FrontiersMay 2014 / Volume XIII, Issue I / www.boeing.com/frontiers
Field of view Anytime and anywhere, Boeing field service reps are there to help customers FRONTIERS STAFF ADVERTISEMENTS Tom Downey The stories behind the ads in this issue of Frontiers. Publisher Anne Toulouse 03 This new Growler ad illustrates the impact of the Editorial director The Growler protects our warfi ghters. aircraft’s production line on the U.S. economy and Now Congress can national security. Part of a campaign to generate support Paul Proctor protect the Growler. Executive director for adding Growlers to the U.S. president’s budget for fiscal year 2015, this ad appears in local news, trade James Wallace and political publications and encourages readers to 11.125 in. Bleed 11.125 in. 10.875 in. Trim 10.875 in.
Editor Live 10.375 in. visit www.supportgrowler.com to sign and submit a petition or letter to Congress to show their support. The EA-18G Growler is America’s only electronic attack aircraft in production. By disabling enemy defense systems, it ensures America’s combat aircraft can perform their missions safely. But now, the Growler’s in danger. Without funding for new Growlers, the production line will close at the end of 2016, leaving the U.S. Vineta Plume Navy without future Growlers. Closing the line would also affect nearly 60,000 jobs around the country and leave the military without competing sources for additional fi ghter aircraft.
The time to act is now. We urge Congress to include funding for Growlers in the 2015 budget. It’s an invaluable Managing editor investment in the safety of our warfi ghters, the strength of our nation’s air power and industrial resource. To learn more, go to www.supportgrowler.com
7.5 in. Live Cecelia Goodnow 8 in. Trim 8.75 in. Bleed
Job Number: BOEG_BDS_E18_3072M_C Approved Commercial Airplanes editor Client: Boeing Product: Boeing Defense Space & Security Date/Initials BOEG_BDS_E18_3072M_C Date: 4/9/14 GCD: P. Serchuk File Name: BOEG_BDS_E18_3072M_C Creative Director: P. Serchuk Date: 04.09.14 70228ID05r0_C.indd Output Printed at: 100% Art Director: P. de Koninck DIGITAL PROOF SPECS. DIGITAL FILES SPECS. Copy Writer: P. Serchuk SCREEN ANGLES DOT SHAPE LINE SCREEN DMAX RESOLUTION PDF Fonts: Helvetica Neue 65 YEL MAG CYAN BLK Line : 2400 RSR 133 280 x1a 90˚ 45˚ 105˚ 75˚ Graphic : 300 Media: Frontiers Print Producer: Account Executive: D. McAuliffe YEL MAG CYN BLK PMS PMS 3C Space/Color: Page — 4 Color — Bleed 50K Client: Boeing 50C Live: 7.5 in. x 10.375 in. 4C 41M Proof Reader: 06 41Y Trim: 8 in. x 10.875 in. Legal: Bleed: 8.75 in. x 11.125 in. Traffi c Manager: Traci Brown Gutter: 0 25 50 75 100 Digital Artist: Diane Stratman Production Artist: S. Bowman Art Buyer: Retoucher: Vendor: Color Inc. PUBLICATION NOTE: Guideline for general identifi cation only. Do not use as insertion order. This ad shows Boeing’s appreciation for and Material for this insertion is to be examined carefully upon receipt. If it is defi cient or does not comply with your requirements, please contact: Print Production at 310-601-1485. Defense, Space & Security editor Frontline Communications Partners 1880 Century Park East, Suite 1011, Los Angeles, CA 90067 gratitude toward the U.S. armed forces. It will run Junu Kim in The Washington Post and The Seattle Times, as well as in regional, trade and military publications, Engineering, Operations & Technology editor over the U.S. Memorial Day holiday. Boeing will air a Len Vraniak similarly themed commercial on the Meet the Press Human Resources and Administration editor television program. Beriah Osorio Shared Services Group editor Eric Fetters-Walp Staff writer 14 –15 ART This ad congratulates recipients Your commitment to excellence, of Boeing’s 2013 Supplier of the PRECISION. precision performance, and accountability has brought us PERFORMANCE. shared success. Thank you for Brandon Luong your dedication. PARTNERSHIP. Year awards. Aero-Plastics Inc.
AMI Metals, Inc. Designer ANACAPA Micro Products Inc. Ball Aerospace & Technologies Corp.
CFM International
Fairchild Controls
Gary Jet Center Katie Sheahan Khrunichev Space Center Lamsco West, Inc., part of the Shimtech Group
Marshall Aerospace and Defence Group Designer Massachusetts Institute of Technology MSI Defense Solutions, LLC
Nabtesco
Novator AB
Progresstech Ltd.
ShinMaywa Industries, Ltd.
Visit boeingsuppliers.com/recognition to PHOTOGRAPHY learn more about recognition programs or for a list of the 2013 Performance Excellence Award recipients.
Bob Ferguson www.boeing.com Photo director SOY_FrontiersAD Final.indd 1 4/4/14 2:25 PM ONLINE PRODUCTION 52 Part of the “Boeing & Brazil. Endless Opportunities” Wendy Manning campaign, this ad focuses on Boeing’s support for Web manager biofuels in Brazil. Translated the text reads: “A partner to Brazil for more than 80 years, Boeing is committed Michael Craddock to improving the environment of Brazil and the world Web designer by developing sustainable biofuels for aviation.” Lynn Hesby Web developer Tina Skelley Information technology consultant
CONTACT INFORMATION ETHICS QUESTIONS You can reach the Office of Ethics & Business Conduct at Email: [email protected] 888-970-7171; fax: 888-970-5330; website: ethics.whq.boeing.com. Mailing Boeing Frontiers address: MC: 5003-0983 IAM PROMOTIONS 100 North Riverside Plaza No promotions listed for periods ending March 28 and April 4, 11 and 18. Chicago, IL 60606 Phone: 866-473-2016 SUBSCRIPTIONS Go to boeing.com/subscribefrontiers.html to receive an email notification Website: boeing.com/frontiers and links whenever a new edition of Frontiers is available online.
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02 Frontiers May 2014 The Growler protects ADVERTISEMENTS our warfi ghters. Now Congress can protect the Growler. 11.125 in. Bleed 11.125 in. 10.875 in. Trim 10.875 in. 10.375 in. Live 10.375 in.
The EA-18G Growler is America’s only electronic attack aircraft in production. By disabling enemy defense systems, it ensures America’s combat aircraft can perform their missions safely. But now, the Growler’s in danger. Without funding for new Growlers, the production line will close at the end of 2016, leaving the U.S. Navy without future Growlers. Closing the line would also affect nearly 60,000 jobs around the country and leave the military without competing sources for additional fi ghter aircraft.
The time to act is now. We urge Congress to include funding for Growlers in the 2015 budget. It’s an invaluable investment in the safety of our warfi ghters, the strength of our nation’s air power and industrial resource.
To learn more, go to www.supportgrowler.com
Frontiers May 2014 03
7.5 in. Live 8 in. Trim
8.75 in. Bleed
Job Number: BOEG_BDS_E18_3072M_C Approved Client: Boeing Product: Boeing Defense Space & Security Date/Initials BOEG_BDS_E18_3072M_C Date: 4/9/14 GCD: P. Serchuk File Name: BOEG_BDS_E18_3072M_C Creative Director: P. Serchuk Date: 04.09.14 70228ID05r0_C.indd Output Printed at: 100% Art Director: P. de Koninck DIGITAL PROOF SPECS. DIGITAL FILES SPECS. Copy Writer: P. Serchuk SCREEN ANGLES DOT SHAPE LINE SCREEN DMAX RESOLUTION PDF Fonts: Helvetica Neue 65 YEL MAG CYAN BLK Line : 2400 RSR 133 280 x1a 90˚ 45˚ 105˚ 75˚ Graphic : 300 Media: Frontiers Print Producer: Account Executive: D. McAuliffe YEL MAG CYN BLK PMS PMS 3C Space/Color: Page — 4 Color — Bleed 50K Client: Boeing 50C Live: 7.5 in. x 10.375 in. 4C 41M Proof Reader: 41Y Trim: 8 in. x 10.875 in. Legal: Bleed: 8.75 in. x 11.125 in. Traffi c Manager: Traci Brown Gutter: 0 25 50 75 100 Digital Artist: Production Artist: S. Bowman Art Buyer: Retoucher: Vendor: Color Inc.
PUBLICATION NOTE: Guideline for general identifi cation only. Do not use as insertion order. Material for this insertion is to be examined carefully upon receipt. If it is defi cient or does not comply with your requirements, please contact: Print Production at 310-601-1485.
Frontline Communications Partners 1880 Century Park East, Suite 1011, Los Angeles, CA 90067 TABLE OF CONTENTS BEST SUPPORTING 20 CAST Their mission is to be where they are needed, when they are needed, in support of Boeing customers and products around the world. Boeing field service representatives are a dedicated group of employees with special skills and numbering in the hundreds. Meet some of them in this Frontiers feature.
