed at the Boeing St. Louis facility to streamline the manual fastener installation process. The PFDS delivers various fasteners, on demand, through a delivery tube to an installation tool used by the operator to install the fasteners in an aircraft assembly. This paper describes the PFDS in its current configuration, along with the associated Huck® International (now Alcoa Fastening Systems) installation tooling, as it is being implemented on the F/A-18E/F Nosebarrel Skinning application. As a “portable” system, the PFDS cart can be rolled to any location on the shop floor it might be needed. The system uses a removable storage cassette to cache many sizes and types of fasteners in the moderate quantities that might be required for a particular assembly task. The operator begins the installation sequence by calling for the particular fastener grip length needed using a wireless control pendant.

Unmanned Aircraft Systems (UAS) have been growing over the past few years and will continue to grow at a faster pace in future. UAS faces many challenges in certification, airspace management, operations, supply chain, and maintenance. Blockchain, defined as a distributed ledger technology for the enterprise that features immutability, traceability, automation, data privacy, and security, can help address some of these challenges. However, blockchain also has certain challenges and is still evolving. Hence it is essential to study on how blockchain can help UAS. G-31 technical committee of SAE International responsible for electronic transactions for aerospace has published AIR 7356 [1] entitled Opportunities, Challenges and Requirements for use of Blockchain in Unmanned Aircraft Systems Operating below 400ft above ground level for Commercial Use. This paper is a teaser for AIR 7356 [1] document.

The rising cost of fuel prices, in part due to the perception of diminishing supplies of common fuelstocks, as well as worldwide attention to reducing emissions has pushed the need to explore the use of many alternative fuels. The aviation industry has been under recent scrutiny due to its contribution of greenhouse gas emissions (GHG). Current contribution of GHG by airplanes is relatively small, 2% of the total GHG emissions, but world air traffic is anticipated to continue to grow and may have a corresponding increase in emissions. Both commercial and government aviation sectors have efforts to seek ways to lower fuel consumption through efficiency and reduce emissions. Development of a suitable alternative fuel that can be seamlessly used in place of conventional jet fuel is desirable. A strategy to enable this goal is to be fuel flexible; utilizing an array of fuels from bio-diesel to current jet fuel.

The patented (US 7,277,811 B1) Position Bar provides precise measurement, machining and drilling data for large Engineering and Tooling structure. The Position Bar also supports end item verification seamlessly in the same machining control code. Position Bar measurements are fast, accurate, and repeatable. The true centerline of the machine tool's spindle bearings are being measured to within .002 in a 20 foot cubic volume (20×20×20). True “I”, “J”, & “K” machine tool spindle positions are also precisely measured. Any Gantry or Post Mill Tool can be converted to a Coordinate Measurement Machine (CMM) with this laser tracker controlled Position Bar. Determinant Assembly (D.A.) holes, for fuselage and wing structures are drilled and then measured to within .006 in X, Y, & Z, over a 40 foot distance. Average laser tracker measurement time, per hole, is 2 seconds.

The ISS U. S. ECLSS contains replaceable component designs to facilitate maintenance. A replaceable component is referred to as an Orbital Replacement Unit (ORU). Total U. S. ECLSS maintenance events that have occurred over the five years (2001-2005) of operations are summarized. A more detailed description is provided for the ECLSS Remove and Replace (R&R) maintenance activities that have occurred during the last two years and the associated logistics that supported these activities. Maintenance activities have replaced failed or degraded ORU's by Corrective Maintenance (CM) and replaced spent expendable ORU's by Preventative Maintenance (PM). Corrective maintenance is performed only when necessary and often on relatively short notice. Preventative maintenance is planned in advance and is normally performed at a specified ORU service time. The paper also describes activities and successful efforts to increase the expendable ORU service life.

The Human Swept Volume (HSV) software described here is an interactive tool that allows users to position and animate articulated human models and then generate tessellated swept volume solids. Inverse kinematics and keyframe interpolation are used to define motion sequences, and a voxel-based method is used to create swept volume solid models. The software has been designed to accept various human anthropometry models, which can be imported from other CAD tools. For our initial implementation, we defined several human models based on dimensions from CAESAR/SAE anthropometric data. A case study is described in which the swept volume software was used as a part of a human space occupancy analysis. Results show the advantages of using complete swept volumes for objective measurement comparisons.

