June 2007 Volume VI, Issue II

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THE RIGHT APPROACH Customers such as Air India make India an immensely important market for Boeing. Here’s why a unified approach will help Boeing position itself and its customers for long-term success. 11.25" Bleed 10.75" Trim 9.875" Live Scale: 1.0" = 1" = 1.0" Scale: w 0 25 3C 4C 50 5100 75 41M 50C 41Y 50K 4 the 787 Dreamliner. In addition to communicating the 747-8’s improved environmental performance, the ads also reaffirm reaffirm also ads the performance, environmental improved 747-8’s the communicating to addition In Dreamliner. 787 the % campaigns in the United Kingdom. The ads highlight the model’s advanced features, many of which were pioneered by by pioneered were which of many features, advanced model’s the highlight ads The Kingdom. United the in campaigns

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ON THE COVER: An Air India 777-200LR jetliner in the airline’s new livery. Air India will use its forthcoming 777s and 787s for nonstop service from India to distant destinations, including those in the United States. Boeing graphic ©iStockphoto.com/Ven I COVER STORY ONE, FOR ALL 12 Forecasts call for India to be one of the world’s most active markets for both jetliners and defense products. Boeing’s strategy for long-term success in India calls for the company to emphasize a unified approach to an even greater degree than it has elsewhere.

In 1967, Boeing opened a facility in Everett, Wash., to THIS RUN’S 32 support manufacturing of the 747 jetliner. Forty years FEATURE later, Everett is the home of four successful airplane programs INCREDIBLE and is the workplace for more than 25,000 Boeing employees. STORY

BOEING FRONTIERS June 2007  A U.S. Navy F/A-18E Super Hornet, assigned to the “Top Hatters” of Strike Fighter Squadron 14, launch- 20 es off the flight deck of nuclear-powered aircraft carrier USS Nimitz. nication Speciali s t Seaman A pprentice John Scorza v y photo by M a ss C omm u nication U.S. N a

BUSINESS UNITS ABL’s big night The Airborne Laser recently met a major milestone 24 when it recorded its first in-flight firing of one of A force today, and tomorrow its lasers at a test target. Here’s a look at what transpired on The Super Hornet fighter aircraft offers more than this important day. After an intense teamwide effort to get 20 just immediate capabilities for warfighters today. to this point, would the team’s work be validated? Because the program has emphasized staying in tune with forthcoming warfighting needs, new capabilities are incor- porated into aircraft—whether in service or in the assembly A project that’s spot on process—as soon as these capabilities are ready. What makes the Advanced Tactical Laser spe- 26 cial? For starters, this airborne weapon will track a moving target miles away and direct withering light Where perfection matters and heat at it. What’s more, it represents people work- The proper and safe operation of the International ing together, as Boeing reached across the enterprise for 23 Space Station, flying far above the earth, requires components, engineering, system-analysis, fabrication and that the spacecraft’s many systems operate flawlessly. systems-integration resources to create the ATL. Boeing engineers help meet this critical need by writing the millions of lines of software code that run on computers across the ISS.

6 Letters 8 Historical Perspective 37 Focus on Finance 41 Around Boeing INSIDE 7 Notebook 10 New and Notable 38 Milestones 42 Spotlight

 June 2007 BOEING FRONTIERS June 2007 Volume VI, Issue II

787 Dreamliner work continues at the program’s supplier partners—including Spirit AeroSystems, 28 which is responsible for the nose section. The 787 program is working toward a major milestone in July: the rollout of the first airplane. P hoto co u rte s y of Spirit A eroSy tem

Keep rollin’ on Employees on the 787 team at Boeing and 28 its supplier partners are working diligently toward a July 8 milestone. On that date—which is 07/08/07 in the United States—the 787 Dreamliner will roll out of the factory in Everett, Wash. That event marks the next step toward the 787 and Boeing providing improvements in passenger comfort, eco- nomic performance and environmental stewardship.

FOCUS ON FINANCE Facilitating connections Tracey Gilbert, a St. Louis–based estimating 36 and pricing specialist in Integrated Defense Systems’ Support Systems organization, created soft- ware tools that help internal programs integrate data Tracey Gilbert (left) and Estimating teammate and systems. These tools ultimately improve estimating Todd Bond review two software tools she accuracy and streamline the bidding process to better 36 developed that help internal programs serve Boeing’s customers. integrate data and systems. peter george photo

BOEING FRONTIERS June 2007  n LETTERS

“I truly enjoy [Frontiers] CALENDAR OF EVENTS Publisher: Tom Downey and read it cover to cover.” Editorial director: Jo Anne Davis —Frank Bacci, University Place, Wash. June 11: 2007 Boeing Human Modeling Symposium. Renton, EDITORIAL TEAM Wash. See http://human-mod- Editor: eling.web.boeing.com on the Paul Proctor: (312) 544-2938 Boeing intranet. This event Managing editor: Having been in the precedes the 2007 Society of Junu Kim: (312) 544-2939 business of technology Automotive Engineers Digital Designer: application for Boeing’s Human Modeling for Design Heather Dubinskas: (312) 544-2118 Rotorcraft products for and Engineering Conference Commercial Airplanes editor: many years, I have seen (June 12–14 in Seattle). Dick Schleh: (206) 766-2124 countless examples of June 18–24: Paris Air Show. Integrated Defense Systems editor: our ability to design and Paris. See www.paris-air- Diane Stratman: (562) 797-1443 build highly energy ef- show.com Engineering, Operations and ficient and cost-effective June 24–28: 17th Annual Sym- Technology editor: systems. Inevitably, air- William Cole: (314) 232-2186 posium of the International craft, satellites, ground Council on Systems Engineer- Shared Services editor: systems—indeed, most Mick Boroughs: (206) 919-7584 ing. San Diego. See www. of the major systems we incose.org/symp2007 Copy editor: build as a company—are Walter Polt: (312) 544-2954 Aug. 6–9: Unmanned Systems great because they make North America 2007. Wash- CONTRIBUTING EDITORS effective use of limited ington, D.C. See www.auvsi. Corp.: energy sources. org/symposium Donna Mikov: (425) 965-4057 Thus, I believe that Aug. 11–14: 2007 Air Carriers if we are seeking new ONLINE PRODUCTION Purchasing Conference. Orlan- opportunities for revenue do, Fla. See www.acpc.com Production manager: Thanks, folks and growth, we—as a com- Alma Dayawon: (312) 544-2936 Sept. 3–6: Asian Aerospace ust wanted to let you know pany with a long history of 2007. Hong Kong. See www. Web designer: tackling tough challeng- how much I enjoy the mag- asianaerospace.com Michael Craddock: (312) 544-2931 J es—should apply our skills, azine. As a Boeing retiree I Sept. 17–19: SpeedNews 8th Graphic artists: technologies, tools and facili- did not know about Boeing Annual Aviation Industry Sup- Heather Dubinskas: (312) 544-2118 ties to help lead the world to Cal Romaneschi: (312) 544-2930 Frontiers until a fellow vol- pliers Conference in Toulouse. unteer at SeaTac airport greater energy efficiency and Web developers: long-term economic prosper- Toulouse, France. See www. Lynn Hesby: (312) 544-2934 brought his in to show me an speednews.com/Conference Keith Ward: (312) 544-2935 article. I truly enjoy it and ity through focused product development in this area. Sept. 18–20: American Institute Information technology consultant: read it cover to cover. of Aeronautics and Astronau- Tina Skelley: (312) 544-2323 —Frank Bacci —Jim Butt Philadelphia tics’ Space 2007 Conference University Place, Wash. and Exhibition. Long Beach, Calif. See www.aiaa.org How to contact us: Powerful idea E-mail: nergy and energy effi- [email protected] assembles the above ciency are hot topics for Boeing Frontiers Mailing address: E listings for the convenience of its read- Boeing Frontiers the world these days. Our ers only, and they do not constitute an MC: 5003-0983 customers, both in the United endorsement by The Boeing Company. 100 N. Riverside Plaza States and around the world, Times, dates and subject matter are sub- Chicago, IL 60606 are seeking to make better ject to change or cancellation. If you have Phone: and more environmentally any items you wish Frontiers to consider (312) 544-2954 for the Calendar, please e-mail them to sound and cost-effective use Fax: [email protected], or send (312) 544-2078 of energy resources, as a them by regular mail to Boeing Frontiers simple matter of economic magazine, 100 N. Riverside, MC: 5003- Web address: www.boeing.com/frontiers competitiveness. 0983, Chicago, IL 60606-1596. Send all retiree address changes to Boeing Frontiers, MC 3T-12 P.O. Box 3707 Seattle, WA 98124-2207 Letters guidelines Postmaster: Send address corrections Boeing Frontiers provides its letters page for readers to state The opinions may not necessarily reflect those of The Boeing to Boeing Frontiers, MC 3T-12 their opinions. The page is intended to encourage an exchange Company. Letters must include name, organization and a tele- P.O. Box 3707, Seattle, WA 98124-2207 of ideas and information that stimulates dialogue on issues or phone number for verification purposes. Letters may be edited (Present addressees, include label) events in the company or the aerospace industry. for grammar, syntax and size.

 June 2007 BOEING FRONTIERS n NOTEBOOK

SNAPSHOT Welcome to Everett The late-April arrival of the first Boeing 787 Dreamlin- er horizontal stabilizer assembly marked a major step toward final assembly of the new airplane. The horizontal stabilizer, manufactured by Alenia Aeronautica in Foggia, Italy, arrived at the Boeing facility in Everett, Wash. It was - ed in five pieces aboard the Dreamlifter (below), a specially modified 747-400 used to transport 787 major assemblies. Gail Hanusa photo

QUOTABLE

e will see [2006] as he 787 Dreamliner symbol- hese tasks could never a year in which we izes the environmentally have been achieved if Wturned the corner and Tkinder aircraft of the fu- Twe did not have such positioned ourselves for a ture—cleaner, quieter and truly a responsive global airlift very strong future.” the best experience in the air.” capability.” —Jim McNerney, Boeing chairman, president —Sir Richard Branson, chairman of Virgin —Air Commodore Jack Plenty, commander, and CEO, during his address at the 2007 Atlantic Airways, on the airline’s recent order Air Lift Group, Royal Australian Air Force, re- Boeing annual meeting of shareholders for 15 787-9 Dreamliners, in the April 25 ferring to intercontinental, time-critical tasks New York Times handled by the RAAF’s first C-17 Globemas- ter III, during a May 11 delivery ceremony for the RAAF’s second C-17

IAM PROMOTIONS ETHICS QUESTIONS? No promotions listed for periods ending You can reach the Office of Ethics & Business Conduct at 1-888-970-7171; Mail Code: 14-14; Fax: 1-888-970-5330; April 27 and May 4, 11 and 18. TDD/TTY: 1-800-617-3384; e-mail: [email protected]; Web site: http://ethics.whq.boeing.com

BOEING FRONTIERS June 2007  n HISTORICAL PERSPECTIVE Reach for the sky How the Bomarc missile set the stage for Boeing to demonstrate its talent in systems integration

An IM-99B Bomarc is ready for launch from one of the later-model shelters at the Eglin Air Force Base, Fla., test range in 1962. BOEING ARCHIVES PHOTO

Tale of the tape: Bomarc versions

Model IM-99A IM-99B Speed Mach 2.5 Mach 2.5 (tested to speeds of Mach 4) Range 250 miles (400 kilometers) 440 miles (710 kilometers) Length 46 feet 9 inches (14.2 meters) 45 feet (13.7 meters) Wingspan 18 feet 2 inches (5.54 meters) 18 feet 2 inches (5.54 meters) Number of production 269 301 models built

 By Michael Lombardi

t was one of the most ambitious mili- tary programs of its day, and it estab- Ilished Boeing as a leader in large-scale systems integration. The program was Bomarc, a supersonic surface-to-air mis- sile that was the world’s first long-range antiaircraft missile and the first missile Boeing mass-produced. Today, the need to defend the United States and allied nations against ballistic missile attacks has made the Ground-based Midcourse Defense Program (GMD) a U.S. priority. In the mid 20th century, the con- cern was the Soviet Union’s nuclear weap- ons program and the capability of Soviet long-range bombers to reach the continental United States. Those grave concerns made a layered area defense against bombers a priority for the U.S. military.

