787 Factory Activation Utilities, The Boeing Company, Everett, WA
Boeing Commercial Airplane Group, the world’s pre-eminent aircraft manufacturer, created an entirely new way of producing the 787 Dreamliner Aircraft. The final production
line created is revolutionary in reduction of assembly time and increased efficiency. Assembled portions of the airplane are flown to Everett, WA where Boeing assembles
the aircraft, much like a pre-fabricated house. Wood Harbinger’s contribution to this new wave, lean manufacturing process was to provide a facility
infrastructure with utility system connections that would be easily accessible at any point as the aircraft travels along its moving assembly line.
The design team met an aggressive schedule where the scope and design
requirements were often developed concurrently with detailed design and construction.
Another challenge was leveling out the early 1990's factory floor. The team designed a state-of-the-art guide rail system of more than 4,000 lineal feet, laser straight, and
level to a few hundredths of an inch. The solution: 100 foot long jigs were prepared to hold the foundation bolts in precise locations, thus allowing for a continuous pour of the
foundation system.
Innovations of this project include designing the point-of-connection for all the utilities. The accessible connections are precisely positioned for the appropriate tools in use at
each production position. Other innovations include specialized piping distribution to support 5,000 psi hydraulic elements on the aircraft, a one-of-a-kind utility trench, and an
efficiently configured tunnel access system.
The Wood Harbinger team quickly developed practical design solutions, managed the concurrent development and implementation of plans, and participated directly in Boeing’s 787
factory integrated design/build process.