COVER: GARY GRUWELL, A BOEING FIELD SERVICE REPRESENTATIVE, SUPPORTS THE GROUND-BASED MIDCOURSE DEFENSE SYSTEM IN FORT GREELY, ALASKA. THE DOMES HOLD A MISSILE DEFENSE COMMUNICATION SYSTEM. ASSOCIATED PRESS
PHOTO: BOEING FIELD SERVICE REPRESENTATIVE EUNJEONG BAHN, SHOWN OUTSIDE A HANGAR AT DAEGU AIR BASE, SOUTH KOREA, SUPPORTS F-15K FIGHTERS FOR THE REPUBLIC OF KOREA AIR FORCE. ASSOCIATED PRESS
04 Frontiers May 2014 MEASURING MODELING 16 UP 32 SUCCESS Boeing mechanics use many tools, such as torque Boeing is helping customers better understand their wrenches and screw guns, to assemble the company’s defense capabilities and needs by creating complex products with exacting precision. Helping keep those tools scenarios at specialized facilities around the world. properly calibrated is a new analytics program—which The situations are simulated, but the learnings predicts future tool performance. PHOTO: BOB FERGUSON/BOEING are real. PHOTO: ASSOCIATED PRESS
WORKING TALENT 28 TOGETHER 36 POOL To increase the value—and competitiveness—of Boeing Considered world-class authorities in their fields, products, suppliers must be as vigilant as Boeing in Boeing Senior Technical Fellows are at the upper looking for ways to reduce costs and streamline operations. echelon of the company’s technical workforce. Meet the Partnering for Success is producing significant results, which newest six, whose expertise ranges from jet propulsion means more business for everyone. PHOTO: BOB FERGUSON/BOEING to the language of machines. PHOTO: BOB FERGUSON/BOEING
INSIDE 07 LEADERSHIP 10 WHAT WE DO 45 MILESTONES MESSAGE
08 SNAPSHOT 12 HISTORICAL 50 IN FOCUS PERSPECTIVE
09 QUOTABLES 31 CUSTOMER PROFILE
Frontiers May 2014 05 06 Frontiers May 2014 LEADERSHIP MESSAGE Designing for value Balancing airplane capability with cost will keep Boeing competitive for the long haul
oeing has long prided itself on 20 years represents a $4.8 trillion achieve design elegance. The result building the best commercial opportunity. Our commercial is lower production costs for Boeing, Bairplanes in the world, but development programs—737 MAX, and lower prices and operating costs today’s hyper-competitive marketplace 777X, 787-9 and 787-10—are vying for our customers. calls for a new equation: Going for a $2.5 trillion share of that We’re implementing this new forward, we must develop the world’s potential market. approach in partnership with best airplanes and offer them at a Price is only one factor—but an organizations across Commercial lower price than we do today. important one—in sealing a deal. Airplanes and throughout the We’ve already taken the first steps. To win in this “more for less” world enterprise, including Engineering, Over the past 18 months, since we also must consistently bring the Operations & Technology and Boeing Airplane Development was established highest-value product to market Defense, Space & Security. By working as an organization, we’ve been when our customers need it. In together and holding one another focusing on initiatives to improve Airplane Development we’re using a accountable we can create a powerful the affordability of our development management framework called the design environment that boosts programs and to make our products Boeing Product Development System our competitiveness. more cost-competitive. We’ve made to help us accomplish all of those goals. This approach requires a substantial substantial progress on both fronts We’re standardizing processes, shift in our culture, but it’s a change that enabled us to launch the 777X using tailored metrics and striving for we have to make. Development costs and the 787-10. more design commonality across our have been climbing steeply for decades But the biggest gains are still development airplanes. We’re innovating and are affecting our ability to compete. to come, and we have to get it when it delivers differentiating value for The Boeing Product Development right because the stakes are high. the customer, and setting aggressive System offers a solution. We’re already Global demand for new jetliners improvement targets. seeing cost reductions from these new over the next We’re also recommitting to first- approaches, and we anticipate many pass engineering quality. As with more gains to come. We’ll continue to all other aspects of our business, focus on value and efficiency initiatives getting it right the first time as we plan for the next generation of promises huge cost savings commercial airplanes and reposition and schedule benefits. our product line for the future. Most of all, we’re challenging Together, we’re breaking the ourselves to change our mindset. development cost curve—and For example, we’re simplifying positioning Boeing for a future design requirements, using fewer of unlimited success. n parts and less complexity to PHOTO: BOB FERGUSON/BOEING
Scott Fancher Senior vice president and general manager, Airplane Development, Boeing Commercial Airplanes
Frontiers May 2014 07 SNAPSHOT Where Eagles dare Two Boeing F-15E Strike Eagles await maintenance checks after a busy day participating in a Red Flag exercise at Nellis Air Force Base, Nev. The fighters, assigned to the 391st Fighter Squadron, Mountain Home AFB, Idaho, were some of more than 125 aircraft and 3,200 U.S. and allied service members participating in Exercise Red Flag 14-1 earlier this year. The objective of the exercise is to increase capabilities to defend against future threats. PHOTO: U.S. AIR FORCE
08 Frontiers May 2014 QUOTABLES “It will instill a sense of pride in Kiwis and turn heads when it touches down at airports throughout Asia and the Pacific.” —Capt. David Morgan, Air New Zealand chief flight operations and safety officer, after Boeing rolled out the airline’s first 787-9, in special all-black livery, from the Everett, Wash., paint shop. Air New Zealand is a launch customer for the 787-9. seattlepi.com, April 5
“Boeing has shown that 10- kilowatt lasers are capable of destroying mortars, unmanned aerial vehicles and small-boat threats.” —Dave DeYoung, Boeing program manager, explaining directed energy capabilities at an exhibition in Washington, D.C. Boeing has worked with the U.S. Army and Navy to design and test laser weapon systems. Boeing News Now, April 9
“The measures we were able to get on signature reduction and flying quality were spot on predications.” —Capt. Frank Morley, F/A-18 program manager for the U.S. Navy, talking to reporters about flight-testing Boeing’s Advanced Super Hornet, which has upgrades including increased “stealth” (lower visibility to radar). FlightGlobal.com, April 7
Frontiers May 2014 09 Carlos Guzman HAS WORKED FOR BOEING: 9 years ORGANIZATION: Boeing Research & Technology HAS BEEN PART OF A TEAM BUILDING INNOVATIVE FUEL TANKS: 4 years
10 Frontiers May 2014 WHAT WE DO Fueling the imagination This engineer is helping build rocket fuel tanks like none before By Nathan A. Hulings and photo by Marian Lockhart
Carlos Guzman is a manufacturing research and development engineer for Boeing Research & Technology in Seattle. In this Frontiers series that profiles employees discussing their jobs, Guzman explains his work on a project that can dramatically reduce the weight of rocket fuel tanks by using composite technology, and how collaboration and hard work pay off.
came to Boeing nine years ago place to plan and successfully When our work pushes the envelope, hoping to work on challenging perform. However, several of the Boeing employees kick into overdrive I programs and learn from some tank’s components still required and work together toward a common of the best engineers in the world. extensive on-the-fly development, goal. Building strong professional and Have I ever. especially on the smaller tank. This personal relationships helps get the During the past four years, gave us several exciting, stressful job done and provides a foundation I’ve been part of a team that is and challenging moments. for future efforts. building something that has never As an engineer working countless I’m very fortunate to work within been built before at this scale. I’m hours dealing with unexpected a facility that has some of the most co-manufacturing lead on NASA’s challenges, I often forget to step advanced lab resources, equipment Composite Cryotank Technologies back from my work and appreciate and, most important, skilled and Demonstration contract, under the magnitude of what’s being professionals. Those of us on this which Boeing designed and built two accomplished. For me, that moment program have a common vision all-composite fuel tanks for use on didn’t occur until I started reading and trust one another to apply our next-generation heavy launch space news articles about the program, own unique skills and expertise. I’m vehicles. In March, the larger tank talking about our work during visits learning things I never dreamed I’d was shipped to Marshall Space Flight by senior management, and seeing need to know at this stage of my Center in Huntsville, Ala., where it is a large photo in the Huntsville airport career. I feel like I’m getting 10 years undergoing testing. If implemented, showing off our robotic operation. of experience in two. At this point, in this technology can reduce fuel It was then that I realized our team what I hope is a long career at Boeing, tank weight by 30 percent, cost by was creating something special. I am honored that management and 25 percent, and increase payload Ask any of the dozens of people my fellow employees gave me the capability on future human space who have worked the program and opportunity to oversee the job. exploration missions beyond low they’ll tell you the road has not Boeing engineers helped put Earth orbit. been easy or predictable. We’ve a man on the moon. Hopefully, Building two all-composite fuel spent sleepless nights and given up our work will open new business tanks (about 8 and 18 feet, or 2.4 and numerous weekends and holidays opportunities for Boeing and help 5.5 meters, in diameter) consecutively working to meet major milestones and fuel the aspirations of and motivate in a 29-month time period seemed an aggressive schedule. the next generation of scientists, like a daunting task. But we were As a manufacturing lead, I am engineers and space explorers. n up for the challenge. pulled in numerous directions every [email protected] Boeing makes a lot of large-scale day. I love the fact that my job allows commercial and military products, me to offset scheduling and budgeting so our team had all the tools in tasks with hands-on factory-floor work.