As a result, the U.S. Air Force in 1949 BOEING ARCHI V E S photo authorized Boeing to proceed with re- search into a new supersonic antiaircraft Boeing employees perform Bomarc manufacturing at the Boeing Missile Production Center missile. Two months after the go-ahead, the in Seattle. Boeing ended up building 570 production Bomarc missiles. Michigan Aeronautical Research Center (MARC) was added to the research project— which was then labeled “Bomarc,” a combi- nation of the names Boeing and MARC. Feb. 24, 1955. The IM-99A was powered by sile’s own seeker could lock on to a target In January 1951, Boeing was awarded an Aerojet–General liquid-fueled rocket and detonate the missile’s warhead at the a contract to develop the missile, which motor that boosted the missile to near closet point of pass or upon impact. was given the designation XF-99. At that supersonic speed. At that speed, twin Boeing built 301 production IM-99B time, these missiles were considered pilot- Marquardt ramjet engines, attached by py- missiles. In all, between 1957 and 1964, less aircraft, since their mission was to in- lons to the underside of the missile, pro- Boeing built 570 production missiles and tercept enemy bombers, and were given an pelled the missile to its target at Mach 2.5 another 130 for various tests. “F” for fighter designation. Later the Air to a range of 250 miles (400 kilometers). Bomarc was a successful program that Force refined its designation system, and Boeing built 269 production IM-99As. met all of its original objectives. But the the Bomarc became the IM-99 (Intercep- One major issue with the early Bomarc nature of the nuclear threat had changed tion Missile). The first of the XF-99 re- was the main booster’s highly corrosive from primarily bombers to ballistic mis- search missiles flew on Sept. 10, 1952. liquid rocket fuel. This fuel could not be siles. In 1970, Congress declared that a Leading up to Bomarc, Boeing had stored on board the missile and had to be continental U.S. air defense missile sys- gained experience in surface-to-air missiles loaded before launch, a process that added tem was no longer necessary and that with a pioneering program called GAPA nearly two minutes to the missile’s launch the primary defense would be an irre- (Ground to Air Pilotless Aircraft). As World time. Fortunately, Thiokol developed a sistible offense supplied by the Strategic War II was coming to a close, Boeing’s lead- large solid-fuel booster that Boeing used to Air Command. On Oct. 1, 1972, the last ership, foreseeing the sharp decline in air- replace the liquid-fueled motor. The result Bomarc was retired from service. plane orders, decided the company needed was the much safer and better-performing The valuable engineering and produc- to diversify its postwar products. One new IM-99B Super Bomarc, which had a re- tion experience gained from Bomarc, as area of products was missiles. sponse time of less than 30 seconds. well as from the design and development In June 1945 Boeing began work on The B model had increased range of of the base facilities and ground equip- GAPA, designed to intercept aircraft flying 440 miles (710 kilometers). While its stat- ment, gave Boeing all it needed to be the at speeds up to 700 mph at altitudes be- ed cruise speed was Mach 2.5, the B model prime contractor for one of history’s big- tween 8,000 and 60,000 feet (or 1,130 kilo- had been tested to speeds of Mach 4 and gest military programs: the Minuteman meters per hour, between 2,440 and 18,300 was effective from sea level to 100,000 intercontinental ballistic missile. Bomarc, meters in altitude). The missile combined feet (30,480 meters). and to a greater extent Minuteman, helped a rocket-powered first stage and a ramjet- Bomarc was integrated into the cen- build Boeing’s reputation as a world lead- powered upper stage. GAPA didn’t go into tralized command-and-control air-defense er in large-scale systems integration. This production but did provide experience that system for Canada and the United States, core competency continues to this day on a became the foundation for Bomarc. known as SAGE (semi-automatic ground number of programs, in particular the 787 The first production model of the environment). The system would guide the and . n Bomarc was the IM-99A, which first flew on Bomarc to incoming targets until the mis- [email protected]

BOEING FRONTIERS June 2007  n NEW AND NOTABLE Lean takes flight

iarized Woodland Park with the 3P meth- see right away if our design fit the intend- Seattle zoo gets hand odology to help them “lean out” the exhib- ed space, and ultimately avoid problems it-design process and dramatically reduce with layouts on paper not matching,” from Boeing, uses 3P introduction times. The production prepa- Bohmke said. ration process is a Lean tool that designs In the coming months, the team will to design new exhibit and implements production processes, tools work on the exhibit’s mechanics and fur- and equipment to increase efficiency. ther enhance the mockup to help build en- By Carrie Thearle One of the many investments Boeing thusiasm for the project among potential makes in local communities, as in this donors. The zoo plans to break ground on hen the Woodland Park Zoo in case, is contributing the expertise of its the new penguin habitat next year with Seattle was first introduced to the employees to help local organizations the exhibit opening in 2009. WLean practice called 3P, the “p” remain successful and available to ev- Lisa Dabek, Woodland Park’s conser- might as well have stood for penguin. That’s eryone looking for services, educational vation director, said, “We really appreci- because the first exhibit where the zoo, with experiences and recreation. ate how Boeing has helped us learn about Boeing’s help, is applying this principle— The zoo formed a cross-functional 3P Lean.” n the production preparation process—is a team and launched a series of workshops [email protected] new habitat for its Humboldt penguins. to understand the Lean principle better. Last year, the Boeing Commercial Shawn Pedersen, who as acting collections Airplanes Lean Enterprise Office famil- manager oversees the penguins’ daily ac- The ABCs of 3P tivities, is one of the 3P team members. “What What is 3P? the team quickly learned 3P (production preparation process) is a was that both time and Lean methodology that focuses on elimi- money could be saved nating waste at the product or process

Jim C oley photo if we provided more up- design stage. When a team uses 3P, it front information in the creates and tests alternative designs and design process,” said process options—and eliminates the in- Pedersen. ferior ones. Then the team builds physical To do that, the team models and performs simulations to iden- produced several of its tify the best option that requires the least own designs and chose time, material and money. Whereas other one to pursue. Bruce Lean methods take a process as a given Bohmke, Woodland and seek to make incremental improve- Park’s deputy director ments, 3P offers the potential to make and facilitator of the “quantum leap” design improvements that team’s exercises, said can enhance performance and eliminate the next step was to test waste beyond that which can be achieved the design by construct- through continuous improvement alone. ing a full-scale model of the layout—a hall- When do I use 3P? mark of 3P. Generally, anything that has a lot of “By building a full- complexity to it is a good candidate for size mockup, we could 3P. The method is an appropriate Lean tool to use when you are introducing a new product, have a change in a product Shawn Pedersen, acting or process, are experiencing chronic collections manager at problems in an area, or are experiencing Woodland Park Zoo in significant changes in volume. Seattle, oversees the activities in several zoo How do I learn more about 3P? exhibits—including the To find out more about 3P, visit the Lean+ penguin habitat. The zoo Web site at http://leo.web.boeing.com on tapped Boeing’s Lean expertise to help it come the Boeing intranet and click on “Prod- up with ideas for a new ucts and Services” in the toolbar. penguin area.

10 June 2007 BOEING FRONTIERS n NEW AND NOTABLE

Global opportunities For Shane Arnott, applying to work at Boeing had one clear attraction. “The job ad said you’ll prob- ably have to go overseas,” said Arnott, Boeing facility director for The Portal and an Australian native. “Within six months I was placed in the U.S. working between Los Angeles and Seattle.” Later he returned to Australia to help get the Boeing Systems Analysis lab on track, and now is in the United Kingdom for his current position. Arnott became one of Boeing’s youngest Technical Fellows in 2002 and is continuing his personal development working on his doctorate from the University of Queensland in Australia. Having left a small software company for Boeing a decade ago, would he recommend Daran Crush (left) and Shane the company to young engineers? “I would, Arnott, directors of The Portal for particularly for the high-technology areas,” he QinetiQ and Boeing, respectively, said. “You get to work on big, challenging prob- view reports at The Portal, their lems—the sort of problems you just wouldn’t companies’ new modeling center in Farnborough, England. have a chance to address in a small company.” QINETIQ Photo —Marc Sklar

It is a capability that includes a team of U.K. nationals, made up of operations analysts A Portal into the future and specialist engineers, that will provide services to Boeing in the U.K.,” said Shane Arnott, Boeing facility director for The Por- tal. “A nice facility and all the technology in QinetiQ’s U.K. facilities, allowing for in- the world is nothing without good people.” New facility boosts teroperability tests across three continents. The opening of The Portal marks an- “The Portal gives us local capability to other step in supporting IDS’ U.K. growth. IDS’ presence in U.K. engage the MOD, to understand their needs In April, Boeing opened a systems engi- and to explore solutions,” said Guy Higgins, neering and integration facility in Bristol, By Marc Sklar Boeing vice president, Analysis, Modeling, England (see Page 40 of the May 2007 Simulation and Experimentation. “In addi- Boeing Frontiers). Both openings come as ext month, Boeing and British tion, we bring extensive experimentation the MOD implements a Defense Industri- firm QinetiQ will jointly open The experience and large-scale systems integra- al Strategy (DIS) that strongly emphasizes NPortal, a modeling, simulation, tion and production expertise, and QinetiQ, procurement of U.K.-developed products, analysis and experimentation (MSA&E) the largest U.K. research firm, brings an in- systems and intellectual property. center in Farnborough, England. The fa- timate knowledge of the customer.” “Boeing decided to invest in The Por- cility is part of Boeing’s growing foot- QinetiQ has a long history support- tal before the DIS was released,” said print in the United Kingdom. Both com- ing the MOD. It’s developed fundamental Eugene Beckles, director for International panies see it as a decision-support center technologies, supported ongoing opera- Analysis Modeling & Simulation. “The for collaboration and experimentation tions, and tested and assessed equipment policy confirmed we needed this capabil- with programs and customers—primar- before it is brought into service. ity in the U.K.” ily the U.K. Ministry of Defence. “The Portal will enable us to bring to- While The Portal marks a first for The center can conduct experiments at gether complementary expertise from Boeing in the United Kingdom, it builds all levels of conflict, as well as homeland QinetiQ and Boeing to support custom- on strong capabilities and brings them security scenarios, in a facility that’s near ers’ aspirations, and cost-effectively close to a key customer. MOD personnel. Using the Boeing Labo- deliver state-of-the-art network-enabled “With each new MSA&E facility we, ratory Network—a network with multiple capabilities,” said Jeremy Ward, QinetiQ’s Boeing, are better able to engage the cus- locations to conduct simulation and test ac- sales director, Command and Intelligence tomer, conduct experimentation and offer tivities—The Portal can tie into Boeing’s Systems Division. solutions.” said Arnott. “The Portal is a integration centers, Virtual Warfare Center For Integrated Defense Systems, The tangible example of Boeing’s commitment and other U.S. facilities; the Boeing Sys- Portal fits its strategy of expanding its U.K. to the MOD.” n tems Analysis Laboratory in Australia; and presence. “The Portal is more than a facility. [email protected]

BOEING FRONTIERS June 2007 11 n COVER STORY The right approach India has tremendous potential for all of Boeing. Here’s what Boeing is doing to set itself and its customers up for long-term success

12 June 2007 BOEING FRONTIERS n COVER STORY

The Air India Express subsidiary of Air India operates Boeing By Junu Kim 737-800s. Not only do each of its 737-800s bear unique designs on the tail, but each side of the tail shows a different image. icture this: There’s a nation with a population of 1.1 billion, and where a city of five million people is considered small. PThis country has a burgeoning economy that’s capitalizing on its expertise in manufacturing and high-tech industries. With that growth comes an increasing demand for air travel. Yet the air- lines there collectively have only about 230 airplanes. Little won- der that forecasts predict this nation’s carriers will need more than 850 jetliners over the next 20 years. Now picture this: With its economic expansion, this same na- tion sees itself as having an expanded role in international affairs, both regionally and globally, and needs to expand its military ca- pabilities. In addition, this country has ushered in a new era of partnership with the United States—which now lets U.S. defense firms conduct business in this nation. That nation exists: It’s India. Little wonder that Boeing views India as one of the company’s most important international mar- kets. Accordingly, Boeing is undertaking a strategy to position it- India at a glance self for the best chances of long-term success in this market—and to create the most value for its many stakeholders, including its Location: Southern , bordering the Arabian Sea and the Bay customers in India and employees around the world. This plan of Bengal, between Burma and Pakistan calls for Boeing to emphasize a one-company approach to an even Area: 1,269,219 square miles (3,287,263 square kilometers); greater degree than it has elsewhere. slightly more than one-third the size of the United States “India is a priority market for Boeing,” said Jim McNerney, Estimated population: 1.1 billion Boeing chairman, president and chief executive officer. “We have a solid business plan and a long-term view of the market. With this Capital: New Delhi approach we are going to create even greater value for Boeing and Other major cities: Mumbai, Chennai, Kolkata our customers and partners in India.” Total gross domestic product, 2005: $805.7 billion; ranked 10th worldwide Jet travel grows Boeing has had a long and successful relationship with India, as Estimated GDP growth rate, 2006: 8.5 percent Boeing airplanes have served this market for more than 60 years. Main export partners: United States, United Arab Emirates, China, Indeed, India joined the jet age on Boeing wings, and Air India in Singapore, United Kingdom 1962 earned the distinction of being the world’s first all-jet airline with its fleet of Boeing 707s. Sources: Republic of India, CIA World Fact Book, World Bank In the late 1960s, Boeing delivered the first of many 747s to Air India. The airline now operates 11 747s, along with four 777-200s and 13 737-800s. In addition, other India-based carriers such as Jet Airways, SpiceJet and Air Sahara have ordered Boeing airplanes. The number of airplanes ordered by India-based carriers has mushroomed in recent years. Since the start of 2005, they have ordered 138 Boeing jetliners (see box on Page 15). Among these orders: one in December 2005 from Air India for 68 airplanes, the biggest-ever civil aviation order in India’s history and that year’s largest aviation-industry order (in terms of price). Those jetliners are needed to meet a rapidly growing number of passengers. According to Boeing, India’s current annual pas- senger traffic growth stands at 25 percent, and this rate is pro- jected to continue. This recent expansion hints at India’s potential for Commercial Airplanes. According to BCA’s Current Market Outlook, Boeing foresees that India will need 856 airplanes worth $72.6 billion over the next 20 years. That potential dollar figure is about double what BCA forecast only two years ago, said Dinesh Keskar, vice president–Sales for BCA. The reasons for this expanded demand for jetliners in India correlates with factors BCA traditionally has identified as leading to air travel increases (see box on Page 14). “Boeing has sold nearly $20 billion worth of jetliners [at list prices] since the start of 2005,” Keskar said. “Now we need to Jim ander s on photo Continue on Page 14

BOEING FRONTIERS June 2007 13 n COVER STORY

Jet Airways recently took the delivery of the first of 10 Boeing 777-300ER (Extended Range) airplanes. The airplane was delivered in Jet Airways’ new paint scheme, featuring a new design, colors and typeface. Tim Stake Photo

