FINAL PROJECT Cesar A Marrero Agenda Introduction Popularity of the Boeing 737 Reliability Program Failures of the Boeing 737 Evaluation Defective Wiring TWA Flight 800 Conclusion Introduction ID: 205211
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MGMT 580 – FINAL PROJECT
Cesar A. MarreroSlide2
Agenda
Introduction
Popularity of the Boeing 737
Reliability Program
Failures of the Boeing 737
Evaluation: Defective Wiring (TWA Flight 800)
ConclusionSlide3
Introduction
Boeing 737 – the workhorse for low-fare airlines around the world
Easier and less expensive to maintain
Fewer parts than older models
Quick turnaround at the terminalsSlide4
Boeing 737 – Popularity
Over 7,500 aircraft delivered to date
Record-breaking orders of any model in a single year
1,124 net orders of the next-generation version (models 700, 800, and 900) in 2012
914 orders for the 737 MAX versionSlide5
Reliability Program
Entire System
Common components reused in all airframes
Unchanged fuselage
Changes primarily to wing structure and engines
Airframe is quite cost-efficient
Redesigning fuselage would not provide much improvement
Increased costs with two separate production linesSlide6
Reliability Program
Humans in the System
Commonality of airframes promotes familiarity
Training costs are significantly reduced
Employees use a common set of tools and procedures Slide7
Reliability Program
Maintenance of the System
Interchangeable parts
Standard technical documentation
Longevity effortsSlide8
Reliability Program
Simplicity of Design
Greater turnarounds for airline carriers
Maximize the use of their fleet
Low stance on the ramp
Easier to maintain and load
Servicing can be done at ground level
Baggage can be loaded from the ground
Last minute cargo/luggage additionsSlide9
Reliability Program
Redundant and fail-safe features
Two engines per aircraft, even though only one is needed to fly
Two electrical systems
Two fuel systems
Emergency Oxygen system
Triple Rudder systemSlide10
Reliability Program
Manufacturing Methods and Purchasing Requirements
Assembly line production, similar to the automotive industry
Accelerated production
Reduced production costs
Fewer order backlogs and customer waiting timesSlide11
Reliability Program
Maintenance of complete product or system performance records
Production and maintenance logs
Records failures, replacements, repairs, warnings, field tests, and operating conditions
Influences changes in the airframe
Improves manufacturing methods
Modifies quality checks
Identifies most reliable components
Extensive field testing before components are fieldedSlide12
Reliability Program
Communication
Valuable collaboration between customers, chief mechanics, and field service reps
Efforts ensure new version of 737 continues the trend of simplicity, reliability and low cost.
Airlines can choose a version of 737 with latest cockpit displays or commonality with older modelsSlide13
Failures of the Boeing 737
Events influenced dramatic changes in the inspection and maintenance process
TWA Flight 800 – Exploded, killing all on board
Southwest Flight 812 – Peeled exterior skinSlide14
TWA Flight 800
Exploded 12 minutes after take off
Boeing Model 747, not 737
230 on board killed
Cause determined to be faulty wiring
Spark caused ignition of fuel fumes
FAA ordered Boeing to inspect all airframes, especially the older 737 modelSlide15
Southwest Airlines Flight 812
Loss of cabin pressure, caused crew to perform emergency landing
Cause determined to be manufacturing flaws on the fuselage skin
Rivet joints not aligned or overlapped, causing fatigue on external skin
Skin peeled off, causing a rapid loss of cabin pressure
Not first time skin peeled-offSlide16
Evaluation of Defective Wiring
Cause and effect diagram:
Aircraft Explodes
People
Machinery / Equipment
Materials
Methods
Different fuel mixture
Failure to detect defective cables
Substandard cables
Insufficient quality control
Missing inspection steps
Inexperienced maintainers
Insufficient testing tools
Inadequate testing toolsSlide17
Machinery / Equipment
Insufficient testing tools
NO tools available to detect fuel leaks
Inadequate testing tools
NO tools to detect electrical shortagesSlide18
Methods
Missing inspection steps
NO instructions on how to inspect for fuel leaks around electrical wiring
Insufficient quality control
NO formal QC oversight when inspecting the areas where fuel cells and electrical wiring are combinedSlide19
People
Failure to detect defective cables
NO training
Unable to physically view defective cables
Inexperienced maintainers
NO experienced workers/mentorsSlide20
Materials
Substandard cables
Outsourced cables delivered by sub-contractors
Different fuel mixtures
Lack of standard fuel operations at airfields world-wideSlide21
Corrective Actions
FAA ensure corrective actions are complied with
Boeing ensures employees receive immediate maintenance notices
Boeing consider redesigning electrical wiring near fuel systems
Boeing consider improving fuel leak detectorsSlide22
Conclusion
“
Reliability
, or quality over the long term, is the availability of a product to perform its intended function over a period of time and under prescribed environmental conditions.” (Summers, 2010).
Based
on this definition, the Boeing 737 has exceeded these
conditions
Surpassed
their intended function by extending its lifespan beyond the prescribed maximum of 75,000 flights. Slide23
References
Boeing Website (2013).
The Boeing Next-Generation 737 Family -- Productive, Progressive, Flexible, Familiar.
Retrieved August 16, 2013 from http://www.boeing.com/boeing/commercial/737family/background.page
Dummeyer
, D. (2013).
Boeing Quarterly Reports (2Q13)
. Retrieved August 16, 2013 from http://www.boeing.com/commercial/aeromagazine/articles/2013_q2/pdf/AERO_2013q2.pdf
Brady, C. (1999).
Boeing 737 Production
. Retrieved August 15, 2013 from http://www.b737.org.uk/production.htm
Irving, C. (2012).
Is Boeing’s 737 an Airplane Prone to Problems? - Newsweek
. Retrieved August 17, 2013 from Newsweek Magazine at http://www.thedailybeast.com/newsweek/2012/03/19/is-boeing-s-737-an-airplane-prone-to-problems.html
Spicer, K., Angers, S. (2002).
Boeing: The Secret Behind High Profits at Low-Fare Airlines
. Retrieved August 15, 2013 from Boeing website: http://www.boeing.com/commercial/news/feature/profit.html
Summers, D. (2010).
Quality
. New Jersey: Prentice Hall