Logistics, information exchange, and people all influence the capability and contribution to profits of the supply chain. Understanding how to analyze the current state, and set a strategy to achieve the desired end state is critical to success in the market place. This paper will focus primarily on the acquisition of components for a manufacturing/assembly operation. However, the principles and processes described can be applied to other segments of the chain, such as from the manufacturer to the customer, or to other components of manufacturing such as maintenance, repair and operating (MRO) supplies.

Three distinct food system paradigms have been envisioned for long-term space missions. The Skylab, Mir and ISS food systems were based on single-serving prepackaged foods, ready to rehydrate and heat. Bioregenerative food systems, derived from crops grown and processed at the planetary station, have been studied at JSC and KSC. The US Antarctic Program’s Amundsen-Scott South Pole Base uses the third paradigm: bulk packaged food ingredients delivered once a year and used to prepare meals on the station. The packaged food ingredients are supplemented with limited amounts of fresh foods received occasionally during the Antarctic summer, trace amounts of herb and salad crops from the hydroponic garden, and some prepackaged ready to eat foods, so the Pole system is actually a hybrid system; however, it is worth studying as a bulk packaged food system because of the preponderance of bulk packaged food ingredients used.

To serve the requirements of the operational environment of modern jet aircraft, the flight crew training program should be kept as simple as possible and be consistent with the total information system for aircraft operation of which it is a part. Systematic tools are described which assist the course developer in optimizing the implementation of Specific Behavioral Objectives, allocating learning elements to the most cost effective learning environment, and organizing those learning elements associated with the classroom environment. Included is a discussion on the management systems applied, the development of a Learning Task Analysis, and a systems approach to course organization.

This paper will describe the Efficient Assembly Integration and Test (EAIT) system level project operated as a partnership among Boeing business units, universities, and suppliers. The focus is on the successful implementation and sharing of technology solutions to develop a model based, multi-product pulsed line factory of the future. The EAIT philosophy presented in this paper focuses on a collaborative environment that is tightly woven with the Lean Initiatives at Boeing's satellite development center. The prototype is comprised of a platform that includes a wireless instrumentation system, rapid bonding materials and virtual test of guidance hardware there are examples of collaborative development in collaboration with suppliers. Wireless tools and information systems are also being developed across the Boeing Company. Virtual reality development will include university partners in the US and India.

Clothing supply has been examined for historical, current, and planned missions. For STS, crew clothing is stowed on the orbiter and returned to JSC for refurbishment. On Mir, clothing was supplied and then disposed of on Progress for incineration on re-entry. For ISS, the Russian laundry and 75% of the US laundry is placed on Progress for destructive re-entry. The rest of the US laundry is stowed in mesh bags and returned to earth in the Multi Purpose Logistics Module (MPLM) or in the STS middeck. For previous missions, clothing was supplied and thrown away. Supplying clothing without washing dirty clothing will be costly for long-duration missions. An on-board laundry system may reduce overall mission costs, as shown in previous, less accurate, metric studies. Some design and development of flight hardware laundry systems has been completed, such as the SBIR Phase I and Phase II study performed by UMPQUA Research Company for JSC in 1993.

The aerospace ecosystem is a complex system of systems comprising of many stakeholders in exchanging technical, design, development, certification, operational, and maintenance data across the different lifecycle stages of an aircraft from concept, engineering, manufacturing, operations, and maintenance to its disposal. Many standards have been developed to standardize and improve the effectiveness, efficiency, and security of the data transfer processes in the aerospace ecosystem. There are still challenges in data transfer due to the lack of standards in certain areas and lack of awareness and implementation of some standards. G-31 standards committee of SAE International has conducted a study on the available digital data standards in aircraft asset life cycle to understand the current and future landscapes of the needed digital data standards and identify gaps. This technical paper presents the study conducted by the G-31 technical committee.

Statistical Energy Analysis (SEA) is a very powerful tool in its ability to guide noise control package design in automobile, airplane and architectural systems. However transmission loss modeling in an SEA frame work has more to do with modeling of sound propagation through foam and fiber noise control materials than classical SEA power flow between groups of resonant modes. The transmission loss problem is reviewed in an SEA frame work with a focus on key paths and input parameter variations on predicted noise control package performance.