Continued from Page 13 A textbook case of growth remain intently focused on delivering on the promises we’ve The increase in India’s airline passenger traffic is based on economic fac- made to these customers.” tors that Commercial Airplanes historically has identified as correlating with Yet in a market with such enormous potential, there are chal- air-travel growth. Here’s a look at what’s driving India’s demand for flying. lenges—notably the nation’s aviation infrastructure. Serving a Economic growth. One of BCA’s market-analysis axioms is that growing number of air travelers means there’s greater demand for air-travel demand correlates strongly with gross domestic product. pilots, mechanics and facilities, including airports. India represents the latest proof point to this theory. According to The Boeing is using its resources to support India in ways that align World Factbook issued by the U.S. Central Intelligence Agency, the with the company’s competencies—and to show that Boeing’s Indian economy has grown by an average of about 7 percent a year commitment to its partnership with India does not end with the in the decade since 1996, thanks in part to the country’s tremendous sale of an airplane. As part of the historic Air India order agree- ment, Boeing last August said it would invest $100 million in a number of people with high-tech skills. planned regional maintenance, repair and overhaul facility in Pent-up travel demand. No doubt, India’s economic growth is impres- Nagpur, India. In addition, Boeing subsidiary Alteon will establish sive. But put that growth in a nation of more than 1 billion people, and a training center in India, and Boeing has provided a $10 million you have a market with enormous potential demand for air travel. grant to fund select pilot-training schools in the nation. In 2004, about 15 million people in India traveled on long-distance “Boeing is committed to helping its customers succeed. It’s also trains—many more than the number of domestic air travelers. Last year, committed to helping strengthen India’s air transport infrastruc- the number of people on long-distance trains jumped to 20 million—but ture,” Keskar said. “Boeing has collaborated with India for more the number of travelers on domestic flights ballooned to 30 million. than 60 years, and we are excited to take part in the amazing future Air-travel liberalization. Over the last 15 years, India has moved to that lies ahead for Indian aviation.” liberalize the nation’s airline industry. That’s meant an increase in the number of domestic airlines in India. In addition, recent signings of “open New defense role skies” agreements between India and the United States, the United Yet India’s demand for aircraft and services extends beyond Kingdom, China, Australia and the member countries of the Association the civil arena—and creates another tremendous opportunity for of Southeast Asian Nations have encouraged international airlines to Boeing. “On the defense side, the potential business for Boeing serve this market. As a result, passengers have more choices in where in India is estimated at $10 billion to $15 billion over the next 10 they want to go and more flexibility in when they want to go. years,” said Mark Kronenberg, vice president–International Business Development for Integrated Defense Systems. “That figure puts India

14 June 2007 BOEING FRONTIERS n COVER STORY

right at the top tier, as one of the world’s largest defense markets.” Repeat customers India recently launched a massive defense modernization drive Orders for Boeing airplanes placed by Indian airlines since Jan. 1, 2005 after reevaluating its role in the world and its region and conclud- ing that its armed forces were not a match for its stature. “India has been called upon to play a more decisive and re- Number of sponsible role in world affairs, particularly in the Asian region. Customer Order placed Model airplanes This has led us to rethink our priorities,” said K.P. Singh, India’s defense production secretary, quoted by Associated Press at this SpiceJet February 2005 737-800 10 year’s Aero India air show. “We are in the process of acquiring Jet Airways August 2005 737-700 2 fresh capabilities for all three wings of our armed forces to opti- mize their operational effectiveness.” 737-800 8 What makes this evolution of India’s geopolitical role more no- Jet Airways September 2005 777-300ER 10 table for Boeing is a shift in the U.S.-India relationship. In recent years, the two nations have forged a closer strategic relationship. Air India December 2005 777-200LR 8 President Bush and Indian Prime Minister Manmohan Singh have exchanged visits to each other’s nations. Both countries have also 777-300ER 15 participated in numerous joint military exercises. And a signifi- 787-8 27 cant impetus was given in December when the U.S. Congress en- dorsed an agreement that calls for the United States to share nucle- Air India December 2005 737-800 18 ar technology with India for its civilian nuclear reactors (see Page Express 10 of the February 2007 Boeing Frontiers). Air Sahara January 2006 737-800 10 This step in the evolving U.S.–India relationship opened the SpiceJet August 2006 737-800 5 door for Boeing, along with other U.S.-based firms, to seek busi- ness from the Indian government that has traditionally gone to non- 737-900ER 5 U.S. defense companies—notably those in Russia and European Jet Airways December 2006 787-8 10 nations. “The closer U.S.-India strategic relationship bodes well for our participation in India’s defense market,” said Anil Shrikhande, SpiceJet April 2007 737-800 10 India country leader for IDS. Total airplanes ordered 138 Also auguring well for Boeing is the fact that India’s emerging defense needs align well with the IDS product and service portfolio. Note: ER is Extended Range; LR is Longer Range Continue on Page 16

An F/A-18 Super Hornet stands on the tarmac at this year’s Aero India air show, as a C-17 Globemaster III airlifter takes to the skies. The Indian Air Force is expected to issue a Request For Proposal for 126 multirole fighter aircraft. Boeing representatives said the Super Hornet could meet the needs stated in the RFP. Kevin Flynn Photo

BOEING FRONTIERS June 2007 15 n COVER STORY

Continued from Page 15 Those needs include multirole fighter jets, heavy-lift helicopters, stakeholders, including customers and employees—is to approach naval training aircraft and antisubmarine aircraft (see box below). this market as a unified manner. “There’s not solely a BCA strat- egy or an IDS strategy. We have clear business-unit priorities and The right approach objectives, but we’re taking an enterprise approach in India,” said Although Boeing’s two major business units have their own Ian Thomas, president of Boeing India. game plans for securing new business, Boeing executives repeat- This approach places a tremendous emphasis on Boeing teams edly emphasized that the company’s most important strategy for and people working together. That emphasis goes beyond Boeing long-term success in India—and for generating value for Boeing India’s office in New Delhi to having shared assets across the enter- prise to address relevant functions, including supplier management, human resources, engineering, industrial participation and others. Although both IDS and BCA recognize the tremendous poten- tial of their respective markets, they’re at vastly different stages of their business lifecycle in India. Not only has BCA spent many more years in India than IDS has, it’s also conducted business with the Indian government: The Indian Air Force soon will operate Boeing Business Jets to transport dignitaries. Accordingly, there’s a tremendous benefit in maximizing Boeing’s knowledge of the Indian market, its customers and business practic- es. That’s especially important on the defense side, where Boeing will be competing against non-U.S. companies that already have de- Continue on Page 18

The Indian Air Force will operate Boeing Business Jets to transport Indian dignitaries.

Something for every need “The total life cycle cost will enter into the equation,” said Chris Chadwick, vice president and general manager of Global Strike Systems, an IDS busi- India’s potential defense acquisitions align with the platforms and services ness. “We will be cost competitive with the competition from both a unit used by other Integrated Defense Systems customers. Here’s a look at a flyaway perspective and from a total life cycle perspective.” few of the many products and services IDS could provide. Antisubmarine aircraft: The Indian Navy is currently evaluating a Boeing- Multirole combat aircraft: The Indian Air Force is expected to issue a led proposal to develop and deliver eight P-8I long-range maritime recon- request for proposal (RFP) for 126 aircraft. It’s believed that India will naissance and antisubmarine warfare aircraft. The P-8I is a variant of its request an aircraft capable of both air-to-air and air-to-ground combat. P-8A Poseidon, currently in development for the U.S. Navy and a derivative In addition, indications are that India will seek highly advanced radar and of the Boeing Next-Generation 737-800 aircraft. network-centric technologies to provide interoperability with other Indian and allied forces; and a growth path to incorporate future technologies Weapon systems: In response to an Indian Air Force request for proposal that would further augment capabilities. for antiship missiles, Boeing offered its Harpoon missile. Boeing has deliv- ered more than 7,000 Harpoons to more than 25 customers. Boeing representatives said the F/A-18E/F Super Hornet meets these needs. Furthermore, the aircraft offers an edge in reliability, maintainability Heavy-lift helicopters: India is considering issuing an RFP for heavy-lift and life cycle costs. helicopters. To help address that need, Boeing would consider offer- ing the CH-47 Chinook, which was one of several Boeing aircraft that captured attention at February’s Aero India 2007 air show. In late 2005, U.S. Army Chinooks conducted humanitarian missions in neighboring Pakistan after a major earthquake.

U.S. A RMY P H O T Carrier-jet training aircraft: The Indian Navy has a need for carrier-jet training aircraft, for which Boeing would offer the T-45 Goshawk. Select Indian Navy pilots currently are in the United States training on T-45s with the U.S. Navy (see Page 24 of the April 2007 Boeing Frontiers).

The Chinook helicopter has performed humanitarian missions in South Asia. Here, U.S. service members prepare to load supplies onto a CH-47D Chinook helicopter in Pakistan, in support of relief efforts for victims of a 2005 earthquake.

16 June 2007 BOEING FRONTIERS n COVER STORY

SpiceJet is emulating the low-cost- carrier business model sucessfully used by airlines such as Ryanair and Southwest Airlines. JIM COLEY PHOTO

costs; a one-class interior configuration; and high utilization. An interesting Who’s who among India’s airlines SpiceJet fact: 40 percent of its passengers are first-time air travelers. India-based airlines are projected to need 856 airplanes worth $72.6 bil- Air Deccan lion over the next 20 years, according to Boeing. Here’s a look at some of the notable carriers in India. Type: Low-cost domestic carrier Approximate number of jetliners*: 19 Air India Key jetliners in fleet: Airbus A320 Type: Full-service airline; national flag carrier Key jetliners on order: Airbus A320 Approximate number of jetliners*: 47 Air Deccan, India’s first low-cost carrier, is seeking to enter India’s smaller Key jetliners in fleet: Boeing 747-400, 777-200ER, 737-800; cities. Like SpiceJet, Air Deccan has a high percentage of first-time air Airbus A310 travelers. As part of its efforts to increase air-travel interest, it recently ran Key jetliners on order: Boeing 787-8, 777-200LR and -300ER, 737-800 a promotion in which it offered 500,000 free tickets. Air India, owned by the Indian government, has been a Boeing customer since IndiGo Airlines the 1960s. Its mammoth 2005 order for 68 airplanes, valued at more than Type: Low-cost domestic carrier $11 billion at list prices, includes 18 new 737-800s. The 737-800 airplanes, operated by the carrier’s Air India Express operation, will fly passengers in a Approximate number of jetliners*: 9 one-class configuration to destinations throughout Southeast Asia and the Gulf Key jetliners in fleet: Airbus A320 region. The Indian government is in the process of finalizing plans to merge Key jetliners on order: Airbus A320 Air India and Indian Airlines, another state-owned carrier. Indian Airlines, which Indigo is a fledgling carrier that’s following a business strategy similar to primarily operates domestic and regional routes, operates a fleet of A319s and SpiceJet. It made a splash at the 2005 Paris Air Show by announcing an A320s and has an order for additional A320-family aircraft. order for 100 A320s. Jet Airways Kingfisher Airlines Type: Full-service domestic and international airline Type: Full-service domestic airline Approximate number of jetliners*: 63 Approximate number of jetliners*: 19 Key jetliners in fleet: Boeing 737-700, -800 and -900, 777-300ER; Key jetliners in fleet:Airbus A319, A320, A321 Airbus A330 Key jetliners on order: Airbus A320, A321, A330, A340 and A380 Key jetliners on order: Boeing 787-8, 777-300ER, 737-700 and -800 Kingfisher is owned by United Beverages Group, which makes the popu- Jet Airlines is India’s largest privately-owned airline in. It recently received lar Indian beer Kingfisher. The airline started as a low-cost carrier but is its first of 10 777-300ERs, which will be used to fly to Europe—and, now offering multiple service classes to compete with Jet Airways. King- starting later this year, then on to the United States and Canada. It recently fisher is the first India-based airline to have ordered the A380, which it closed its acquisition of India’s Air Sahara, which Jet Airways will position would operate internationally (pending Indian government approval to in a niche between a low-cost carrier and a full-service airline. serve markets outside the nation). SpiceJet Go Air Type: Low-cost carrier Type: Low-cost domestic carrier Approximate number of jetliners*: 11 Approximate number of jetliners*: 5 Key jetliners in fleet: Boeing 737-800 Key jetliners in fleet:Airbus A320 Key jetliners on order: Boeing 737-800 and -900ER Key jetliners on order: Airbus A320 SpiceJet is following the business model of successful airlines such as Go Air is owned by the Wadia family, owner of Bombay Dyeing, a major Southwest Airlines in the United States and Ryanair in Europe. That model Indian textile company. The airline in one of the latest start-ups in India. includes a fleet of one airplane type, to contain maintenance and training * Excludes regional jets

BOEING FRONTIERS June 2007 17 n COVER STORY

That will raise everybody’s prospects,” Thomas said. There’s one other important aspect of the one-company strat- egy. Should India deals require industrial participation, or the placement of work in another nation, an enterprisewide approach can help maximize the benefits for both Boeing and the other country. Boeing representatives said such agreements would constitute opportunities to create strategic industrial alliances and partner- ships that would help support existing Boeing programs. India Air India has been operating the Boeing 747 since the late 1960s. features a large English-speaking technical talent pool that gives The airline’s most notable next step in its long-time partnership the nation’s IT companies and research institutions world-class with Boeing was its 2005 order for a total of 68 787, 777 and 737 capabilities. airplanes—the year’s biggest jetliner order, in terms of price. These strategic alliances and partnerships “will create the

boeing archi v e s photo kind of customer insight, relationships and footprint on the ground that we need, and those relationships will aid our global competitiveness,” Thomas said. veloped relationships with India, as well as U.S.-based firms. Boeing officials emphasized that these offset arrangements “We are leveraging our existing BCA presence, starting to would support existing Boeing programs and the jobs of people operate as an integrated enterprise in-country under one roof working on them, both in the United States and in other nations. and harnessing the synergies from a ‘one company’ strategy,” “It’s of paramount importance that if we’re going to be success- said IDS’ Shrikhande. ful here and competitive in a global sense, we have to partner with Furthermore, this approach means that Boeing aims to extend Indian industry to leverage benefits of India and help them move its presence in India beyond sales. This activity includes strate- up the value chain,” Thomas said. “Offset is not a zero-sum game. gic relationships with Indian research, manufacturing and infor- Being agile and adaptive and innovative internationally and in In- mation technology firms—areas where India has proficiency and dia will protect jobs and contribute to the bottom line. India will be that support Boeing’s strategies (see box below). India graduates spending billions of dollars on commercial airplanes and military about 200,000 engineers a year, compared to about 80,000 annu- aircraft. That is protecting Boeing jobs.” n ally for the United States. Through this approach, Boeing hopes to [email protected] get the most benefit from its involvement in India—and to position itself for the long haul in that nation. “We are bringing the best of Boeing to India. We can also bring the best of India to Boeing.

