down to the body shop to fix them.” The 777 line move actually begins at 2:30 p.m., with tasks assigned using Lean+ disciplines. While just one of these planes typically exits the factory at a time, three or four others must be advanced forward on the factory floor, requiring restaging for each one. “There are a lot of things that get moved with a few bodies to do it,” said Jill Klages, a materials processor, or parts mover. “It’s like a marathon for us.” At 8:20 p.m., while employees begin retrieving the imposing collection of equipment set up around the departing jet, security personnel walk the outside route and check for anything that might get in the way. They will remove four stop signs and lower more than 50 yellow bridge railings to allow engine clearance for the 777. By 8:45 p.m., the factory’s massive doors slide open on three separate tracks and a thick, low-slung tug driven by Site Services’ material handler Mark Ginnis pulls up to the entrance. “My job is pretty crucial,” Ginnis said. “I have to be focused and I turn off the radios. Once I hook onto it, it’s my plane.” At 9:02 p.m., a siren sounds in five short blasts, giving the “all ready” signal, and the tug moves into position, connecting with the 777’s nose landing gear. The jet is slowly towed forward and out the door. Six employees stand on all sides, monitoring the rollout. A Boeing security vehicle with a flashing red light escorts the plane up the road. At 9:30 p.m., after methodically traveling half the length of the factory and crossing a bridge, the 777 eases nose-first into an open parking stall. The jet, in varying shades of green protective coating because its parts come from different suppliers, will be tested before it’s painted for delivery to the customer. The rollout never loses its sense of importance or cohesion. “I’ve done a lot of things at Boeing, but the line move is like family,” said Doug Butner, 777 operations manager. “Everybody comes together.” n da niel .w.rale y@boeing.com Photos: (Far left) Once the factory doors open, the 777 is ready to depart. (Above) It takes nearly 30 minutes for a 777 to leave the factory and reach the paint hangar. am y 2015 31
Frontiers May 2015 Issue
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