Frontiers May 2014 11 HISTORICAL PERSPECTIVE
End of a LEGACY Last passenger flight of the DC-10 closes a chapter in Douglas aviation history By Mike Lombardi
12 Frontiers May 2014 n July 23, 1970, a typical sunny The DC-10 originally was planned California summer day at the as a high-capacity, four-engine ODouglas Long Beach plant, double-deck design, but with the more than a thousand employees advent of the widebody 747, the design and guests, including then–California changed to a high-capacity widebody Gov. Ronald Reagan, gathered for able to fit in the same footprint as a not very typical celebration. existing single-aisle jets. It was 50 years and one day after Douglas designers set several Donald Douglas had started the basic goals for their new airplane: airplane company that carried his speed comparable to that of the 747, name. Bagpipers, acknowledging the economy superior to that of the DC-8, Scottish heritage of Douglas as well low approach speed better than that as his new business partner James of the 727, low external noise level and S. McDonnell, ceremoniously led a being able to operate from the short new plane with the Douglas name field and confined gates of New York’s out from Building 54. LaGuardia airport. The designers There was high enthusiasm for arrived at an optimum design of a the new DC-10, and great hope that three-engine, high-capacity widebody accompanies the completion of a with nine-abreast seating for 250 to design process that revealed not 340 passengers. Later, the cabin was only a beautiful new airplane but one fitted for 10-abreast seating and that promised to continue one of 380 passengers. the world’s most famous families of The first DC-10s, known as the commercial airplanes. It had started Series 10, were built for domestic routes in 1935 when the DC-2 and the DC-3 of up to 3,500 miles (5,600 kilometers) captured the air travel market. And in and were powered by General Electric the post–World War II era, the DC-4, CF-6 engines. DC-6 and DC-7 ruled the skies. Two other major models were built The DC-10, however, would mark for longer-range international flights. the end of a Douglas legacy—there With two-thirds the capacity of the would be no more all-new DC designs. 747, the DC-10 found success flying For four decades, the DC-10 has long-haul routes that did not need been a familiar member of the world’s the capacity of the larger 747. In all, widebody jetliner fleet. It continues to 386 commercial DC-10s were built in operate as a freighter and the military a production run that ended in 1989. uses a modified version as a refueling Sixty KC-10 aerial refueling tanker tanker. But the last DC-10 passenger versions added to the production total. plane in scheduled service was retired Unfortunately, the rollout of the PHOTOS: (Clockwise from far left) earlier this year by Biman Bangladesh DC-10 was not the continuation of the The first DC-10 rolls out in July 1970 Airlines. The DC-10 was the flagship of famous DC dynasty but rather its end. at the Douglas plant in Long Beach, the Biman fleet for three decades; it is The new McDonnell Douglas planes Calif.; James S. McDonnell, from being replaced by Boeing’s 777-300ER that followed were all derivatives of left, Vice President Spiro Agnew and (Extended Range). the DC-9 or the DC-10. Those MD-11s, Donald W. Douglas advance throttles to signal the start of rollout of the first On Feb. 20, the remaining DC-10 MD-80/90s and the 717 (initially called DC-10; a KC-10, the U.S. Air Force in the Biman fleet, carrying 30 aviation the MD-95 before the merger with Tanker version of the DC-10, flies with enthusiasts and writers as well as a Boeing) continue to carry the Douglas Douglas A-4 Skyhawks of the U.S. Navy film crew from the British Broadcasting airliner legacy. And the ageless DC-3 Blue Angels demonstration team. Corp., took off on a long-haul flight likely will still be flying many years from BOEING ARCHIVES Biman’s DC-10-30 arrives at the Birmingham, England, from Dhaka to Birmingham, England. now—another reminder of the genius of airport, ending a chapter in aviation The trip marked a somber farewell to Donald Douglas and his incomparable history. BIMAN BANGLADESH AIRLINES the last member of a Douglas legacy. commercial aviation dynasty. n [email protected]
Frontiers May 2014 13 Your commitment to excellence, PRECISION. precision performance, and accountability has brought us PERFORMANCE. shared success. Thank you for PARTNERSHIP. your dedication. Aero-Plastics Inc.
AMI Metals, Inc.
ANACAPA Micro Products Inc.
Ball Aerospace & Technologies Corp.
CFM International
Fairchild Controls
Gary Jet Center
Khrunichev Space Center
Lamsco West, Inc., part of the Shimtech Group
Marshall Aerospace and Defence Group
Massachusetts Institute of Technology
MSI Defense Solutions, LLC
Nabtesco
Novator AB
Progresstech Ltd.
ShinMaywa Industries, Ltd.
Visit boeingsuppliers.com/recognition to learn more about recognition programs or for a list of the 2013 Performance Excellence Award recipients.
www.boeing.com
14 Frontiers May 2014
SOY_FrontiersAD Final.indd 1 4/4/14 2:25 PM Your commitment to excellence, PRECISION. precision performance, and accountability has brought us PERFORMANCE. shared success. Thank you for PARTNERSHIP. your dedication. Aero-Plastics Inc.
AMI Metals, Inc.
ANACAPA Micro Products Inc.
Ball Aerospace & Technologies Corp.
CFM International
Fairchild Controls
Gary Jet Center
Khrunichev Space Center
Lamsco West, Inc., part of the Shimtech Group
Marshall Aerospace and Defence Group
Massachusetts Institute of Technology
MSI Defense Solutions, LLC
Nabtesco
Novator AB
Progresstech Ltd.
ShinMaywa Industries, Ltd.
Visit boeingsuppliers.com/recognition to learn more about recognition programs or for a list of the 2013 Performance Excellence Award recipients.
www.boeing.com
Frontiers May 2014 15
SOY_FrontiersAD Final.indd 1 4/4/14 2:25 PM Tuning tools
16 Frontiers May 2014 Tuning tools
Predicting when tools need calibrating improves quality—and saves rework and money By Eric Fetters-Walp and photos by Bob Ferguson
oeing jetliners are packed with if the tools had been used to their full high technology and cutting- calibration cycle.” B edge design, but it still takes The program analyzes rafts of torque wrenches, screw guns and data on the tools—how they are used other relatively low-tech tools to put and when they are prone to slip out of them together—along with mechanics calibration or just wear out. In simpler who use the tools. terms, it builds on a concept that has And the quality of Boeing products proved successful in Major League depends, in part, on making sure these Baseball. The book and film Moneyball tools are properly maintained. tell the story of how the Oakland On the 787 program, for example, Athletics’ general manager used 57 different tools that are especially empirical analysis of player statistics, critical to the final assembly of the especially statistics and data patterns Dreamliner are calibrated every three to that previously were undervalued four days to minimize tool-related risks. by other teams, to predict a player’s While inspectors and extensive Quality future performance. The Athletics Assurance processes catch work have built winning teams as a result. performed with tools out of calibration, Boeing continues to expand its preventing it from happening saves time use of predictive and other advanced and money. analytics into new areas where they To that end, teams in Commercial might be useful, explained Paul Ortman, Airplanes and Engineering, Operations Manufacturing Operations Advanced & Technology have developed a Analytics manager in Commercial predictive analytics program to keep Airplanes. Boeing has reams of data tools better calibrated and working available, and within Commercial well, which prevents costly rework that Airplanes, it is his team’s job to figure can slow production. In less than a out how to use it productively. His team year, the program has identified dozens worked with an Information Technology of “significantly out of tolerance” team in Huntington Beach, Calif., to create (commonly referred to as SOOT) tools and apply specialized analytic formulas. in Boeing’s factories and helped predict “They previously had no way to when others need to be calibrated. proactively prevent SOOTs before they “By applying the analytics model, we were able to ‘pull ahead’ a number of our out-of-tolerance tools that would PHOTOS: (Far left) Commercial have taken months to find,” said Martin Airplanes’ Paul Ortman, from left, Tracie Wingrove, Alan Davis and Ohman, SOOT mitigation leader for Bobby Lohnes review tools tagged Fabrication. “This saved the programs for repair or for being out of tolerance. potentially millions of dollars in rework (Above) Davis displays a nut runner.
Frontiers May 2014 17 “By applying the analytics model, we were able to ‘pull ahead’ a number of our out-of-tolerance tools ... This saved the programs potentially millions
of dollars in rework.” —Martin Ohman, SOOT mitigation leader for Fabrication
18 Frontiers May 2014 happened,” said Melanie Lorang, of the analytics software at Commercial throughout Boeing’s businesses. Associate Technical Fellow and Product Airplanes sites. It quickly made a Commercial Airplanes is sharing what System Analytics program manager in difference, they said. For example, one it has learned as well, Ohman said. Huntington Beach. “They only could torque wrench that was taken out of “Our SOOT team is working on see what happened and eliminate the service in Renton, Wash., after it was making analytics a permanent part problem tools after the fact.” identified as being out of tolerance of the tool management system,” Using tools that are beyond their safe would have stayed on the factory Ohman said, “and we are also sharing tolerance range can require rework on floor for up to a year under the old re- our discovery with Boeing Defense, parts of the airplane that were touched calibration schedule. In all, more than Space & Security to see if they may by those tools, potentially causing 40 SOOT tools were discovered and be able to benefit from the use of expensive production rework and delays a significant number of less seriously advanced analytics.” for customers. It’s happened before, out-of-tolerance tools were discovered As Commercial Airplanes sites said Steve Onustack, senior manager as well, Ortman and Davis explained. from Everett, Wash., to Salt Lake City of the Metrology Lab Operations in Using the predictive software to North Charleston, S.C., use the the Puget Sound region. Metrology program and its findings has led the predictive program to find problem employees, part of Boeing Test & Metrology team to help mechanics tools, more information is gathered, Evaluation, are tasked with making calibrate their tools more often than Ortman added. sure Boeing’s tools stay calibrated. before, Onustack said. At the same “As we discover new insights, Lorang and the project’s primary IT time, there is a related effort to we can add substantial new data to data specialist, Irene Umamoto, along remove more than 13,500 older tools, fine-tune this,” he said. “All signs point with statistician and Associate Technical which are at greater risk for creating to this being the right thing to do for Fellow Bob MacLean and Aviana Global tolerance problems, from Commercial the business. We’re remedying the Technologies consultant James Bettles, Airplanes factories by the summer. potential for damage and reputational combined their specialties in designing “Right now, we’re choosing to err risk by doing this.” n a computer program specifically for on the side of reducing risk as much [email protected] predicting out-of-tolerance tools. While as possible,” Onustack said, adding using predictive mathematical formulas that the Metrology team has developed and computer programs has boomed in other tools to help users identify specific PHOTOS: (Clockwise, from far left) a number of industries in recent years, poor-performing tools so they can remove Lohnes inspects a motor in a tool MacLean has worked with predictive them from service. Also, commonality storage area at the Everett, Wash., models since the 1970s. The main among tools is increasing, and the factory; Wingrove, left, and Davis refer difference is that today’s technology company is planning to place torque- to a laptop for a list of at-risk tools by makes it easier to harness facts and checking devices closer to mechanics’ tool family and location; bins full of worn-out and out-of-tolerance screw figures into useable prediction tools. work areas at Commercial Airplanes sites. guns, nut runners and torque wrenches Ortman and the lead analyst on his Meanwhile, Lorang’s team is trying are destined for destruction after being team, Alan Davis, led implementation to make this project repeatable retired from the factory floor in Everett.