Established in India As a sign of Boeing’s involvement in India, here’s a partial list of the many partnerships Boeing has with companies and universities in that nation. Partnership category Partial list of participants Involvement Information technology supplier/partner Wipro Various companies handle IT projects. Areas of work include flight Infosys test and embedded systems, manufacturing systems, business processes, engineering systems and airplane support systems Infotech Tata Consultancy HCL Technologies

University Indian Institute of Science In early 2005, Boeing announced its partnership with the IISc in Bangalore to conduct research in aerospace materials, structures and manufacturing technologies. The alliance provides Boeing with innovative ideas, and it helps infuse the best of these tech- nologies into Boeing.

Airplane component manufacturing and Hindustan Aeronautics Ltd. HAL performs work including making aircraft components (such related-services supplier/partner as 777 Main Landing Gear Uplock Boxes) and assemblies, and digitization of engineering drawings.

Engineering and construction Larsen & Toubro In February, Boeing signed a memorandum of understanding with Larsen & Toubro, India’s largest engineering and construction company, for the joint exploration of business opportunities in India’s defense sector.

18 June 2007 BOEING FRONTIERS n COVER STORY

ness partners,” said Neha Gupt, SSG regional leader for Middle East, Africa Boeing India integrates offices and India. “As Commercial Airplanes, Integrated Defense Systems and Boeing International integrate, so must Shared Services.” New facility displays one-Boeing strategy A long-range plan built last year with participation by all these groups pro- When Boeing relocated its office in New Delhi earlier this year, the Boeing vided the foundation for the lease at the new site in Nehru Place, a major India team moved into a more efficient workspace—and into the forefront business center located in the heart of South Delhi and a major hub of the of the company’s integrated global business strategy. Indian information technology industry. “The strong, enterprisewide group based in Delhi is working closely “Long-range planning at our international sites involves all of our business together as one team under one roof to shape the market, win new busi- units taking a holistic view of their operations and goals in the country or ness and make our customers successful,” said Ian Thomas, president of region,” Quinn said. The payoff is lower operating costs and easier access Boeing India. to key services: finance systems, IT, staffing, procurement and facilities. Keeping in step with this integration of global business operations, Lean growth Shared Services Group is implementing a global, integrated service delivery strategy for Boeing. The new facility supplants the previous Boeing office in New Delhi, opened in 2003. By applying Lean principles such as standardization “By helping integrate Boeing’s operating infrastructure, we allow our and eliminating waste, the office design accommodates the growth business partners to focus on customer needs,” said Tracey Quinn, Shared of the India team with efficiency. “We use a standard office size and Services business support leader for International Services. encourage shared use,” Gupt said. The office dividers and the computer Anil Shrikhande is India country leader for Integrated Defense Systems. and telephone systems allow offices and desks to be rearranged easily “Being under one roof helps us present a unified image to our stakehold- and to permit mobile workers to plug in conveniently. ers,” he said. “And it helps the free flow of information between members A drop-in space for visitors and members of the Boeing-India team who of the Boeing-India team as we roll out the enterprisewide strategy.” don’t work regularly in New Delhi avoids the waste of unused offices. Larry Coughlin is director of India Operations for Commercial Airplanes. Video conferencing capabilities allow the New Delhi office to function as “Clearly, having the team assembled in one office facilitates communi- a focal point for the rest of the Boeing worksites in India. “We designed cation and hence the integration of India activities across the business meeting and gathering spaces, like the lobby and conference rooms, so units and support organizations,” he said. “The Delhi office, with its lean they could be shared,” Gupt said. The conference room can be used as a in-country team, is well-positioned to support the growing Boeing pres- classroom or reconfigured into individual work desks. ence elsewhere in India.” —Steve Davis Planned growth “We worked hard at understanding the business goals of our major busi-

Neha Gupt (left), Shared Ser- vices Group regional leader for the Middle East, Africa and India, talks to Lizum Mishra, director, Corporate Commu- nications, India, in the Boeing India office conference room. It’s equipped to support enterprisewide meetings and improve cross-team workflow.

19 n INTEGRATED DEFENSE SYSTEMS o n Sp e c ia l ist 3r d C ass Jo shua Sco tt vy p h o t b y Mass C omm uni c ati

Staying out front U.S. N a

that our customer doesn’t have to wait for An F/A-18E Super Hornet assigned to the Vigilant customer focus something to become available.” “Eagles” of the U.S. Navy Strike Fighter Boeing is currently building Super Hor- Squadron 115 launches off the Nimitz- drives upgrades for class aircraft carrier USS Ronald Reagan. nets under a contract with the U.S. Navy The F/A-18E provides the Ronald Reagan for 210 Super Hornets. Through 2011, the Strike Group with a strike fighter that has F/A-18 Super Hornet Navy plans to buy a minimum of 460; significant growth potential and increased just last month, Australia signed a con- range, endurance and ordnance-carrying capabilities. By Kathy Cook tract for 24 of the jets. From the beginning, the Super n the movie industry, it’s called a sleep- Hornet program defied conventional air- er—a film that doesn’t seem to grab craft design, which dictated that upgrades much publicity initially but turns out to be incorporated in blocks (adding several been increasing the aircraft’s capabilities, I it’s also strongly focused on decreasing the be a great film. capabilities at once much like car manu- The Super Hornet could be considered a facturers do for a particular model year). aircraft’s unit cost. sleeper of the aerospace industry. Through While the Super Hornet program divides “We have generated almost $2 billion in its gradual spiral development, the fighter its aircraft into blocks for planning pur- savings to the (U.S.) government and taxpay- plane has quietly but steadily become a poses, each engineering change is incor- ers through our first two multiyear procure- devastating force for the United States and porated into aircraft in the assembly pro- ments, by involving the team and applying its allies. It offers real and immediate capa- cess as soon as a single new capability is Lean,” said Gower. “We are prepared to bilities for today’s forces, and the program ready. New capabilities are retrofitted, as drive the cost down even further if the Navy team ensures that it’s keenly in tune with available, on earlier models. elects to contract for a third multiyear con- forthcoming warfighting needs. As a result, the customer always has the tract. We are committed to continually pro- “The Super Hornet is one of the most most capable aircraft in its squadrons and viding the new systems the customer wants capable weapons system in the air to- on its flight decks. Boeing currently is de- and needs at the lowest possible cost.” day and the foreseeable future,” said Bob livering Block II Super Hornets, with new Gower, Boeing vice president for F/A-18. systems and upgrades that have been add- Systems make a difference “We are continually adding new capabil- ed incrementally over the past two years. The new systems aren’t usually visible to ity and upgrading or refining systems so Although the Super Hornet team has the casual observer, but they make signifi-

20 June 2007 BOEING FRONTIERS n INTEGRATED DEFENSE SYSTEMS

two-seat F/A-18F, the pilot can secure the Super Hornet fast facts airspace, while the weapon systems officer in the aft cockpit can prosecute a target on Missions: All-weather precision attack, maritime strike, air-defense suppression, close-air support, the ground, Gower said. air superiority, electronic attack, reconnaissance, fighter escort, air-refueling tanker That ability to defend airspace while Maximum takeoff weight: 66,000 pounds (29,900 kilograms) delivering bombs is augmented by anoth- er system, which also was introduced in- Maximum landing weight: 44,000 pounds (20,000 kilograms) crementally. The Joint Helmet-Mounted Maximum speed: Greater than Mach 1.6 Cueing System, provided by Vision Engines: Two General Electric F414-GE-400 turbofan engines with afterburner System International under contract to Boeing, projects critical information onto Total thrust from engines: 44,000 lbs. (195 kilonewtons) of thrust; 9-to-1 thrust-to-weight ratio the aircrew’s visors, literally connecting Total delivered as of May 2007: 313, all on or ahead of schedule what’s seen by the pilot and weapon sys- tems officer. Instead of having to physi- How many the U.S. Navy intends to buy: 460 cally point the nose of the aircraft at a tar- Weapons carriage: 11 under-wing, wing-tip and fuselage store stations can carry 27 different types get to be able to attack that target, either of air-to-air and air-to-ground weapons crew member can select a target simply by Number of arresting cables on an aircraft carrier for the aircraft to “trap” on landing: 4 looking at it and identifying it as the target, without changing the aircraft’s course. Number of U.S. Navy F/A-18E/F squadrons: 21 The system originally was intended for Price: The current “flyaway” price is $53.8 million. This includes several items such as engines and the pilot, but the helmet is now being used ejection seats that are government-furnished equipment. in both the forward and aft cockpits. That creates the added benefit of improving information-sharing among the aircrew. A symbol on the aircrew member’s display cant differences to the men and women who “It’s a game-changer,” said Capt. Don- shows where the other crewmember is fly these jets. One of the newest advances is ald Gaddis, the Navy’s F/A-18 program looking. Confirming that both have iden- Staying out front the plane’s advanced sensors and radar— manager, about the new radar. tified the same target is as simple as veri- the APG-79 Active Electronically Scanned This new radar has greater capability fying that both symbols are “looking” in Array (AESA) radar, provided by F/A-18 and range than previous radar systems, the same place. program teammate Raytheon. AESA ra- providing significant tactical ranges for tar- The helmet, working with the aircraft’s dars feature short-to-instantaneous (milli- geting both air and surface targets. It also targeting sensors—such as the Advanced second) scanning rates and have a desirable offers near-simultaneous air-to-air and air- Targeting Forward-Looking Infrared low probability of intercept. to-ground operations. As a result, in the (ATFLIR) sensor and a new digital solid- state recorder—allows the crew to work in a networked environment with other air and ground elements to effectively prose- cute a number of targets. One scenario, Gower said, could have v id L . Smart the crew heading into a target area, view- ing what it believes to be the target through the ATFLIR streaming video, frame- grabbing a still image of that target, and sending it via datalink to an air controller on the ground. That controller would veri- fy the target and identify friendly forces or other key elements on the image, and send it back to the aircraft so the crew could de- liver a weapon on target—all in a matter of minutes and while the aircraft is still quite a distance from the area.

A sailor verifies the weight of an F/A-18F Super Hornet assigned to the “Black Aces”

nication Speciali s t Seaman A pprentice D a v y photo by M a ss C omm u nication of Strike Fighter Squadron 41 prior to launch aboard nuclear-powered aircraft

U.S. N a carrier USS Nimitz. The Nimitz Carrier Strike Group deployed in April in support of operations in the U.S. Central Command area of responsibility.

BOEING FRONTIERS June 2007 21 n INTEGRATED DEFENSE SYSTEMS

He knows a smart plane when he sees one No one has to tell Steve Klaus the Super Hornet is evolutionary. He knows it firsthand. An avionics technician on the F/A-18E/F flight ramp in St. Louis, Klaus was there when the first Engineering, Manufacturing and Develop- ment jet, F-1, rolled out in 1995. And he can tell you just how different today’s F/A-18E/F Block II Super Hornet is from its predecessors. “It’s definitely a smarter airplane,” said Klaus, who checks the plane before test flights and troubleshoots any issues that occur during test Ri c ha r d Rau p h o t flights. “This airplane will tell us what’s wrong with it. It will even tell us where to look.” From Klaus’ view as an aircraft maintainer, the Steve Klaus, an avionics technician on the flight plan in place that defines what’s next biggest change over time has been in the jet’s flight ramp in St. Louis, will tell you the for the aircraft. That includes distributed F/A-18E/F Block II Super Hornet is a avionics reliability. “The avionics today have smarter airplane than its predecessor. targeting; net-centric operations and bat- fewer problems. We don’t change black boxes tlespace management; sensor integration; as frequently as we did early in the program; and advanced weapons. and the software has fewer ‘bugs’ in it,” he One of the planned systems is the In a media briefing this spring, Gaddis said. “The fault-reporting systems that run in Infrared Search and Track (IRST) sys- the background, the self-diagnostics, are more demonstrated how effective these systems tem—a passive, long-range sensor system can be by showing an ATFLIR video that in-depth and robust and monitor more systems that searches for and detects long-wave in- than ever before. This is necessary since the highlighted individuals in Iraq planting frared emissions within its field of view. It aircraft is more complex.” improvised explosive devices into a road- can track several targets simultaneously bed. The aircraft used its systems to effec- and provide an effective air-to-air target- That complexity means Klaus needs more tools tively target and eliminate the threat from ing capability, even when facing advanced in his toolbox. Among them, he said, is “one a significant and safe distance. threats with radar jamming equipment. that you can’t pull out of a drawer: knowledge. These are just a few of more than a doz- The Navy will begin funding IRST next The new technology, the new systems that en major systems, upgrades and refine- summer with a planned integration into are constantly being added to the plane–they ments Boeing and its industry partners the aircraft by 2013. demand constant training.” have added to the aircraft since it first flew IRST is just one of the capabilities in the in 1995. The Super Hornets made today Klaus is proud of the Super Hornet, of his indi- offing for this aircraft that is continually vidual contribution and that of the entire team are “way beyond the capabilities of earlier evolving according to customers’ needs. versions,” Gower said. in making a real difference in the defense of the “People talk about aircraft generations,” United States and its allies. Gower said. “We think those lines are Future plan in place blurred; we think of the Super Hornet as next “This team really cares about the plane and the As important as these capabilities are generation because it’s continually evolving pilots who will fly it in extreme environments, today, the Super Hornet has never rested on to stay ahead of the threat. Our mission from such as a carrier deck,” he said. “We know we its laurels. The team—a best-of-industry day one has been to provide today what our need to make the best aircraft in the world. And teaming of the Navy, Boeing and its ma- customers will need tomorrow. And we’ve that’s what we do.” jor subcontractors, Northrop Grumman, made that mission a reality.” n —Kathy Cook Raytheon and General Electric—has a [email protected]

