Perfect of the 737 is in demand when groups are looking for processThe measurement group was created to investigate fit problemsThe team’s expertise in collecting digital data on every partdiscovered by Engineering. fit measurement equipment has garnered the team recognition“The 737 MAX team has asked us to start collecting data onPushing the boundaries on how they use their data-capturingimprovements or designing a new airplane.currently built airplanes,” said Pat O’Dowd, Quality Assuranceanalyst and team member. “They’ll use that data to verifytheir configuration.” beyond the 737 program and, for that matter, beyond Boeing. 737 team uses digital technology NASA tapped the group to help with the Shuttle Columbia’s to ensure parts fit, or figure digital reconstruction after its re-entry accident.“We scanned the recovered wing debris from the Shuttle out why they don’t Columbia as it was collected,” said Mike Patton, toolmaker and Scanning subject-matter expert. “We also scanned the By Dawsalee Griffin Shuttle Discovery’s leading edge, so we would have a reference Iand be easy to assemble.In building airplanes, that’s not always the case, though,nsert peg A into hole 7B. The directions say that it should fit and often factory assemblers have no way of knowing why. That’s where the 737 Renton Computer-Aided Measurement Systems Services Group comes in. Team members use digital measuring systems to precisely measure 737 parts, assemble them on a computer and figure out how to make parts that fit together perfectly, every time. Their skills also are proving useful across a broader set of problems in Boeing manufacturing and beyond. “Several groups recently asked us to figure out why galley doors sometimes bind during flight,” said Brian Campbell, toolmaker and subject-matter expert in the use of photogrammetry—a specialized PhOTOS: (Far left) Karl Pyle, 737 toolmaker, uses a special digital digital camera. camera to collect precise 737 wing data that will ensure wing panels The team already suspects they know what is happening. are cut to a perfect fit. JIM ANdERSON/BOEING (Above) This computer- “The airplane fuselage changes shape during flight,” Campbell generated pattern, shown projected on a 737 wing, enables scanning said. While these changes may be small, they can have an impact. BOEINGequipment to collect highly accurate measurements. Using Campbell’s camera, the measurement team is able to definition to use in digitally reconstructing the Columbia wing capture what happens to an aluminum airframe during a flight. leading-edge debris.” Since the camera’s accuracy is not affected by vibration, the The reconstructed data showed evidence of the cause of the team can take measurements while the 737 is flying. catastrophe: a hole in Columbia’s leading edge caused by impact Based on past experience, the team expects the data they with a piece of foam insulation during launch. develop will show Engineering how these minute fuselage shape Within Boeing, others are now looking at Renton’s Computer- changes affect the opening and closing of interior galley and Aided Manufacturing applications. lavatory doors—which will help Engineering institute the design Teams at the Everett site, where Boeing’s twin-aisle jetliners changes needed to prevent binding in the future. are assembled, are interested in how they can apply the The photogrammetry team originally discovered the fuselage Renton model. flexing after the Sept. 11 terrorist attacks on the United States. Jennifer MacKay, 777 Wing production support, turned to They were asked to find out why flight-deck security doors put the Renton measurement group when the 777 Wings group holes in an interior ceiling panel when opened during flight. They was looking for ways to improve quality and efficiency in wing found the new door design didn’t take into consideration that production and the wing-to-body join to help meet production the ceiling panel lowers slightly as the shape of the fuselage rate increases. changes during flight. “Renton’s measurement team members have been generous “It’s been a continuous education process to help people un- in sharing their knowledge and lessons learned,” MacKay said. derstand what we do and how we can help them,” Campbell said. “We’re looking at how we can use their expertise and processes, The Renton Computer-Aided Measurement Systems Services including their team structure, to improve wing production.” n Lab is part of the Production Platform Organization that provides dawsalee.griffin@boeing.com tooling, equipment and manufacturing measurement services to the Renton, Wash., site. BOEING FRONTIERS / SEPTEMBER 2012 37
Frontiers September 2012 Issue
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