Frontiers May 2014 19 depth of field Field service representatives are the face of Boeing to customers By Bill Seil
round the world and around the representatives, a dedicated group clock, their primary mission is of employees with special skills and “We work toward ... Ato be where they are needed, numbering in the hundreds. situations where when they are needed, to support “Field service representatives are Boeing customers. Their careers are the face of Boeing and our customers the customer is as varied as the company’s diverse depend on them to get the information global base of airline, space and they need,” said Eric Anderson, satisfied at the end military customers. director of the Logistics Services Barrie Grubbs, for example, is a Capability Center for Global Services of the conversation. former U.S. Marine helping maintain & Support, based in St. Louis. the Bell Boeing MV-22 Osprey for the “A lot of times, it’s not a matter We build bridges.” U.S. Marine Corps. He’s based in of waiting for the customer to ask,” — Sue Fullington, director of Field North Carolina. Meanwhile, in Anderson said. “It’s knowing what the Service for Commercial Airplanes Buenos Aires, Argentina, Chris DiVito customer is doing and anticipating is supporting the airline Aerolineas what they need.” Argentinas, which has a growing Global Services & Support, part of fleet of Next-Generation 737s. Boeing Defense, Space & Security, Both are Boeing field service has approximately 350 field service
20 Frontiers May 2014 depth of field
representatives based at nearly when working with customers.” Grubbs, the Marine Corps veteran, is 115 global locations. Some Boeing subsidiaries also have often deployed with the MV-22 crews to Commercial Aviation Services, their own field service representatives combat zones. In one case, he was part part of Boeing Commercial Airplanes, to help customers. Insitu, for example, of a team that was sent to Afghanistan has more than 330 field service maker of the unmanned aircraft to recover an MV-22 that was damaged representatives based at more than ScanEagle, has more than 190 full-time in the field. A few days after the team 60 locations around the world providing field service representatives. They arrived and repairs were completed, the on-site technical support to airline also have access to supplier-provided tilt-rotor Osprey was flown back to base. customers who operate Boeing field representatives to supplement “I consider it a privilege to go on jetliners. Their knowledge must extend their own workforce. Insitu currently to all Boeing airplane models, including has nearly 200 full-time and supplier- PHOTOS: (Portraits, from far left) Field the 787 Dreamliner. provided field representatives deployed service representatives Irina Turanskaya “The reps are the customers’ around the world. in Kiev, Ukraine; Mike Snover on a advocates back to Boeing,” said Field service representatives—both mezzanine in Dublin, Ireland; Eunjeong Sue Fullington, director of Field military and commercial—sometimes Bahn outside a hangar in South Korea; Barrie Grubbs. ASSOCIATED PRESS (Products, Service for Commercial Airplanes go to rugged, even dangerous parts of from far left) A Boeing 737 in flight; a and based in the Seattle area. the world. Some even are asked to go 787 Dreamliner in Japan Airlines livery; “They’re also Boeing’s advocates to areas where battles are taking place. an MV-22 Opsrey at night. BOEING
Frontiers May 2014 21 these missions, because I’m going “In field service, frequent with the Marines,” said Grubbs, who communication is important,” is based out of Air Station New River Yamamoto said. “Even when there in Jacksonville, N.C. “I want them to are no technical issues, you need know that there are people back home to go to the customer and have who are willing join them in the things conversations. Listen carefully and they do to protect our freedoms.” try to put yourself in their shoes.” Another field service representative, Boeing Commercial Airplanes Alain Garcia, supports ground-based has a Field Service organization pilot training for the Singapore Fighter within Commercial Aviation Services. Wing, which takes place, under contract, Field service representatives support at the Cazaux Air Base in France. He all Boeing jetliners, including some helped develop the curriculum that is out-of-production models. used in the training. While serving as When hiring a field service a fighter pilot in the U.S. Navy, Garcia representative, Fullington said she flew numerous combat missions in looks for people who have a good Afghanistan and Iraq. technical knowledge of the airplanes “I have a background in tactical as well as an understanding of airline flying, which gives me credibility customers. They must have a passion with the Singapore pilots who are for solving customer problems and conducting the training, as well as experience in working within the pilots who are being trained,” Garcia company’s various networks. said. “We can all relate to one another, “We look for people who know which makes it easier for us to work how airlines operate because there together and understand each other.” are times when we get in the middle DiVito, the field service of some very intense discussions representative in Buenos Aires, said between Boeing and a customer,” her daily routine includes checking Fullington said. “We work toward on airplanes in need of maintenance, win-win situations where the discussing issues with Argentine customer is satisfied at the end of the engineers over a hot cup of yerba conversation. We build bridges.” maté tea and communicating with her Field service representatives with Boeing colleagues in the Seattle area. Global Services & Support, unlike Some of her greatest challenges have Commercial Airplanes representatives, involved AOGs (Airplane on Ground), support specific programs and in which a plane is unable to fly due generally focus on individual products. to some problem. While many Global Services & “It often involves waking up in Support field service representatives the middle of the night, and working have military experience, others through the night and on weekends,” developed their experience through she explained. “You work until it’s a range of past Boeing assignments. done—until the airplane is flying again.” “In many cases, our reps Takeshi Yamamoto, based in are stationed side by side with Tokyo, supports Japan Airlines’ 787 customers in war zones,” Anderson Dreamliners and Skymark Airlines’ said. “And like our customers, Next-Generation 737s. He joined they are in harm’s way. They are Boeing in 2010, after previously committed to doing whatever it takes working at Japan Airlines. He finds to support our customers’ missions— that his experience with the airline has anytime, anywhere.” n helped him provide better customer [email protected] support. He has handled difficult issues, including early problems with 787 batteries.