22 June 2007 BOEING FRONTIERS n INTEGRATED DEFENSE SYSTEMS Perfection’s required

the software for environmental control, life forming well on orbit,” he said. Boeing engineers write support and thermal control (removing heat Huntsville engineers write the software from the electronics), as well as payload and integrate it for ISS elements built at software that keeps ISS, operations. “All of the systems that circu- Marshall. They also recently finished soft- late the air, maintain correct temperatures ware for Node 2, which is slated for launch its payloads working and keep the equipment cool are the types later this year and will serve as a connect- of control software we do,” said Jay Kissell, ing module for the Japanese Experiment By Ed Memi Boeing ISS Huntsville software manager. Module and Columbus laboratory. About 60 Huntsville engineers develop “The on-orbit performance and reliabil- t runs quietly in the background, open- and test vehicle software. About two dozen ity of the ISS software is a direct result of ing and closing valves, turning on fans folks develop software to support science process discipline and maturity, attention Iand ensuring critical systems and pay- payloads (experiments installed in refriger- to detail, and the personal commitment loads work properly. It’s the software that ator-sized racks in laboratory modules) and and accountability of our software engi- controls the International Space Station as payload experiments developed by NASA, neers,” said Boeing Huntsville chief engi- it flies more than 220 miles (350 kilome- universities and other organizations. neer Daniel Olberding. ters) above the earth—software that’s run The ISS’ capabilities have evolved, and Engineers in Houston stay busy provid- non-stop by Boeing and NASA engineers. the software requirements are different to- ing all the top-level command, control, These engineers make up a team of soft- day than when the program was first estab- communications and power management ware and hardware specialists that ensures lished in the 1990s. “A lot of the software software and hardware. Once new soft- the ISS operates as it was intended. Boeing has been instrumental in finding better ware is written, a formal qualification test engineers wrote the millions of lines of ways to operate the thermal or the environ- is performed to make sure it works proper- software code that run on computers across mental life-support systems,” Kissell said. ly. After that comes a stage test in a Hous- the ISS. The software brings safety-related Kissell said the software needs to be ton lab, where the software is loaded and features that are critical in space. perfect. “It is very satisfying and reward- integrated with the rest of the software on Boeing engineers at the Marshall Space ing to see our software work in a test en- station in an integrated ground-test envi- Flight Center in Huntsville, Ala., provide vironment and then ultimately see it per- ronment. Boeing engineers work closely with NASA engineers at Houston’s John- son Space Center, who upload software changes following checkout. “We focus on building the flight and ground software for the payload control for the racks, and then test the software utiliz- ing the ground tools and equipment,” said M ike c C ormick photo Mike Faulkner, Boeing ISS Payload Rack Software manager in Huntsville. Boeing also writes the software that al- lows the astronauts to use laptops to com- municate with payloads. The payloads are also designed so that users can build their own unique displays and command in- terfaces. This lets them send commands through Marshall Space Flight Center that are routed to the station. n [email protected]

Boeing software design engineers Allen Johnson (foreground) and Mark Rockwell evaluate International Space Station flight software in Huntsville, Ala. Their evaluation tool is based on a simulation component that provides a visual indication of the performance of the flight software.

BOEING FRONTIERS June 2007 23 n INTEGRATED DEFENSE SYSTEMS

Their work’s on target

ter months of ground tests, flight tests and Also in flight that night was Big Crow, a An account of the night constant analysis of data, it was time for U.S. Air Force KC-135 test plane with one the Airborne Laser (ABL) to live up to its very distinguishing feature: a white mis- ABL made its first name with the first in-flight firing of one of sile painted on a black fuselage to simulate its lasers at a test target. a missile in flight, complete with a plume in-air laser firing Up in the night sky aboard ABL, a emulator to simulate the flame and heat as- By David Sidman modified Boeing 747-400F, the flight crew sociated with a missile in flight. of 14 was ready. They were cruising high That simulated missile was the night’s ou are clear to engage.” above the Pacific Ocean, a short flight from target. ABL was clear to engage. The order The command was con- Edwards Air Force Base, Calif.—ABL’s to fire the tracking illuminator laser was “Ycise, clear, and welcome: Af- U.S. west coast headquarters. given. This was the moment of truth for a

24 June 2007 BOEING FRONTIERS n INTEGRATED DEFENSE SYSTEMS

cessfully fire the tracking illuminator laser Ray then gave the five-word command (TILL) for the first time in flight and get a to fire the TILL laser: “You are clear for return signal about the target into the ABL Falkor” (the name of the fire-breathing, system. It was a critical milestone for the flying dragon from the 1979 fantasy novel program—which, when operational, will “The Neverending Story”). fulfill part of the Missile Defense Agency’s When the ABL fired its tracking laser vision for a layered missile defense system for the first time at Big Crow’s simulated to protect the United States, deployed forces missile, it wasn’t like a movie with great and allied nations against ballistic missiles. special effects. There was no red beam, no ABL is designed to detect, track and spectacular explosions and no sound. In- destroy ballistic missiles while in the stead, the low-power tracking laser sent an boost—or launch—phase. In an engage- infrared beam to the target. ment, the TILL would be the first of three lasers to be fired. The low-power TILL would hit the missile and provide target- ing information to ABL. A second low- “Tonight’s the power laser would then be used to deter- mine and compensate for atmosphere- induced distortions before the third and fi- big night.” nal laser, a high-energy beam, would make — Mike Rinn, deputy program manager contact with the missile and destroy it. for the Airborne Laser, before the aircraft Watching the ABL team in motion, Mike took to the air to make its first in-flight Rinn, deputy program manager for ABL, firing of one of its lasers made a prediction. “We will show [Missile Defense Agency director] Gen. [Henry] Obering we can do what we said we would,” Rinn said. “Tonight’s the big night.” Infrared light is invisible to the eye, The two planes lifted off the runway. like the signal a TV remote control sends ABL with its distinctive nose-mounted to a television set to change the channel. turret that houses the laser-beam point- The results of this test, however, were ing system was first, followed by Big Crow anything but invisible. The Airborne Laser recently made its with the painted missile on its side. ABL successfully fired its TILL laser first in-flight firing of one of its lasers Once the planes were in the air, coor- three times that night. Special cameras on at a test target. Piloting this modi- dination focused on that night’s test. With Big Crow’s wings captured images of the fied Boeing 747-400F was Boeing test intercepts. The laser light transmitted tar- pilot Doug Benjamin. “The piloting one plane in the sky set to fire a laser at is challenging, but that part is trivial, another plane, communication between get data back to ABL. The first open-air compared to the stuff the mission the planes and the control room would be firing of an ABL laser was successful. crew is making happen” to fire the critical. Data from both aircraft flowed “Firing the TILL and getting informa- laser, he said. into the control room, where the mission’s tion back into our system on the simulated

orp. photo K ellie M a s ter / TYBRIN C orp. test director Mitch Ray reviewed the list of target’s range was a significant step for- 64 “Go/No-Go” parameters. Each had ward for the program,” said Greg Hyslop, to be a “Go” prior to the authorization to ABL program manager for Boeing. “This team that had put in a tremendous amount open-air lase. success positions us well for our next mile- of work. Would their efforts be validated? In addition to the data from the systems stone, which is firing the other solid-state Here’s a look at this recent important aboard each aircraft, Ray was monitoring laser, the beacon illuminator laser.” day for the ABL program. air traffic control information and C-band The beacon illuminator laser (BILL) radar data. Also, he was in communication detects—and determines how to compen- with the test conductor aboard ABL who sate for—atmospheric turbulence that the It was two hours before takeoff, and acted as the in-air focal point for the mis- high-energy laser will encounter in its path ABL was being prepared for flight on the sion crew and its systems. to the target. The final test for ABL will be 417th Test Flight Squadron’s tarmac. The Nearing the end of the checklist, Big when both the TILL and BILL lasers are ground crew serviced the plane while Crow was told to activate its plume emula- fired, followed by the high-energy laser, at flight crew members conducted their mis- tor, the heat source that made the painted a simulated target. sion briefing. At the top of everyone’s missile look like it had a plume of flame. After the successful lasings that night, minds: safety, adherence to proper pro- Once Ray cleared ABL to engage, ABL’s the team landed and debriefed. They then cedures, and accomplishment of that eve- sensors detected the target, its turret was had one more process to complete. Said ning’s flight-test goals. pointed and the plume detected. With ABL flight test manager John Parks: “Every That’s where the similarities between focused on the target and Mission Control time we make our next major step, we buy this and the previous 59 missions ended. verifying readiness, it was now time for the ice cream for the team.” n This mission’s objective was to suc- TILL to be fired for the first time. [email protected]

BOEING FRONTIERS June 2007 25 n INTEGRATED DEFENSE SYSTEMS

represents Boeing’s best COIL laser ex- the target, you can pull the trigger and pertise developed over many years.” it happens,” said Ron Dauk, who led the ATL is people working together. “I ATL optical-control team and is director joined team members assembled from of programs at Boeing-SVS in Albuquer- Fielding U.S. Air Force and Boeing organizations— que, N.M. “You don’t have to wait for air including Commercial Airplanes—all pull- or ground support.” ing in the same direction,” said Wally Page, • There’s no telltale exhaust. The on- on loan from Boeing in St. Louis. Page ar- board laser has a sealed exhaust system rived at the team during the ATL’s transfer with a Boeing-patented cryogenic pumping laser from lab to aircraft, so his practical experi- application. It ensures only inert nitrogen ence with the F-15 and C-17 aircraft made gas escapes during operation. him an important integrated product team • “Jitter” doesn’t matter. The optical- leader. “This leveraging from all of Boeing control system, while it is finding and will be a key to success,” he added. locking on the target, detects the slight- What is distinctive about ATL? A lot: est movements, called “jitter,” on the dreams • There’s no time lag. The beam trav- four-turboprop aircraft—and instantly els at the speed of light. Plus: “If you see neutralizes them. Boeing-SVS designed All-Boeing team works to develop a precise in-air weapon B ob ferg us on photo

By Walter Polt

t’s precise. It’s selective. It’s remote. It performs invisibly day or night. IIt’s airborne. You can select a spot on a moving target many miles away, and it will track—and direct withering light and heat at—that spot. It’s the Advanced Tactical Laser, field- ing multiple Boeing technologies. “Ex- perts from around the company (see box at right) have come together to integrate the 45,000-pound (20,000 kilogram) system,” said Cliff Hall, program director, Airborne Tactical Lasers, and ATL program manag- er at West Hills, Calif. A chemical oxygen-iodine laser (COIL) installed in a C-130 aircraft will engage a wide range of ground targets via a turret extending below the plane. The laser was designed at West Hills, Calif., where Jeff Hambleton is the Boeing laser integrated product team manag- er. “This is a fourth-generation chemical oxygen-iodine laser,” Hambleton said. “It

Seen reflected in the Advanced Tactical Laser turret below a C-130 at Kirtland Air Force Base, N.M., Stuart Penner (left) and Sean Burkland, engineering technicians, confer in “the trench.” The 140-foot (43-meter) tunnel leads to a wide canyon for testing of the ATL sighting mecha- nism—and to find and track targets more than a mile (about 2 kilometers) away.

