computer—resulting in a reduced reliance on expensive and time-consuming real-size mock-ups. Richardson and his team have taken the latest technological advances and customized them in an effort to design and build the next Boeing commercial jetliners as intelligently as possible while further improving employee safety during the build process. They’ve shared their virtual-reality concepts with fellow engineers from design, manufacturing, tooling, reliability and maintainability, plus safety administrators, mechanics and others. “We have some unique capabilities in terms of tools designed in-house that give us a superior advantage over our competitors,” Richardson said. IC.IDO is part of Boeing’s overall push toward immersive development, or a blurring of the lines between the physical and digital worlds, and placing engineers in the design environment brings higher-quality engineering, said Terry Beezhold, vice president and 777X chief project engineer. The different Boeing sites also have the ability to simultaneously link together to conduct design reviews. Gripping an oversize remote control, Richardson can manipulate the on-screen mannequin to reach into an extra-tight space and attempt a job-related function to determine whether it’s feasible for a human to do the same. The virtual person moves as the engineer moves. By using IC.IDO, ergonomics and workplace safety risks can be assessed without putting an employee in harm’s way, and costs are lowered when those risks are mitigated before entering production, Richardson explained. For example, an early simulation of installation procedures for the thrust reverser on the 737 MAX indicated a design change was necessary. It was found that mechanics had limited-reach access and sightlines. The 3-D technology, used by a Renton team, prevented a blind installation and a costly late-stage change, and the thrust reverser installation went as smoothly as planned. Richardson is currently working on a similar issue with the 777X. The 3-D technology also creates a sense of intrigue, continually bringing wondrous looks and curious questions from employees whenever they encounter the brightly colored IC.IDO displays splashed across a darkened room for the first time. “It’s kind of like a video game,” said Josh Little, 777X manufacturing engineer. “Once you get past the cool factor—and this is amazing and cool— you get used to being in this environment and you start to do your job. It is fun, but we’re serving a purpose.” Richardson’s team, in cooperation with all 777X integrated product teams, will review designs for nearly every part of the new airplane before it moves into the manufacturing phase. Decisions will be made on airplane design, the manufacturing plan, tooling concepts and ergonomics solutions that could stand for decades—and significantly affect efficiency, quality, cost and cycle time. They’ll train others to use IC.IDO, too. “We were responsible for bringing it into the company, but we’re not going to own it,” Richardson said. “We want other people to learn to use it, just like any other tool that’s available.” Meagan Haugo, a 777X production engineer, will use IC.IDO training to concentrate on safety and ergonomics 18 Boeing Frontie rs
Frontiers June 2015 Issue
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