22 Frontiers May 2014 Gary Gruwell SUPPORTS MISSILE DEFENSE AGENCY BASED AT FORT GREELY, ALASKA
ocated southeast of Fairbanks, power plants for use in emergencies. Alaska, Fort Greely is home to He leads a team of 15 electricians, L grizzly bears, moose, wolves— generator technicians, and power control and a ground-based missile defense and monitoring system operators. They complex to defend the U.S. against monitor system health and operations long-range ballistic missile attacks. around the clock, 365 days a year. They Winter temperatures tend to hover try to schedule projects so outdoor work a little below zero degrees Fahrenheit takes place in warmer weather, but that’s (-18 Celsius), though they have, from not always possible. time to time, dropped to 60 below When Gruwell first went to Fort Greely (-51 Celsius). High winds create in 2002, his job was to help convert a snowdrifts and can cause extreme closed U.S. Army base into a missile wind chills. Daylight is scarce in the defense complex. Today, the base is in full winter, but plentiful during the summer. operation, with modern facilities. There Gary Gruwell, a Boeing field service are also amenities for the people working representative, has lived at Fort Greely there, including a well-stocked PX (post since 2002, part of the Boeing team exchange, or store) and a gymnasium. there that supports the Ground-based About a year ago, Gruwell bought Midcourse Defense system, for which a hay farm, which he operates as a Boeing is the prime contractor. His side business. He also maintains a customer is the Missile Defense Agency, kennel for older rescue dogs that have part of the U.S. Department of Defense. difficulty living in the cold climate. He “I get to live a remote, rural-type is preparing to build a greenhouse lifestyle and still go to work each day in on his property, which he will use for a challenging aerospace job,” Gruwell gardening. Sometimes he travels to said. “That doesn’t happen too often.” California to see his grown children Gruwell, a Global Services & and other family members. Support representative at Fort Greely, “In the summer, if I’m not on the is responsible for maintaining power farm or with the dogs, I’m off hunting, production and distribution. He is fishing, rafting or backpacking,” also involved in maintaining specialty Gruwell said. “I really love our small equipment used at the site. While the community, and spending time with complex has access to commercial the people who live here.” n power, it has two Boeing-designed PHOTO: ASSOCIATED PRESS
Frontiers May 2014 23 Eunjeong Bahn SUPPORTS F-15K FIGHTERS IN KOREA BASED AT DAEGU AIR BASE, SOUTH KOREA
s a former logistics officer in the most important. That’s where force, recently transferred to Daegu Air the Republic of Korea Air Force, her background as a captain in the Base to train as an F-15K pilot. Bahn AEunjeong Bahn knows the Republic of Korea Air Force comes in. also is pursuing a master’s degree in importance of fleet readiness. “Readiness is vital, so everything business administration. Today, she is a Boeing field service is considered urgent,” she said. Bahn decided in high school that representative supporting the Korean “That’s a big challenge for me, but my she wanted to work in aerospace, and air force’s F-15K program at Daegu understanding of our customer and that the military was the best path to Air Base. Her primary responsibility is their needs helps a lot.” pursuing her career. So she graduated fulfilling the company’s Performance She can usually email the Global from the Republic of Korea Air Force Based Logistics agreement with the air Services & Support team in St. Louis Academy and went on to active service force, in which Boeing uses forecasting and have an answer in the morning. as an air force logistics officer. While methods to ensure that parts and repairs But in some cases, issues have to be in the air force she went to the United are available when needed. This keeps resolved by phone. States to take logistics-related courses the fleet operationally ready to defend Bahn said the South Korean culture through the U.S. foreign military training the country. focuses heavily on relationships, and program. She also participated in a “For the Republic of Korea Air this begins by building trust. In her case, U.N. peacekeeping mission in Lebanon. Force, it’s a whole new concept in she had to find a way to transfer the She joined Boeing in 2009 and logistics support,” Bahn said. “It’s relationships she developed as an air began her current field service based on measurable performance to force officer to business relationships in assignment in 2011. ensure that the level of support needed her role as a field service representative. “Supporting Korea’s F-15K’s on behalf by the customer is met.” Her hobbies include playing golf of Boeing is a wonderful opportunity,” A chief challenge of the job is and various forms of dance, including she said, adding: “Some people complain setting priorities. Each day she the tango. But her life recently became about the sound of the F-15K’s engines. receives numerous requests for busier with the birth of her first child. But hearing it makes me so happy.” n support and must decide which are Her husband, who is in the Korean air PHOTO: ASSOCIATED PRESS
24 Frontiers May 2014 Mike Snover RECENTLY SUPPORTED RYANAIR IN DUBLIN, IRELAND NOW BASED IN BEIJING
uring his 18 years as a field also would make rounds, in which service representative, Mike they’d meet with key management DSnover and his family have personnel. By midafternoon, calls experienced life on four continents. would start coming in from the home He started out supporting Delta Air office in Seattle, consuming most of Lines in Atlanta. From there, he moved their time until around 6 p.m. on to a six-year assignment in Buenos While technical skills are important, Aires, Argentina, and then a five-year Snover said building relationships with assignment in Taipei, Taiwan. customers and developing trust are Prior to beginning a new essential to doing his job. assignment in Beijing last month, he Snover, with his wife and two was stationed in Dublin supporting daughters, has found time to explore Ryanair. The low-cost carrier operates the regions where he has been based. a fleet of 300 737-800 Boeing jetliners, He said they especially enjoyed living all with the same specifications. in Buenos Aires, and visiting Latin “Probably the neatest thing about American sites. the job was being in a position to find Snover’s main passion is downhill and report any problems with the skiing, and he has taken his family on airplane very early on,” Snover said. ski outings in four continents. “That’s information that’s valuable to Snover noted that while growing the fleet as a whole.” up, his two daughters never attended Snover supported Ryanair with school in the United States. His two colleagues based in Dublin and assignment in Atlanta concluded when London Stansted Airport. His day they were 3 and 5 years old. would begin with a meeting with airline “While they gained a lot from being representatives, where they’d conduct educated around the world, they’ve a review that covers every airplane in missed out on American culture,” the fleet. Afterward, he would follow he said. “So we’re asking them to up on any issues that needed to be complete their education by going addressed and handle email traffic— to college in the United States, and much of which would arrive overnight they agreed. from Boeing Commercial Aviation His oldest daughter is now attending Services colleagues in the Seattle a university in Washington state. n area. The field service representatives PHOTO: ASSOCIATED PRESS
Frontiers May 2014 25 Orian Steen SUPPORTS INSITU CUSTOMERS ASSIGNMENTS INCLUDED IRAQ AND AFGHANISTAN hen Orian Steen was a flight While supporting the U.S. Marines engineer in the U.S. Air Force, in Afghanistan, Steen had about 50 Whe could look out the window Insitu field service reps assigned to of his aircraft and get a good sense of him. Operating with multiple aircraft his surroundings. from various sites, they flew thousands Today, as a field service representative of hours each month. In some cases, for Insitu, he flies a very different kind they operated from large air bases with of aircraft. His only view comes from a modern amenities. In other cases, they camera that’s pointed at the ground. were at isolated locations surrounded Insitu is a Boeing subsidiary in by wire fences. Bingen, Wash., that produces Steen said one of his most unmanned aircraft systems (UAS), interesting assignments was working such as ScanEagle and Integrator. from a U.S. Navy destroyer. After 10 “At Insitu, our role is different from years in the U.S. Air Force, he had the typical field service representative,” never served on a Navy ship before. Steen said. “Most reps are out there “I enjoyed it,” he said. “On the ship, helping customers support and it was a different lifestyle, with customs maintain Boeing aircraft. In our case, and courtesies that were new to me.” we’re flying the aircraft ourselves.” When he’s not deployed, he spends In most contracts, Insitu retains as much time as possible with his wife ownership of the unmanned aircraft and children. and sells customers the video taken In his spare time, Steen enjoys riding during surveillance missions. But there his motorcycle and flying remote control are cases where a military customer will helicopters. But why would someone buy, and fly, the equipment. In those who flies sophisticated unmanned cases, Steen and his colleagues serve aircraft want to fly a toy? The Air Force a more traditional field service role. veteran still enjoys the freedom and Steen has worked for Insitu for spontaneity of old-fashioned flight. five years and been deployed to Iraq, “Flying a remote controlled helicopter Afghanistan and a U.S. Navy ship, and had involves a lot more manual flying than a special assignment in the Netherlands. an unmanned aircraft, which is highly In the Netherlands, Steen spent two automated,” he said. “It’s relaxing just to months supporting the use of ScanEagle pick up the controls and fly it around.”n by the Dutch Ministry of Defence. PHOTO: JEREMY PHILLIPS/INSITU
26 Frontiers May 2014 Irina Turanskaya SUPPORTS AIRLINES OPERATING BOEING JETLINERS BASED IN KIEV, UKRAINE