26 June 2007 BOEING FRONTIERS n INTEGRATED DEFENSE SYSTEMS

and built this system; it is a combination of algorithms coordinating advanced tech- nologies such as fast-steering mirrors, sensors and Global Positioning System instrumentation. • Things around it are not affected. “That is the game changer,” Dauk said. “The laser beam concentrates all the en- ergy in a very small area.” Indeed, after extensive testing, its final U.S. Air Force exam will be twofold: to surgically destroy a communication tower and to disable a moving truck. The Advanced Tactical Laser was made cost-effectively and quickly. “The optics team showed we can go from an idea on a map to placing new hardware into the plane in three years,” Dauk said. “In the laser business, that is most impressive.” While building this intricate optical hardware, the team saved time and mon- ey using simulations and analysis to test the design. “We measured the vibrations on the plane—then used large shakers and shook the hardware,” Dauk said, “and showed it did its job: At first you’d see the [surrogate] laser spot wiggling around all over the place [on the target board]; turn on the mirror system—you see the spot sit- B ob ferg us on photo ting perfectly still.” Technical Fellow Chris Musial (left) and George Rosier, Boeing-SVS real-time software engi- Kirk Powell, Optical Control inte- neers, check Advanced Tactical Laser operator consoles onboard a C-130 at Kirtland Air Force grated product team lead, said the Boeing Base, Albuquerque, N.M. Screens on the left display target images from two cameras with dif- team validated this state-of-the-art optical- ferent magnifications; screens to the right show aircraft location and ATL system status. control system “from end to end” in April. Similar swiftness—coupled with cau- tion—shaped the whole program. For safety during ground tests at Kirtland Air Force Base in Albuquerque and the flight Thanks for pitching in tests that followed, a low-power laser re- To create the Advanced Tactical Laser, Boeing reached across the enterprise for components, engi- placed the high-energy COIL. neering, system-analysis, fabrication and systems-integration resources. Here’s who contributed. “In flight, the surrogate laser propagated to a target board on the ground,” Powell said, “while infrared cameras and sophisticated ATL elements Boeing providers algorithms scored and analyzed the results.” The surrogate laser, said Shawn O’Keefe, Program management Boeing West Hills, Calif. Test Execution lead, will be used for the Design and building of high-energy chemical oxygen- Boeing West Hills, Calif. dual final exam too. “Then,” he said, “the iodine laser high-energy COIL system will be installed, Design and building of optical-control module Boeing-SVS at Albuquerque, N.M. integrated, and tested with the optical- control system. The full-power ground and Building of battle management system with two Boeing Huntington Beach, Calif. flight tests are expected this year.” operator stations Why is ATL important? “The ATL advanced concept technology demon- Building of turret retraction system Boeing Huntsville, Ala. strator,” Hall said, “will provide the Integration of hardware on C-130 aircraft Boeing Fort Walton Beach, Fla. warfighter the first airborne tactical directed-energy capability. There is a Final integration and testing Boeing West Hills, Boeing-SVS, with strong commitment from the Air Force to Boeing-LTS group at Kirtland Air Force bring directed energy to the battle—and Base, N.M., and final flight testing at ATL will lead their efforts.” n White Sands Missile Range, N.M. [email protected]

BOEING FRONTIERS June 2007 27 n COMMERCIAL AIRPLANES

Getting ready to roll

Employees on the 787 team at Boeing As 787 parts take shape around the 787 team’s aiming and its supplier partners are work- world, the main link to the global manufac- ing toward the July 8 787 Dreamliner turing network has already hit the ground for 07/08/07 rollout— Premiere—one of the many milestones running. The first of a fleet of four Boeing along the path of this revolutionary air- Dreamlifters—specially modified 747s and to fulfill promises plane. Through their efforts and use of that transport 787 major assemblies—has innovative Lean manufacturing process- been busy in recent months. Picking up By Scott Lefeber and Travis Ness es, the 787 Dreamliner soon will roll out and dropping off 787 parts from program eep this date in mind: July 8, of the factory—and will be aloft later this partners around the world, the Dreamlifter 2007. That’s 07/08/07 in the year, on its way to provide improvements is demonstrating its importance in the pro- United States. in passenger comfort, economic perfor- duction of the Dreamliner. The recent de- K mance and environmental stewardship. livery flights are also serving as flight tests It’s an easy date to remember for Boeing stakeholders—especially for employees of for the Dreamlifter’s certification. Boeing and its global partners who sup- Dreamlifter as ‘integrator’ “The Dreamlifter is an unbelievable port the airplane. A big part of turning the 787’s promises integrator that is changing the way we do On that day, the first 787 is set to roll out of into performance is the task of coordinat- business,” said Gary Blattenbauer, 787 se- the Boeing factory in Everett, Wash. ing the airplane’s large supply network. nior global logistics manager. “I like to refer

28 June 2007 BOEING FRONTIERS n COMMERCIAL AIRPLANES

Watch the 787 rollout event live on 07/08/07 The 787 Dreamliner Premiere will be available for the world to view. In an unprecedented move, the event will be broadcast live via satellite TV and a live webcast in nine different languages at 3:30 p.m. Pacific time on July 8—or 07/08/07 in the United States. To view the event live • View a webcast over the Internet. Visit www.boeing.com or www.newairplane.com to be connected. • In the United States, the show will be broadcast live on the Dish Network satellite TV system and DirecTV system. There is no additional charge to those subscribing to these systems. Further details and channel information will be posted on www.boeing.com closer to the 787 rollout event date. • The show will be broadcast in Europe, Asia and the Middle East on a number of different satellite sys- tems. Additionally, the broadcast can be received by anyone with a DVB “Direct Video Broadcast” satellite receiver. Channel information will be published on www.boeing.com closer to the 787 rollout event date. The hour-long ceremony will be produced and broadcast in nine languages, using language- specific commentators broadcasting in their own cultural style. These languages include English, Arabic, Chinese, French, German, Japanese, Korean, Italian and Spanish. In addition, closed cap- tioning will be provided in English. Not sure what time 3:30 p.m. Pacific time on Sunday, July 8, is at your location? Here’s a handy table.

Location Day and time Seattle (U.S. Pacific time) Sunday, 3:30 p.m. Auckland, New Zealand Monday, 10:30 a.m. Tokyo Monday, 7:30 a.m. Seoul Monday, 7:30 a.m. Beijing Monday, 6:30 a.m. Mumbai Monday, 4 a.m. The first composite wings for the Boeing Rome Monday, 12:30 a.m. 787 Dreamliner arrived last month at the Boeing facility in Everett, Wash. They London Sunday, 11:30 p.m. were flown on the Dreamlifter, a spe- South Carolina (U.S. Eastern time) Sunday, 6:30 p.m. cially modified 747 that 787 major assemblies. The aircraft brought Wichita, Kan. (U.S. Central time) Sunday, 5:30 p.m. the wings from Nagoya, Japan. Ed Turner photo

to the Dreamlifter as a time machine: We around-the-globe team, Blattenbauer said. “All of our partners have been there are reducing the travel time incredibly.” “We treat each payload as a separate for us,” Blattenbauer said. “Everyone has First to arrive at the 787’s final- mission,” he added. “It’s a huge commu- stepped up and done a phenomenal job to assembly site via the Dreamlifter was the nication effort to coordinate all of the de- make this program become a reality.” horizontal stabilizer, on April 24. Manu- tails. We have constant communication, factured by Alenia Aeronautica in Italy, connecting all our global sites, to make In factory, the future is now the horizontal stabilizer was transport- sure we have everyone in the right place With components now in Everett, final ed in pieces. The shipment configuration at the right time.” assembly of the 787 is well under way in the measured 9 feet wide, 13 feet high and 42 Evergreen Aviation Technologies 787 factory, located adjacent to the 777 pro- feet long (2.7 meters, 4 meters and 12.8 Corp., part of ’s Evergreen Group, duction line. The factory’s 40-26 building meters respectively). Other parts arriv- is modifying the fleet of Dreamlifter air- has seen a major transformation in the past ing at Everett include the composite cen- planes at its facility in Taiwan. Sepa- year and now sports new utilities, cement, ter fuselage sections known as Sections 44 rately, Evergreen International Airlines, work stands, tooling and other support in- and 46, the aft fuselage sections known as Inc., a subsidiary of Evergreen Interna- frastructure for the all-new airplane. Sections 47 and 48, and the wing box. tional Aviation Inc., will operate the fleet Prior to setup in the factory, digital Scheduling and coordinating the Dream- of aircraft and the Dreamlifter’s unique engineering simulations tested the fea- lifter pickup and deliveries requires an ground-support equipment. sibility of the final-assembly process

BOEING FRONTIERS June 2007 29 n COMMERCIAL AIRPLANES

Workers at Vought’s South Carolina 787 The Spirit AeroSystems 787 factory in factory prepare to join their first two Wichita, Kan., is busy building noses for barrel sections. 787s. The plant has approximately seven Photo courtesy of Vought Aircraft Industries nose sections in work for the program at any given time. ©iStockphoto.com/Illustrious Photo courtesy of Spirit AeroSystems by using technology that replicates the allowing the facility to accommodate var- to improve the environmental performance production process. The new toolset was ious 787 models more easily. of its product line, and the 787 Dreamliner launched at a “virtual rollout” event last “Final assembly has hit its stride and is no exception. year and revealed how the process will is making steady progress,” said Steve In fact, the 787 is a revolutionary air- work. The technology enables Boeing Westby, 787 vice president of Manufactur- plane that has made generational leaps in and its business partners to optimize ing and Quality. “We are in an exciting but technology and performance. That’s made the Dreamliner production system and very important time right now. Our teams it the choice of many airlines around the avoid costly late-stage errors that can are focused and ready to take on any un- world that share Boeing’s commitment to occur with untested designs and produc- foreseen challenges that could come up.” the environment. tion planning. Final assembly continues through the “Our deeply held belief is that lessening “Every partner that supplies major beginning of July, culminating with the the impact of aviation on the environment structural components to the airplane has first 787 Dreamliner rolling into the fac- is simply the right thing to do, and the in- participated in a final-assembly simula- tory for the July 8 premiere. First flight is troduction of the 787 Dreamliner is a sol- tion,” said Tom Cogan, airplane systems scheduled later this year, followed by flight id example of our efforts,” said Jeff Hawk, integration leader. test and entry into service next May. director for 787 Certification, Government Preintegration of wing parts takes Relations and Environment. place in the factory’s 40-36 building, Stewardship of the skies Among the 787’s environmental which was outfitted with a new door to In addition to an innovative manufac- benefits: accommodate the large-size 787 struc- turing system, the 787 brings with it a • By including the latest advancements ture. The factory features modern equip- new era of environmental responsibility. in technology, materials and manufactur- ment, which is almost entirely portable, Throughout the jet age, Boeing has striven ing processes to increase fuel efficiency,

30 June 2007 BOEING FRONTIERS n COMMERCIAL AIRPLANES

Workers in the Mitsubishi Heavy Indus- tries 787 factory in Japan put the finishing touches on the first set of 787 wings. Lori Gunter PHOTO

the 787 will burn up to 20 percent less fuel more than 567 airplanes since launch cus- tomers with airplanes capable of flying than today’s comparable aircraft. That will tomer ANA placed the first order in April point-to-point, enabling passengers to fly reduce greenhouse-gas emissions. 2004. The reasons behind the 787’s stun- where they want, when they want, is be- • The 787 will be quieter during take- ning initial sales success are many, but it ing validated by the 787’s sales record. offs and landings. can be traced back to one basic founda- “Getting 567 orders since becoming • 787 manufacturing will generate sig- tion: focus on the customer. offerable beats such popular airplanes nificantly less waste. “The 787’s incredible sales numbers as the 737, the 727 and even the venera- “These improvements allow us to build are a fine example of the success we can ble DC-3, each of which enjoyed record- the airplane our customers want: an effi- achieve through listening to our customers setting success in its own right,” said cient, environmentally progressive airliner and executing on our promises,” said Mike Larry Dickenson, vice president of Sales that allows passengers to fly the most di- Bair, vice president and general manager of for Boeing Commercial Airplanes. “We rect route to their destination,” Hawk said. the 787 program. “The Dreamliner is tru- got to this record with a relentless focus ly a remarkable airplane, and as it moves on our customers and the environment in Customers captivated closer to rolling out of our Everett facto- which they operate and an understanding As shown by its sales achievements, ry and taking to the skies, it’s important of how that landscape is changing. The 787 the Dreamliner has captivated airline to remember the hard work of our employ- has changed everything for commercial customers. ees and partners. It is their dedication and aviation. That change will accelerate as we The 787 has become the fastest- expertise that is turning this revolutionary turn promises into performance.” n selling new jetliner in the history of com- airplane into reality and meeting the needs [email protected] mercial aviation. At press time, 44 differ- of our customers.” [email protected] ent customers collectively have ordered The Boeing strategy of providing cus-

BOEING FRONTIERS June 2007 31 n FEATURE STORY 1967

When the first airplane manufacturing crews began work at the Boeing site in Everett, Wash., on May 1, 1967, the facility was still under construction. The major assembly buildings were not com- pleted until September of that year. Boeing Archives photo That’s incredible!

ent recalled the area was a sea of mud less than a year ago and Boeing, Everett community mark marveled at the speed of construction taking place at the site. But while others marveled, ‘pioneer’ employees—vanguard of 40 years of growth and success more to follow—donned hard hats and began setting up wing- panel jigs … and plugging in the machines in the 40-31 bay of By Bill Seil the huge manufacturing building.” The first group of employees to work in the buildings was called his may be hard to believe, based on what we know to- “The Incredibles.” That nickname recognized their efforts to devel- day. But the May 1, 1967, opening of the Boeing facility in op the 747, the world’s first jumbo jet, despite numerous challenges TEverett, Wash., to support 747 manufacturing was an- and an aggressive schedule. While The Incredibles were focused nounced with little fanfare. on getting organized that first day, there was a sense of excitement. The headline in that week’s issue of the Boeing News newspa- One employee remarked, “Everything is so new, it’s going to be per simply said, “747 Manufacturing Opened for Business This great working in a facility that’s still wet with fresh paint.” Week.” The accompanying article described opening day in a Now, 40 years later, Boeing and the Everett and Snohomish modest, businesslike way: “The massive 747 assembly building County community in Washington state recently celebrated the at the Everett Branch opened for business Monday. Those pres- anniversary of a partnership that changed commercial aviation

32 June 2007 BOEING FRONTIERS 2007 n FEATURE STORY

Today, factory buildings at the Boeing Everett site total 472 million cubic feet (13 million cubic meters), with the main assembly area remaining the largest building by volume in the world. Following major expansions over the years, the site now has 282 acres (114 hectares) of building area and employs more than 25,000 people. Ed Turner photo

and made the area north of Seattle one of the world’s most impor- Snohomish County, Wash.; a site adjacent to McChord Air Force tant manufacturing centers. The 98.3-acre (39.8-hectare) factory Base in Pierce County, Wash., south of Seattle; Moses Lake in building where the airplanes are manufactured is the world’s larg- Eastern Washington; and Walnut Creek, Calif. Sutter said he est building by volume. This summer, Everett—the home of the believes the company made a wise decision in choosing Everett, successful 747, 767, 777 and 787 airplane programs—will deliver which offered access to rail service and maritime shipping, as its 3,000th widebody jetliner. well as an airfield. Also, under a tight schedule, it was important to have a site near the company’s engineering talent. Early history Construction of the Everett plant took place under the di- The Boeing partnership with the Everett community began long rection of Bayne Lamb, 747 program director of facilities, and before the opening of today’s Everett site. During World War II, Malcolm Stamper, president and general manager of the the company operated two facilities in Everett to provide subas- 747 Division. Building the plant was a monumental task, with sembly support for the B-17. In October 1956, employees build- drainage being a particular problem because of the constant rain. ing jigs and shipment fixtures for the B-52 and KC-135 programs moved their operations to the Everett-Pacific Shipyard. Happy anniversary While today’s Everett site has been enormously successful, the On May 1, 2007, the 40th anniversary of that grand opening was decision to locate the plant in Snohomish County was not an easy observed with a short ceremony in the 40-22 assembly building. one. At that time, Boeing was working on the Supersonic Trans- With a 747 towering in the background, Ross R. Bogue, vice pres- port and developing both the 737 and an improved 727, said Joe ident and general manager, 747/767/777 Airplane Programs and Sutter, who led 747 engineering development. “We were the fourth Everett site, described the early days of the site and the remarkable guys in line for resources, and that included facilities,” he recalled. work performed by the hundreds of people who worked there. Design work on the 747 began in a variety of borrowed and impro- “These were the construction workers, mechanics, engineers, ad- vised locations, most of them along Seattle’s Duwamish River. ministrators and many others who made aviation history by build- The 747 was so big that no factory that Boeing had at the ing the 747—the largest civilian airplane in the world—in less than time could house it, so the company evaluated locations for 16 months,” Bogue said. “Little did we know 40 years ago about the new production facilities elsewhere: a site near Paine Field in impact this factory, and the people who worked and now work here,