n 1994, Irina Turanskaya applied “I needed some technical knowledge, me to talk with people in Seattle and for a six-month position supporting so I enrolled in a three-year course have answers ready for my customers IBoeing Commercial Airplanes’ field in mechanics at the National Aviation in the morning—especially on urgent service representative in Ukraine. University in Kiev,” she said. issues,” she said. At that time, she didn’t have any After serving in a supporting Often, she uses her language skills experience in aerospace. But she did role for six years, Turanskaya was to help her customers find help, even have a Ph.D. in linguistics. promoted to field service associate if it’s not directly related to her job. Turanskaya got the job, in part for Ukraine. Turanskaya does most of her because the company’s airline Today, she supports five airlines: work at Boryspil International Airport, customers knew little English and Ukraine International Airlines, where she is close to the airline the field service representative didn’t UT Air Ukraine, Kharkiv Airlines, engineering departments. speak Ukrainian. Bravo Airways and Air Onix. Boeing In her spare time, Turanskaya has “I had worked as a teacher of airplanes in local fleets primarily several hobbies and avocations. She is English and French, and I speak include Next-Generation 737s, taking classes in Gestalt psychology, Ukrainian and Russian,” she said. 737 Classics and 767 jetliners. which helps her establish balance in “Primarily, I was hired as an interpreter, She generally starts her day at work, relationships and daily life. She and to assist the rep with everything 8 a.m. and works until around 6 in also has been active in Toastmasters. else that needed to be done.” the evening—although she keeps her She enjoys cooking, including Italian, In 1998, she was asked to come computer on until after 10 p.m., just French and local cuisine. back to the job, this time on a full-time in case important messages come “I really love cooking,” she said. “I have basis. Turanskaya soon developed a in. There is a 10-hour time difference so many cookbooks at home. When I’m passion for the work. But to continue, between Kiev and the Seattle area, in the kitchen I just go crazy.” n she realized she would have to where her Commercial Aviation PHOTO: ASSOCIATED PRESS take her education in a dramatically Services colleagues are headquartered. new direction. “Evenings are the best chance for
Frontiers May 2014 27 MORE FOR LESS Boeing and its suppliers work together to cut costs and be more productive and efficient By Liz Verdier and Antonella Bellman
nside the fuselage of a 737-900ER He was part of that initial brain what Partnering for Success is about,” (Extended Range) on the Renton, storming group. It began as an effort said Mike Zyskowski, director of IWash., assembly line, Boeing technical by the 737 Environmental Control Engineering with Commercial Airplanes designer James Pounds watched—a Systems team to find a way to reduce cost Supplier Management. smile of satisfaction moving across his and weight on the best-selling airplane. The supply chain accounts for about face—as a mechanic prepared to make Working with longtime supplier two-thirds the cost of Boeing products the first installation of a redesigned part PECO Astronics of Portland, Ore., and services, so suppliers must be for the airplane’s ventilation system. which makes the 737 Environmental as vigilant as Boeing in looking for With the whir of an electric Control Systems, a Boeing team came ways to reduce costs and streamline screwdriver, the mechanic fastened up with an out-of-the-box solution. their operations, he and other Boeing the part securely to the aluminum What had been a three-nozzle air leaders say. The reward for those who track along the fuselage frames, the distribution system on the 737 will be do, they point out, is a huge opportunity attached hose snaking down. The task changed to one with only two nozzles. for growth in the years ahead. completed the first phase of the project. The result? Boeing expects an eventual PECO, the 737 supplier, has been Installing the part took no more savings of about $4 million a year, along doing just that—working with Boeing to than about 30 seconds. But getting with a weight reduction of 26 pounds reduce costs and improve efficiencies. to that moment in the Renton factory (12 kilograms) per plane when the second Through initial PECO collaboration several weeks ago was the result of phase of the project installs in 2015. with Boeing, some 100 component a brainstorming session two years It’s but one example of the value part numbers for the 737 ventilation earlier—and lots of work in between being created around the company by system were reduced to 10, said Dave by Boeing and one of its suppliers. the Partnering for Success program. Freund, PECO’s vice president. “It is really satisfying to be able to “We can’t implement a true cost “It’s been encouraging to our team save Boeing so much money—and now savings for our customers unless our members to be able to take ideas up we want to find even more projects like supply chain is able to realize the same to Boeing knowing they’re getting this,” said Pounds, a 737 mechanical improvement in quality and efficiency legitimate review and resources when systems design engineer. in their production systems. That is the project makes sense and there’s
28 Frontiers May 2014 a value proposition,” Freund said. production, spares and retrofit pricing “We can’t implement Jack House, Boeing’s Partnering in support of the customer’s fleet. for Success enterprise leader, said “The economies of scale were a true cost savings achieving mutual cost reduction goals is substantial,” Loetscher said. “We were everyone’s business. At Boeing, it means able to secure significant savings for for our customers first-time quality and design efficiencies the package.” that improve production performance But the teamwork doesn’t end there. unless our supply while reducing costs, he explained. Representatives of the F-15 and House is vice president of Supplier F/A-18 programs are making the most chain is able to Management for Boeing Defense, out of certain commonalities of these Space & Security, where coordination aircraft, including their work with realize the same with a supplier across business units Raytheon. By focusing on common provided the most affordable pricing designs and support staff, as well as improvement solution for an F-15 program customer. common companies within their supply Fighter aircraft components such chains, the F-15 and F/A-18 teams were in quality and as radar systems are technically sophisticated and can be very expensive to purchase, especially if they’re procured efficiency ... That is PHOTOS: (Far left) Designer James individually. A Boeing team led by Sharon Pounds stands in a 737 cabin, where what Partnering for Loetscher, a Supplier Management the first parts of a lighter, simpler senior manager, worked with colleagues air distribution system—developed in Boeing Military Aircraft and Global with supplier PECO Astronics—are Success is about. ” Services & Support to integrate their being installed. MARIAN LOCKHART/BOEING (Insets) PECO employees Dave Freund —Mike Zyskowski, director of needs into one set of requirements. (top left), Fred Blake (top right) and Engineering with Commercial The team then worked with supplier Julie Lee (above) inspect parts to be Airplanes Supplier Management Raytheon to negotiate the best possible sent to Boeing. JIM ANDERSON/BOEING
Frontiers May 2014 29 able to capitalize on synergies across responsible for purchasing all non- accomplish when we work with our the platforms and production lines. production goods and services. supplier partners,” Broughton said. “And that created significant Instead, he said, Boeing had “Partnering for Success has brought savings for our customers,” said Tim 10 different contracts spread across the relationships we built with our Myers, supplier program manager. Commercial Airplanes, Defense, Space & suppliers to a whole new level.” n Partnering for Success, however, Security, and Engineering, Operations [email protected] is not just about aircraft parts. It’s & Technology. Without one contract for [email protected] about finding more efficient ways of the enterprise, each of the business units doing business everywhere—even was buying jet fuel at different prices To see a video about PECO’s work for at the gas pump. and under different contract terms. Boeing, visit boeing.com/frontiers/videos/ Commodity costs, such as jet fuel, So a Boeing team was brought may14. For more about Partnering for play a big part in the cost of Boeing together to figure out a better and Success, see the Leadership Message products. Boeing consumes nearly cheaper way. in the March 2014 issue of Frontiers. 50 million gallons (190 million liters) The result: one contract covering of jet fuel each year. the entire company that reduced the “It’s hard to believe, but we didn’t number of suppliers from about 40 to a PHOTO: Procurement agent Sheri have a single contract for the company handful—and saved millions of dollars Sintzel, left, and procurement manager when it came to buying jet fuel,” said almost immediately. The team also Bob Madigan review information about the F-15. To streamline how it works with Mike Broughton, procurement agent negotiated coverage for an additional suppliers on fighters such as the F-15, from Shared Services Group Supplier 28 Boeing sites around the world. Boeing has integrated its needs into one Management, the business unit “It’s amazing what we can set of requirements. RICHARD RAU/BOEING
30 Frontiers May 2014 CUSTOMER PROFILE DREAM CONNECTIONS Kenya Airways will use Dreamliner to help connect Africa to the world, and the world to Africa By Daniel Mosely and photo by Paul Gordon
ast month, hundreds of Kenya 787 also will improve the airline’s Adding the 787 to the airline’s fleet Airways employees welcomed economic performance. will open up direct, long-haul routes to L the airline’s first 787 Dreamliner Kenya Airways was founded in 1977 major cities in Europe and Beijing, he at its home base of Jomo Kenyatta with two leased Boeing 707s and has explained, as Kenya Airways explores International Airport in Nairobi. grown to become one of the leading new markets that will help it achieve its The 787, the first of nine planned for airlines on the African continent. It strategic objective and contribute toward the carrier’s fleet, arrived from Everett, currently operates an all-Boeing long- the sustainable development of Africa. Wash., after a nonstop delivery flight haul fleet of six 767-300ERs (Extended “The introduction of direct flights of 7,800 nautical miles (9,000 miles, Range), four 777-200ERs and one with the 787 to destinations like Paris or 14,500 kilometers). And no one was 777-300ER, with the 787 as its newest and Amsterdam will boost key sectors more excited by the 787’s arrival than addition. On short-haul, inter-African of Kenya’s economy such as tourism Kenya Airways Chief Executive Officer routes, the airline operates a mix of and horticulture, while the 777-300ER is Titus Naikuni. 15 Classic and Next-Generation 737s. a perfect fit for our network expansion The airline, known as the “Pride The carrier has adopted a 10-year plans,” Naikuni said. “It will enable us of Africa,” is on a mission, according strategic plan called Project Mawingu to serve our existing markets much to Naikuni: “Connecting Africa to the to increase its fleet from 44 airplanes to more effectively and facilitate the world, and the world to Africa.” And 107 by 2021, and expand destinations opening of new long-haul routes in the 787 is going to help Kenya Airways from 62 to 115. As part of that plan, the the near future.” n do just that, he said, by opening new airline took delivery of its first 777-300ER [email protected] route possibilities for direct service less than six months ago. During 2014, to Europe and Asia. Kenya Airways will add two 777-300ERs “The delivery of this airplane and five 787s as it moves forward on its PHOTO: The first of nine 787 Dreamliners set to join the Kenya Airways fleet is opens a new chapter at a very path of ambitious growth. The stream shown at the Everett (Wash.) Delivery exciting time for our airline,” Naikuni of Boeing deliveries is set to continue Center prior to departing for a celebratory said, explaining that the fuel-efficient in the years ahead, Naikuni said. homecoming in Nairobi.