BOEING FRONTIERS June 2007 33 n FEATURE STORY

‘Today’ in Everett: Live, with Matt Lauer would have on the community, Washington state and the world.” In its 40-year history, the Boeing site in Everett, Wash., has Bogue noted that today Boeing employs more than 25,000 peo- hosted many visiting VIPs from around the world. Among the ple in Snohomish County, and approximately 25 to 30 percent of recent visitors was Matt Lauer, co-anchor of the “Today” show the Snohomish County work force is in the aerospace industry. on the U.S. NBC television network, who made a special live Boeing is the state’s top exporter, and Washington leads the United broadcast April 30 from the Everett factory. States in exports as a percent of total personal income. The Everett broadcast was featured as the opening day The ceremony included presentations by Snohomish County of the program’s popular series “Where in the World is Matt Executive Aaron Reardon and Everett Mayor Ray Stephanson, Lauer?” During the broadcast from Everett, Lauer explained who read proclamations honoring the occasion. Also in attendance how Boeing teammates in Everett assemble a 777 jetliner. He were representatives of the Snohomish County Economic Devel- also sat in a 777 simulator and “landed” an airplane. opment Council, the Port of Everett, Snohomish County Airport, The goal of the “Where in the World” series is to take United Way of Snohomish County, the Everett Area Chamber of “Today” viewers to a place they’ve never been and show them Commerce and the American Red Cross. Bogue expressed his ap- something they’ve never seen. preciation to the county, the city and the community for their con- tinued support over the years. The final speaker was senior blueprint clerk Millie Hughes, who has 40 years of continuous service in Everett. While today’s com- Where in the Everett, Wash., factory is Matt Lauer? In this muters face traffic jams, Hughes noted that driving to work was no photo, he’s reporting from the engine inlet of a Boeing 777. picnic in the early days of the site. “In 1967, it was like mudflat alley Lauer, co-anchor of the “Today” show on the U.S. NBC televi- getting here every day from Renton, where I lived,” she recalled. “It sion network, recently made a live broadcast from the Boeing took me more than four hours to drive one-way to Everett.” site in Everett. For the community Boeing and the Everett community continue to grow togeth- er. Government and civic organizations promote a healthy busi- ness environment where companies such as Boeing can operate efficiently and effectively. Meanwhile, Boeing and its employees G ail H an us a photo contribute to the community through the Employees Community Fund, volunteerism and corporate contributions. Boeing and its employees help to build a robust community through involvement and a willingness to give, said Carl Zapora, president and CEO of United Way of Snohomish County and presi- dent of the United Way of Washington. “Every day, throughout the Puget Sound, people’s lives are im- proved because of the generosity of the people of Boeing,” Zapora said. “They do it all and do it well: corporate philanthropy, individ- ual employee giving and a real commitment to volunteerism.” Zapora added that Boeing and the United Way have a part- nership that’s lasted for more than 55 years, and benefits of the company’s corporate citizenship can be seen daily. Among the many other Everett-area organizations that have benefited from Boeing’s presence is the Boys & Girls Clubs of Snohomish County. “We have tripled in size over the last 20 years and serve over 17,000 school-age youths in 13 clubs. This would not have been possible without [Boeing’s] good corporate citizen- ship,” said Bill Tsoukalas, the organization’s executive director.

A MORE IN-TUNE WORKPLACE As Everett employees continue to support their communities, they are finding their work environment is becoming more collab- orative and attuned to their personal needs. John Akiyama, program manager for the Everett Future Factory initiative, said the factory is offering busy employees more con- veniences and amenities, such as on-site Tully’s Coffee stands. An Employee Service Center recently opened at the Everett site that has a Boeing Store, a laptop service center, a BECU (formerly known as the Boeing Employees Credit Union) office, a dry clean- ing drop-off facility, DVD rentals and other personal services (see Page 28 of the March 2007 Boeing Frontiers).

34 June 2007 BOEING FRONTIERS n FEATURE STORY

In one of the latest Lean improvements at the Everett factory, crawlers move the forward and aft fuselage sections of the 777 during systems installation. The fuselage sections fit into cradles located on top of the crawlers, which move at a rate of one inch (2.54 centimeters) per minute in an automated mode while follow- ing a white line on the factory floor. Scott Lefeber photo

Akiyama said offices and engineering personnel are being moved onto the factory floor, bringing them closer to assembly areas and the people with whom they need to interact. Collaboration rooms provide window views of airplanes under construction, and glob-

al videoconferencing equipment connects team members to global gail han us a photo business partners. “We’re improving the employee experience and at the same time enhancing production efficiencies through collab- oration and connection to the product,” Akiyama said. What would employees in 1967 have thought of all this today? One can imagine them strolling past factory floor offices, sipping lattes, peering into videoconferencing centers and exclaiming, “It’s incredible!” n [email protected]

For more on the Everett site’s 40th anniversary, visit www.boeing.com/everett40.

At the Everett site’s 40th anniversary ceremony, Ross Bogue, vice president and general manager, 747/767/777 Programs and Everett site, introduced Millie Hughes, a senior blueprint clerk, who has 40 years of continuous service at Everett.

BOEING FRONTIERS June 2007 35 n FOCUS ON FINANCE Keen on Lean systems cannot talk to each other without quests for the applications. The Lean train- How a 2-year employee manual intervention. PNT, which integrates ing, which gave her a broader perspective common systems in a standalone package, of operations and the impact an individu- came up with a tool opens the dialog. al could have on company performance, “It’s pretty sophisticated, sleek and pow- guided her design efforts. These efforts to streamline processes erful,” Gilbert said, “but I have tried really support the companywide Lean+ and In- hard to make it user-friendly, too.” ternal Services Productivity growth and By Liz Lane Gilbert is eager to share these Lean productivity initiatives. tools with other internal groups for the Gilbert said she loves her work and re- racey Gilbert is on a mission to benefit of all. The open design and inherent alizes her good fortune of ‘owning’ proj- streamline processes in Train- adaptability of ICERS and PNT make them ects from concept to completion. “Creating Ting Systems and Services’ finance ideally suited for estimating, contracting, these tools was quite rewarding,” she said. group. A trained mathematician internally financing and negotiating processes in oth- “They’ll shorten negotiation cycle times wired for efficiency, she simplifies standard er departments. “Jim had the vision to im- and lower cost for Boeing and its custom- processes with well-written software code. prove these processes. He and I have shown ers. It doesn’t get any better than that.” Gil- “If I can find a way to do something these tools to other groups, and they have bert’s also looking forward to expanding faster and more effectively, I am definitely been very well received,” noted Gilbert. distribution of the tools across Boeing— willing to put the upfront effort in to save Well received, indeed. These days, that, and a good night’s sleep. n time in the future,” said Gilbert, a St. Louis– her phone is ringing off the hook with re- [email protected] based estimating and pricing specialist in Integrated Defense Systems’ Support Systems organization. Armed with four hours of Lean training, Gilbert—who joined Boeing in 2005—did just that. Under the direction of her former manager, Jim Boster, she developed two in- novative software tools that improve esti- P eter G eorge photo mating accuracy and streamline the bidding process to serve Boeing’s customers better. Known as Interactive Cost Estimating Relationships and the Proposal Negotiation Tool, these software applications automate functions to eliminate repetitive pricing tasks—a benefit that draws appreciative smiles from employees who use the system. ICERS analyzes multiple cost-related variables, rather than averaging historical project expenses, to estimate future proj- ect costs more accurately. PNT stream- lines negotiation processes by minimiz- ing manual documentation. Its automated features enable users to revise scope eas- ily, make financial adjustments on the fly, and run new bid reports quickly during negotiations. Both tools will save the organization’s finance team a lot of time and effort—and that’s a worthwhile result from Gilbert’s work, which has exacted many long days and sleepless nights over the last year and a half. Based on other internal programs written by Chris Hand, Eugene Stathis and Clark Tracey Gilbert explains to Estimating teammate Todd Bond Tweden, these tools integrate data and sys- two software tools she developed that improve estimating tems. Gilbert explained that there is a huge accuracy and streamline the bidding process. The tools disconnect between systems. Often, two help Boeing better serve its customers.

36 June 2007 BOEING FRONTIERS n FOCUS ON FINANCE Boeing stock, ShareValue STOCK WATCH Trust performance The chart below shows the stock price of Boeing compared to other aerospace companies, the S&P 500 ShareValue Trust is an employee incentive plan index and the S&P 500 Aerospace and Defense index. Prices/values are plotted as an index number. The that allows eligible employees to share in the base date for these prices/values is May 14, 2004, which generates three years of data. The prices/ results of their efforts to increase shareholder values on that date equal 100. In other words, an index of 120 represents a 20 percent improvement value over the long term. over the price/value on the base date. Each data point represents the end of a trading week.

The program—which runs for 14 years and ends in 2010—features seven overlapping Boeing vs. U.S.-based competitors investment periods. The program is currently 250.0 in Periods 6 and 7. Boeing General Dynamics Lockheed Martin Northrop Grumman Period 6 Raytheon Ending June 30, 2008 200.0 $100 $96.20 $6,000 as of 5/17/07 150.0 $5,600 $90 $5,000

$4,000 Estimated Stock 100.0 $80 ShareValue price $3,000 distribution

$70 $2,000 50.0

$1000 7/14/04 1/14/05 5/14/05 5/14/06 7/14/06 5/14/04 9/14/04 9/14/05 1/14/06 3/14/06 9/14/06 1/14/07 3/14/07 5/14/07 $60 3/14/05 7/14/05 11/14/04 11/14/05 11/14/06

$0 $50 Boeing vs. stock indexes and international competitors Threshold $54 250.0 $40 Boeing S&P 500 EADS S&P Aerospace index Period 7 200.0 Ending June 30, 2010 $120 $3,000 150.0

$110 $2,000 Estimated Stock 100.0 ShareValue price distribution $100 $96.20 $1,000 as of 5/17/07 50.0 $800 $90 7/14/06 1/14/05 5/14/05 9/14/05 5/14/06 9/14/06 3/14/05 7/14/05 1/14/06 3/14/06 1/14/07 3/14/07 5/14/07 5/14/04 9/14/04 7/14/04 11/14/05 11/14/06 $87 $0 11/14/04

Threshold Comparisons: Four-week comparison 52-week comparison $87 Price/value Price/value Percent Price/value Percent 4-week, 52-week as of 5/11/07 as of 4/13/07 change as of 5/12/06 change $70 BOEING 93.40 91.03 2.6% 87.01 7.3% The above graphs show an estimate of what a U.S. COMPETITORS “full 4-year participant” ShareValue Trust distribu- General Dynamics 80.15 76.72 4.5% 65.20 22.9% tion (pretax) would be for Periods 6 and 7 if the Lockheed Martin 98.84 96.24 2.7% 74.62 32.5% end-of-period average share prices were the Northrop Grumman 74.87 74.75 0.2% 66.67 12.3% same as the recent price shown. Raytheon 54.22 54.37 -0.3% 46.26 17.2% The share price shown is the average of the day’s INT’L COMPETITORS EADS * 23.24 23.62 -1.6% 30.42 -23.6% high and low New York Stock Exchange prices. Updates to participant/employment data will be U.S. STOCK INDEXES made periodically. S&P 500 1505.85 1452.85 3.6% 1291.24 16.6% S&P 500 Aerospace 413.74 392.04 5.5% 356.93 15.9% For more information on the ShareValue Trust, and Defense Index visit http://www.boeing.com/share. * Price in Euros