Frontiers May 2014 31 Fast-for ward to the future
uring his three decades in the office building in downtown Seoul. It’s the working together in person, Republic of Korea Army, Taewoo As the manager of Boeing’s Korea according to Kim, that makes this DKim, or “TK,” helped make sure Analysis & Experimentation Lab, Kim virtual environment so valuable. his nation had the data needed to defend leads a team of operations analysts, “In Korea, relationships are very itself from existing and future threats. systems engineers and software important. We want to partner with the Among other responsibilities, he analysts tasked with creating virtual participated in developing C4ISR environments where they, alongside systems (short for command, control, Korean military leaders, explore the PHOTOS: (Top) Ashwini J S, foreground, communications, computers, intelligence, future of combat and weaponry. Here, and Puneet Loona at Boeing’s Strategic surveillance and reconnaissance) and teams engage in complex analysis Development & Experimentation Center served as chief of Information Operations of defense scenarios—all simulated— in Bangalore, India. (Near right) Joshy development at the army’s headquarters. to better understand what and how Sebastian, from left, Ajit Mate and Shaifali Sinha in Bangalore. (Far right) Tongho Today, he’s still working to ensure much capability a customer may Sihn (top) at work in the Analysis & his country can protect itself. Only need for protection, communication Experimentation Lab (bottom) in Seoul, now, he’s doing that job from a Boeing or support systems. Korea. ASSOCIATED PRESS
32 Frontiers May 2014 Fast-for ward to the future Simulating complex defense scenarios helps Boeing customers prepare for the future By Eric Carlson
Frontiers May 2014 33 “Simulation and analysis allow you to fast-forward the future.” —Raveeswaran Nagarajan, an operations analyst at the Boeing facility in Bangalore, India
34 Frontiers May 2014 Republic of Korea. We want to grow embodies Boeing’s global growth advantages of visualizing combat with them. By helping them understand strategy, according to Shane Arnott, scenarios through simulation. their capability gaps, we’re not just director of Phantom Works’ Strategic “It helps our customers understand saying that—we’re showing them,” Development & Experimentation— what capabilities they need to invest Kim said. International Engagement, the part in—it helps them stay ahead of the Boeing teams are engaging of Boeing Defense, Space & Security game,” he said. with customers at similar facilities developing these facilities. Abdulrahman Al-Huthail, a around the globe. In Brisbane, The investments Boeing has systems analyst in Boeing’s Riyadh Australia; Bangalore, India; Riyadh, made—in people, resources and facility, agreed. Kingdom of Saudi Arabia; and Fleet, technology—are all evidence, he said, “These are great tools for United Kingdom; similar scenarios of a commitment to mutual success understanding and visualizing the are being “war-gamed” through video and directly support the company’s problems and related issues—they projection on large screens, alongside activities in each region. make it clearer for the customers,” international customers, in otherwise “Having centers in these countries, he said. “They can see the model nondescript buildings. All are part staffed by local nationals, always or sample a solution before they try of a Boeing effort to help customers available to the customer is a great to solve the problem.” better determine everything from the way to grow trust,” Arnott said. “Our Although providing these right mix of fighter, aerial refueling and staff live and breathe the problems capabilities to customers is key to reconnaissance capabilities to the our customers face and are invested growing business, manager of the role advanced services and support in solving them.” Riyadh team AJ Curtis underscored might play in their plans—and budgets. No one understands that better the mutual benefit of partnering Exploring scenarios in this way helps than Rahul Bapat. Prior to joining with customers. “We’re not here to ensure mission success for military Boeing’s team in Bangalore, where he come in and sell something and then decision-makers well before the real manages the simulation facility, Bapat leave,” he said. “We’re here for the mission begins. spent several decades in the Indian long-term relationship.” n “Simulation and analysis allow you Air Force, culminating as a test pilot. [email protected] to fast-forward the future,” explained “Having local teams working local Raveeswaran Nagarajan, an operations problems, in the local language,” analyst in Boeing’s Bangalore facility. he said, “helps our customers view PHOTOS: (From far left) Software engineer “You can run exercises, then rewind our solutions as an indigenous Hyokyung Kim presents the results of a time to see what happened, what product—a big advantage in our study in Seoul, Korea; Alharith Almusa, foreground, operates a flight simulator in mistakes you have made and how competitive environment.” Riyadh, Saudi Arabia, as Azzam Alrajhi you can improve.” And through his air force looks on; the Analysis & Experimentation Teaming with these customers experience, Bapat can relate to the Lab in Seoul. ASSOCIATED PRESS
Frontiers May 2014 35 Expert findings Meet Boeing’s six newest Senior Technical Fellows, who are world-class authorities in their fields By Candace Barron
oeing people enterprisewide envision, design and build complex, highly capable engineering marvels Bthat improve lives for people worldwide—and captivate imaginations. Leading this effort are members of the Boeing Technical Fellowship, which make up the top 5 percent of the company’s talented technical workforce. At the upper echelon of the Fellowship are the company’s Senior Technical Fellows. These individuals are seen not just as aerospace-industry experts but as global authorities in their disciplines. And like their cohorts within the Technical Fellowship, they help Boeing teams overcome technical barriers to meet challenging customer business and mission needs. This year, the six employees featured here have been installed as Senior Technical Fellows. They represent a diversity of talent and experience, and include the second of two women currently amid this rank. Boeing employees can contact them, along with every one of their colleagues, on inSite. n [email protected]
36 Frontiers May 2014 Finding answers ERIC CREGGER
While some kids spout baseball stats, as a youngster Eric Cregger quoted performance information of World War II airplanes. By fifth grade, Cregger, a strong math student, had found a calling—aerospace engineering. Cregger grew up in Virginia and studied engineering at Penn State University. After a brief stint with General Dynamics, he was offered two positions: one in Baltimore and the other in Seattle. Cregger decided to head west, a choice he hasn’t regretted. “I’ve never picked jobs solely based on what they might do for my career,” he said. “Any promotion has come as a side benefit and is based on my ability to jump in, work on big challenges and have an impact.” Each day, Cregger said, he is energized by the fun of solving technical problems. While he worked for many months to resolve 787 side-of-body design issues, he was confident in the eventual outcome. Witnessing the first flight of the 787 Dreamliner from the flight line, he said, was the payoff for long hours spent searching for the fix. Spurred by an innate curiosity, Cregger said he is driven to figure out answers and solve problems not just locally but across the whole company. “I know I’m hooked when I’m fascinated in just finding the answer simply for the sake of knowing,” he said. n PHOTO: BOB FERGUSON/BOEING [email protected]
Frontiers May 2014 37 Data to knowledge ANNE KAO
Most people wouldn’t think of blending the fields of philosophy and computer science, but Anne Kao is not like most people. Born and raised in Taiwan, Kao traveled to the United States to study the philosophy of language. As a college student before the age of personal computers, Kao was turned off by the technology after watching peers struggle with punch cards and waiting days for data processing. But after computers took off in the late 1980s, she quickly realized that the machines spoke a language she wanted to understand. Since 1990, Kao has skillfully blended her passion for philosophy, language and text data to become one of Boeing’s foremost experts in data analytics. The essence of Kao’s research uses the philosophy of language as it relates to computer data to theorize how people view the world. At Boeing, she developed tools and solutions for an array of applications, including aviation safety, airplane maintenance and reliability, and knowledge discovery and management. Kao encourages others to take charge of their development plans. “Don’t sit around and wait for your next assignment. Chart your own course,” she said. “If you work hard and work smart, and have real influence, you can make it, too.” n PHOTO: MARIAN LOCKHART/BOEING [email protected]
38 Frontiers May 2014 The bigger picture ROBERT STUART
Rob Stuart was introduced to an engineering career as a high school sophomore—when his math and physics teachers sat him down and told him that’s what he was going to do when he grew up. It was an example of how the right teacher at the right time can make a world of difference, Stuart said. “I wasn’t very good at math, but I had a good mechanical mind,” Stuart said. “Somehow, those teachers, they saw that in me.” Stuart grew up on a cattle farm in Arkansas. He learned his skills by helping his father fix and maintain machinery. He then earned a degree in electrical engineering from the University of Arkansas. Since then, Stuart has been living the dream as an aerospace systems engineer at Boeing. Based in Huntsville, Ala., he has done much of his work on a variety of space programs, and is currently the lead for Space Launch System stages product development. He also played a pivotal role in resolving technical issues surrounding the 787’s lithium ion batteries. “I set myself up to learn a broad base of knowledge,” he said about his career path. “Systems engineering requires an understanding of the bigger picture and being able to think from several technical disciplines. And it’s exciting.” n PHOTO: ERIC SHINDELBOWER/BOEING [email protected]
Creativity in technology TIM MURPHY
In college, Tim Murphy started out perfectly happy as a Fine Arts major until he took a 100-level class called “electronic music.” “I thought we were going to be listening to Pink Floyd albums for college credit,” he recalled. “But it turned out to be a pretty serious electrical engineering class.” The professor was a synthesizer enthusiast, and the class was Murphy’s introduction to theoretical concepts such as frequency and amplitude modulation. It was the first time that he realized engineering could be a creative endeavor. Even though Murphy was not particularly drawn to math, he engrossed himself in studying technical papers about FM synthesis and in doing computer-generated music experiments. After a couple of years, he changed his major to electrical engineering. Murphy, now an expert in satellite navigation, communication and surveillance, has spent nearly 30 years in aerospace technology. But he still holds a fondness for the arts. He is a keyboardist in a jazz band that gigs regularly. He plays guitar and sings. His expertise extends to pottery, too. “But I enjoy being creative with technology as well,” he said. n PHOTO: MARIAN LOCKHART/BOEING [email protected]
Frontiers May 2014 39 Engine of advancement JAY CARSKADEN
Growing up in Hawaii, Jay Carskaden understood the importance of air travel—a means of connecting his islands in the Pacific Ocean to the rest of the world. It spurred a lifelong passion for aviation in general and jet engines in particular. Although Carskaden was interested in aerospace early on and was recruited by Boeing during the University of Hawaii’s annual engineering career week, his employment was not a foregone conclusion. After missing the deadline for setting an interview time, he added his name to the waiting list and hoped for the best. On the last recruiting day, a spot opened up. Carskaden joined Boeing Propulsion’s “90-day engine study” team where he focused on one small part. “This experience allowed to me to observe Boeing’s experts in action, as they drove to meet an important and technically complicated goal. By the conclusion of the study, I was hooked,” he said. Now an expert in jet propulsion, Carskaden is a bit more formal these days. His job is to help select engine partners. Once a decision is made and challenges arise, he convenes people who will develop multidisciplinary and system-oriented solutions. But the love of engines and airplanes he experienced as a child remains. “After all, an airplane without an engine is just a glider,” he joked. n PHOTO: BOB FERGUSON/BOEING [email protected]
40 Frontiers May 2014 Ideas take flight JAMES CLAYTON
James Clayton didn’t feel guilty leaving the family farm on the Yakama Indian Reservation in Eastern Washington state to pursue an engineering degree. “Luckily I have two older brothers who stuck around to help out,” he said. After earning undergraduate and graduate degrees in civil engineering and structures and structural mechanics, Clayton knew he wanted to put his education to work at Boeing. “I grew up in the Northwest, and have always had a fascination with airplanes,” he said. “In first grade, I had photos of P-51 fighters on my notebook.” As a young engineer, Clayton started working on the 767 program designing the horizontal stabilizer and the floor support structure for the airplane’s fuselage. His work was soon noticed by Boeing Defense, Space & Security, which has requested his assistance on a variety of programs including the P-8A Poseidon maritime patrol aircraft and the KC-46A tanker. One of the most rewarding aspects of being an engineer, Clayton said, has been watching his ideas take flight from the runway. But the highlight of his career has been working alongside brilliant technical colleagues. “During my career, I was very fortunate to be a member of groups that had very senior engineers,” he said. “I’ve learned that you have to find those senior folks and learn what you can from them.” n PHOTO: BOB FERGUSON/BOEING [email protected]
Frontiers May 2014 41 Playing by the rules Global Trade Controls team works to support sales
and speed production—while ensuring trade compliance
By Marc Sklar
42 Frontiers May 2014 hen Kellie Levack’s phone folder. It contains the documents rang at 2 a.m., it was a they need to legally depart for and WBoeing flight-test crew arrive at each of their stops. Every needing quick answers. takeoff on an international leg is an A 787-9 had landed in Kona, Hawaii, export and every landing on those to continue remote flight testing after flights is an import. flying from a test site in Australia and If everything doesn’t go to plan, the local customs agent wasn’t sure or there is a last-minute change in the how to handle the paperwork. test schedule, there is one more thing “The flight-test director got to me in the blue folder—phone numbers and I explained where the agent should to reach the Global Trade Control sign the document and that we retain specialists who can help whenever the copies,” recalled Levack, a trade needed. Boeing’s businesses rely on control specialist with Boeing’s Global Levack and her teammates to help Trade Controls in Seattle. move everything from aircraft to parts A similar phone call to Levack, this to marketing materials in and out of all time at noon on a Saturday, ensured the countries where Boeing operates, a Boeing flight crew, waiting in their and in full compliance with global trade airplane on an airport tarmac in Chile, regulations. Levack, in turn, relies on didn’t take off until they could get her partners in Supply Chain Logistics, a customs agent on the airplane to Boeing Test & Evaluation, Supply stamp the paper needed to legally Chain Security, Corporate Finance depart that country. and other parts of the company. Before they depart on international Most of the time the import and flight tests, Boeing flight-test directors export compliance work is done well are handed a very important blue in advance, thanks in part to Global Trade Controls employees embedded within the company’s businesses and “Our focus is programs. This allows the group’s experts to advise their partners on the most effective export and import keeping trade strategies as well as make required preparations for moving parts and compliance products. It also can lead to potential new business. a competitive “Our focus is keeping trade compliance a competitive differentiator for Boeing, helping our global business differentiator for grow,” explained Kathryn Greaney, vice president, Global Trade Controls. “We Boeing, helping not only want to do an excellent job in meeting trade requirements, but we our global PHOTO: In the flight deck of a 787-8 test aircraft, Paul Newton, left, a business grow.” Boeing Test & Evaluation pilot, and —Kathryn Greaney, vice president, Kellie Levack, a Global Trade Controls specialist, review the plane’s export Global Trade Controls, Office and import documentation. of Internal Governance BOB FERGUSON/BOEING
Frontiers May 2014 43 want to do it in a way that saves our throughout the development of the a piece of paper with technical company time and money.” rules and spent years preparing for data, the Global Trade Controls team While Global Trade Controls implementation. Since the regulations makes sure Boeing can move it around supports Boeing’s day-to-day were implemented, Global Trade the world where and when it’s needed operations, helping keep parts flowing Controls and Boeing businesses have in compliance with all trade rules. to busy production lines and exporting been working together on capturing And, noted Greaney, by always products to global customers, it also the benefits. For example, some improving how Global Trade Controls has to adapt to rapidly changing global spare parts for CH-47 Chinooks supports the company’s businesses, trade regulations, Greaney explained. owned by the United Kingdom now saving time and money, it helps ensure In the United States, trade rules can be shipped under what’s called Boeing can continue to compete and are undergoing significant change, a license exception, meaning less grow globally. known as Export Control Reform. The paperwork and faster responses to Even if it means the occasional goal, announced by President Barack customer needs. 2 a.m. call. n Obama in 2009, is to ensure the “Although challenging at first, we [email protected] tightest control on key technologies, are now seeing the benefits of having while revising requirements on other a less restrictive environment in items to help U.S. companies which to operate, both for hardware compete globally. shipments and for the use of controlled PHOTO: Myiah Johnson, left, a specialist with Global Trade Controls, The first major rules changes technology in our program,” said works with F/A-18 Global Services & under these reforms took effect Boeing’s Maggie Ritchie, UK Chinook Support team members such as Larry last October. Global Trade Controls Programme Export representative. Hassel to support F/A-18 customers was engaged with the government So, whether it’s an aircraft or around the globe. RICHARD RAU/BOEING
44 Frontiers May 2014 NUMBER OF MILESTONES EMPLOYEES: Service Awards: Boeing recognizes the following employees in April for their years of service.
William Ackley Jesusa Elizalde Connie Lamm 01 55 years 55 YEARS Albert McDowell Allan Albright Verne Eller Rita Latty Lois Alford Diane Ellis John Layman 50 years Steven Allen Sharon English Joseph Leger George Becht Terrance Allen Thomas Ermel Dianna Lehman Alfred Brazil Jeffrey Altaras Richard Evans Stephen Lennon Lowell Jenkins Lori Ambrose Jon Fehrenbach Byron Lewis Neil Scott Steven Anderson Harold Fisher Robert Loesche James Solet Michael Andre Steven Fitzgerald Henry Loftin Thomas Armijo Gregory Fjellman John Lohrey Dwight Arney Robert Flaherty Joseph Lombardo 05 45 years 50 YEARS Gilbert Banford Debra Arnold Charles Flinchem Dianne Loux Guntis Ernesons Randall Auster Christine Fredericksen Charles Lubin Larry Fenton Paul Baczewski Craig Freeberg Jeffrey Lukins Robert Gawers Martin Barnes James Frohardt Michael Lundi William Haley Lori Battles Curtis Fukushima Anna Marchi Janet Monette Robert Beamer Steven Gagon Bradley Marino Doyle Bell Edward Garcia Larry Marshall 40 years Timothy Bell Teri Garten Richard Mc Kinley Jerry Bowman Tammy Ben Howard Gessel Gregory McBee Raymond Buchmann Joseph Berlino Richard Gildart David McCarthy 06 Duane Chapman Richard Beutz Rodney Goe Donna McCarty 45 YEARS Michael Cotton Bernard Bidgood Michael Goforth Stephen McDonough Nicholas Disalvo Daniel Blais Alan Grenville John McElroy David Ellebrecht Matthew Boyle Bernard Groceman Mark McGarrity Guy Essmeier Rosemary Bozan Alice Gruttola Craig McWilliams John Fox Noel Brandon Diane Gundersen Michael Meyers Donald Foy Dennis Brandow Thomas Hagale Mark Mihalco Ricky Galloway Robert Brewer Kimber Hansford Keith Miya Kenneth Hamilton James Broach Gary Hinds Cynthia Murphy Kathleen Henneford Jay Brown Kathy Hopp Gregory Musser 32 John Iverson Rodney Brown Clifford Horton Manuchehr Nassiri 40 YEARS Charles Jacobson Frank Bryant Guy Hutcherson Edwin Nester Lonnell Johns Randall Burbach Melvin Hutchinson Janis Newbill Richard Johnson James Bush Eugene Izumi Jerome Nnanabu Laurel Jones Conrado Caballero Mark Janes Donald Nordby Cleveland LaFlore Brian Campbell Gail Jarvis Kevin O’Brien
Donnie Lampkin Abraham Chavers Raymond Johnson Duane Oda 217 Steven Morgan Regina Clancy Sherry Johnson Cindy Ott 35 YEARS Christopher Root James Clayton Christopher Johnston David Ott Jeannie Sage John Cline Bobby Jones David Overcash Barbara Sawyer Robert Coad Warren Kansanback Daphne Page Mark Snyder Thomas Coalson Keith Kapp Jill Palumbo Kam Soo-Hoo Sheila Connoley Susan Kastel Angela Parvu David Cook Larry Keller Teddy Paull
Craig Swineford Rocky Thomas Thais Davis-Evans Wayne Kelly Tom Peterson 242 Phillip Tuggle Robert Deel Patti Kindle Kenneth Pidgeon 30 YEARS David Wade Helen Delaine Daniel Kinney Cary Politte Kyle Wakasugi Laurie Dewater Jeffrey Kirchgessner Tyrone Pollard Dennis Westbrook Judy DiCioccio Dean Knudtson Keith Pratt Charles Yankosky Craig Dodd Dale Kohn David Printy Daniel Dudley David Koza Bradley Reavis
Brian Duffy Arthur Kozai Robert Redwing 35 years Robert Durdy Gary Krantz Michael Reed 494 Michael Ackley Pamela Eakins Daniel Kuehl Roy Reid 25 YEARS
Frontiers May 2014 45 IN FOCUS Riders on the storm A Boeing P-8A Poseidon flies over a stormy Washington state coast recently. Based on the 737-800 commercial jet and assembled in Puget Sound factories in Renton and near Boeing Field, the P-8 is a maritime patrol and reconnaissance aircraft developed for the U.S. Navy as a replacement for the Lockheed P-3. The Poseidon is now in full-rate production and 13 had been delivered through the end of April. The Navy plans to eventually purchase 117. India also has ordered P-8 aircraft, with three delivered to date; Australia’s government recently approved acquisition of eight P-8A aircraft. PHOTO: LEO DEJILLAS/BOEING
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