BOEING FRONTIERS June 2007 37 n MILESTONES

Boeing recognizes the following employees in June Dale Cox Lamar Jacobs SERVICE AWARDS: for their years of service. Lori Creager Richard Janes John Crosetto Dennis Japhet 65 Years William Kortkamp Lyle Hocking Edward Alcala Steven Crowley Mark Jenkins Albert Seifert Richard Lapinski Harry Huey Thomas Alexander Thomas Cummings Karen Joerding Jerry Lawrence Thomas Hurt David Allen Robert Damitz Lonny Johnson 50 Years Richard Lederich Michael Jacobs Stephen Allen Patricia Daniels Richard Johnson Archie Campbell Charles Magruder Stephen Jennings Sheryl Amick Raymond Danner Arthur Kalemkarian Webster Heath Joseph Materne Rick Jensen Dennis Andersen Ralph Davis Gregory Karalus Norman Knobloch William Matson Donald Johnson John Anderson Douglas Delaurenti Randy Karg Leonard Roth Herman Millard Robert Johnson David Archer Michael Denton Paul Keck Rex Smith Anna Miller Gary Joraanstad Gary Armstrong Frederick Diemert Gerald Keeven Gary Miller William Lamanna Sharon Ashurst Scott Dobrowolski Ronald Kelley 45 Years Gregg Miller David Leonard Kerry Atchinson Christopher Dutton Elizabeth Kennedy Michael Andrews Donald Mitchelar Gerald Lienhop Roger Bacon Randall Edick Jacquelin Kirchner John Bomar Roland Mueller Jenera Lopez Scott Badger Tony Edwards Frank Kittle Bernadine Bronson Catherine Mulry Philip Martin Jay Badgley Gary Ehresman Steven Knapp Donnie Coleman Francis Murray Warren Martin Paul Bailey Steven Elton Wayne Koffler Darrell Cox Stanley Myron Mary Mayfield Edward Baker Walter English Daniela Konicek David Dethlefs May Niitsuma Michael Maynes Edward Balzer Alan Esker Dennis Kostchuk Lee Eccles Gerald Norton Thomas Mealy Alan Baumgarten David Esp Carol Kuchik Donna Fairfield Gary Nuttbrock Diana Miller Dolores Becks Larry Farrington John Kvasnosky Richard Hagmann Michael Paleen Earline Miller Patrick Beireis Felix Ferrise Daniel Lackie Carolyn Haynes Quentin Rock Creon Nims Gary Benning Randolph Finley Barry Ladd James Hotz Raymond Rudy Kenneth Noggle Stephen Bentley Darrel Fleck Michael Landgraf Nicholas Mallas Dwight Schaeffer Ronald Norland Ira Benton Stephen Ford Mark Landram David Mayne Gregory Schmidt William Novak Joseph Black Edward Fox John Lang Lee Muchow Marilyn Schoeck Gerald Paluszek Joyce Blackwell Pamela Fox Robert Lang Michael Nothdurft William Schoening Dennis Pitts Kevin Blanscet Pamela Freemon Jess Lantz Carol Olson James Simms Arthur Puett John Blue Kenny Fung James Larson Robert Pearson Leo Smith Michael Quam Brian Bowden David Gacek John Larson Richard Peer Michael Smith Charles Raiff Billy Boyd Michael Gay Doristeen Leslie Stephen Petrilla Carol Sprouse Patricia Ramey Linda Brandes Paul Gee Charles Lewis Harold Rosenstein Sharon Stevens Harold Redd Michael Britt Peter George Sandra Liedtke David Sawdy David Stone James Richardson Curtis Brockway Max Gertsch Steven Lien Charles Slade James Waddington Joseph Richardson Craig Brooks Douglas Gile William Lindsay Eugene Sutliff Gary Wiebusch Neil Ruggieri William Brothers Charles Gingrich Clem Little Laurence Wicklund William Young Jerry Sabbs Joy Brown David Glynn David Loch Charles Wiswall Richard Sackman Fred Bruce Phillip Godlewski Gregory Lockey 35 Years Thomas Schmidt Donald Buesking Steven Graunke Charles Lohse 40 Years Christopher Aldridge Terry Schulze William Buetow Fred Gray David Loyet Maurice Adams Froilan Alipio Stephanie Sikorski George Bundren James Greek Robert Lundeen Gerald Aschoff Larry Ashford Karen Smith Debbie Burger Mitchell Griffith John Lynch Richard Baum Michael Baldoz Michael Smith John Bussoletti Richard Grubenhoff Richard Lytle Kenneth Bell Bruce Beenken Shirley Smith Thomas Butler Donald Grzina Anthony Macias Patrick Blakely Catherine Bell William Sotelo Mark Bystrom Leonel Guerrero Warren Malkowicz Morris Botkin Larry Bender John Stoner Jose Cabatit Roger Gunderson William Maraulja Rosalie Boulieris Douglas Blue Stephen Storm Gary Campbell Dennis Gunzelman John Marino Arthur Brockschmidt Theresa Bouvay Richard Suchland Phil Cane Keith Gust Derrick Mathews Edmund Carroll Henterson Carlisle Simon Suthoff Mark Carney Gary Hanby Steven Mathews Richard Carroll Ken Carlson Ronald Vanhorn Wilma Carrillo Paul Hanks Ricky May Julie Craig Nancy Carr Richard Wagner David Carson Barbara Hansen David McCammon Raymond De La Cruz Delores Chester Geoffrey Waldron Albert Carter Steven Heeren Philip McCollum Stephen Dibbert James Cobble Gary Waller Christopher Carter Michael Heitmann Michael McComb Dale Dodrill Richard Cook Ken Wardell Chanmay Chen John Henrickson William McConnon Martin Eigenmann Jene Crandall Oaker Webber Philippe Chicoineau William Herling Dale McFarland Barbara Feltes Paul Dare Dennis Welch William Childers Denis Hetherington Thomas McGill Michael Ferretti Mary Dellerman Marlene White Randy Choat Duane Heutmaker Robert McGreevy Norman Frause Debra Downs Edward Winkler Wendell Choy Michael Hickok Scot McLean Jerry Grammer Gregory Dunn Henry Woo Judy Churchill Kathleen Higgins Michael Meanor Jeffrey Griffiths George Eastman Lee Wright Ernest Clark John Hill James Merrifield Gary Haines Francis Foster John Wyrwich Kelly Clark Paula Hill Sheree Meyrose William Haley Thomas Gammon Roland Yancey Kenneth Cnossen Richard Hoag Rodney Michael Richard Hall James Gapp Randy Coggeshall John Hoefer Joan Miller Dale Haller Vincent Gatto 30 Years Cynthia Cole Timothy Holey Joseph Millhouse Leslie Harmon Michael Gilbertson Ronald Aarns Hermon Cole Douglas Holm Bryan Mills Earl Hatton Leatrice Gradford Franklin Abramson Randy Collins Stephen Holmes Norman Miura Leonard Hoffmann Larry Greene Gerald Adams Jean Connelly Cynthia Howard Michael Montgomery John Hurley Oren Hadaller Carol Adkins Gary Cooper Daniel Hudson William Montgomery Miles Johnson Richard Hahn Jay Ahlbeck Arnold Cordray James Huff Henry Morgen Paul Kenyon Rikard Hill Robert Alaniz Fletcher Cottrell Daniel Jackson Lyle Mudge

38 June 2007 BOEING FRONTIERS n MILESTONES

Philip Muhm Paul Thomas Kevin Bryant William Elmendorf Shelley Jacobson Dashiell Moore Timothy Murray Robert Thouvenin Ralph Buchanan Charles Eriksen Michael Jaimes Eric Moore Bert Nakagawa Stephen Tomlin Joseph Buivid Karl Ettling Ronald Jarratt Randy Moore Renold Nanstad Harry Townsend Richard Burns Thomas Farquhar Cathy Jenkins Mark Morgan Clark Nixon Paul Tucker Richard Burns Bradley Fischer Earl Johnson Steven Morris Jody Null Dennis Underwood James Burschinger Steven Fischer Steven Johnson Christopher Morrow Robert Olshan John Updegraff Cynthia Buschmann Eugene Fisher Paul Johnston Alfred Mueller James Olson Manuel Urrutia David Bushur Dennis Floyd Linda Jones Janet Mueller John Olson Russell Vandyk Frederick Businello Anne Ford Teresa Jugan Kevin Murphy James Palmer William Vannoy Ronald Butchart Richard Fowell Steven Julison Michael Neff Michael Parshall Kenneth Vaughan Cassie Cairns Rodney Fowler Clark Kaltenbach Robert Neibling Joseph Pasquarello Scott Vesey Stephen Caldwell Michael Frandsen Robert Karibo Mark Neville Eugene Pfaff Richard Voss Michael Cameron Michael Frawley Jennifer Kennedy Michael Newton Michelle Phillips Joanna Wagner Dimas Cardoso George Fredrickson Ramona Kennedy Khoi Ngo Mary Pieper Ralph Warren Kim Carruth James Freed Jeffery Ketchum Long Nguyen Castel Pittman Thomas Watson Richard Caruso Peter Freymuth Steven Ketchum Minh Nguyen David Plumley Thomas Weaver Robert Casale Donald Fry Kevin Kinman Lee Nicholson William Powell Patricia Wells Adam Casten Markham Fry William Kinney Marianna Nissen Edward Puckett Terry Wiblitzhouser Albert Celis Kevin Fuhr Roy Kish Loren Norberg James Ray Paul Wiggum Christopher Chadwick Eugene Gallaher Mark Klasson Michael Novack Ronald Redd Robert Wilbur David Chamberlin Joanna Gamble Thomas Klemme Francis Nowak Michael Redington Thomas Williamson George Chambers Connie Garcia John Klewer Tammy Oates William Reed Jeffrey Wilson Sammy Chan Curtis Garcia Gary Kmieciak B.J. O’Bannon Patrick Reid Lyle Wilson Peter Chiang Gay Garcia Hilary Knight Terrence O’Connor Ambrose Reisenauer Robert Wilson Mark Christman Santiago Garcia James Kotva Tae Oh William Reynolds Bill Wise Michael Clancy Donna Gatlin Michael Kraus Kurtis Ostlund Bobby Rhine Terry Wohlers Michael Claypool Bryan Gerard Neil Kubota Michael Owings Edward Rhine Matthew Wolf Brian Clebowicz Gary Gersch Richard Kupis Wesley Oxenrider David Riley James Wortkoetter James Clevenger Roosevelt Gilliland John Landeck Craig Painter Stephen Riter John Ybarra Gabriel Cocco Michael Goff Ronald Lane Richard Parks Richard Ritter Gail Yee Clint Combs Kenneth Golden Charles Langford Patrick Pekkarinen Douglas Robbins Phillip Zerillo James Condon Jose Gomez Michael Lavelle Jane Pestoor David Robinett Karen Conmy Celso Gonzales Phong Le David Peterson Diane Robinson 25 Years Loren Connot Jon Goodney Virgil Lee Kelly Peterson Laila Robinson Larry Abeln John Cooper Jeffrey Grandilli Matthew Lenhardt Wayne Pike Gary Rodenberg Bryan Adams Linda Correll Gerald Grant Robert Lensegrav Michael Pilon Ben Rogers Robert Agate Sang Crawford Barry Griffin Mary Lew Eric Pinick Mary Rutherford Timothy Albert Kathy Cretsinger Bruce Griffin Jeffery Lewis Jimmy Piszar John Rychlewski Stephen Alford Jack Crowers Gregory Grimstad James Livingstone Joseph Pointer Mary Samuel John Ambrosino Carlos Cuevas David Grzesiak Dan Lowe Richard Popken Bruce Samuels Eugene Andersen Dennis Cummins Philip Gustafson Stephen Lubman Brett Porter Calvin Sand Clare Anderson David Curnutte John Hagedorn Collins Lum Tommie Powell Mark Sandstrom Eric Anderson Yolanda Da Silva Richard Hallock Armando Magallon Doreen Price Judith Sanislo James Anderson Marcia Daily Donald Hamilton Cindy Mann John Price Steven Saucier Paul Andrade Sandra Davis Thomas Hansen Richard Manzer Donald Pritchett Jeffrey Schaible Stuart Archer Louis Dayton Patrick Harrington Curtis Maris Mary Renner Monty Schmitz Kathleen Bailey Steven Degroote Paul Harry Thomas Masterjohn Gregory Reynolds Stephen Schoettler Kenneth Baldwin Gregory Deiter Ernest Hartenstein Kenneth Masters Richard Reynolds Jeffrey Schonbrun Linda Barns Marsha Delgado Mark Hasselbeck George Mateo Bonny Rhoden Gregory Schreiner Elbert Bates Tracy Dempsey Jeffrey Hawkins Timothy McCarten Charles Rhodes Ronald Seelye Jeffrey Beam David Derigne William Henry Michael McCuen Bernadette Rice Diana Shane Robert Beisler Shannon Deveney Scott Hinn Thomas McGehee Chuck Ridge Carol Shepard Dwight Benard Anthony Dias Stuart Hirschkorn Philip McGuire Lawrence Rieders David Shineman Lowell Benishek Victor Diaz Albert Hitt Donald McIntire William Roberts Jack Shumate Roger Bennett Terry Dickerson David Hobbs Ligia McLean Nancy Robertson Gale Simpson David Benson Darwin Dickinson Greg Hocking Samuel McPeak Ruben Rojes Dan Simson Rodney Bentley David Dillard Richard Hodgson Brian McQuaid David Rosner Beverly Skelly Larry Benton Joel Dixon Stephen Hoebelheinrich William McQuinn Charles Royas Joseph Smyth Noel Bernabe Mark Dodds Jeanine Hoffmann Rodney McVey Jan Rucker Jerome Solam Brian Bernsen Timothy Doxtater John Holmquist Matthew Meckley Scott Rudolph George Sotolongo James Berreth Ross Drake Ronald Honer Don Meeker Donald Ruis Ronald Spence Daniel Bianca Thomas Duffey Ronald Hoppe Thomas Meier James Ryan Sherwood Stolt David Bird Darrell Duncan Donald Horner James Melquist Robert Sagui Wesley Stout John Blanas Lynn Duncan Mark Hreha Linda Melton Dennis Salazar Nancy Stovall Richard Bowman Terrance Dunder Loren Hubbard Robert Metzger Timothy Sanders William Strand Randolph Brandt Kenneth Dunn Ha Huynh Edward Meyer Keith Schafer Mark Talbott David Brooks Dennis Durant Gregory Hyslop Patricia Meyer Michael Schavietello Meliton Tampico Christopher Brown Kevin Durbin Charles Irwin Rex Miller Daniel Schell Carl Tarricone Frederick Brown Randall Ebert John Jackalous Scott Mills Kurt Schindler James Terhune Thomas Brown Thomas Eivins Anthony Jackson Bettye Mitchell Karl Schmerbauch Jay Thomas David Brunnenmeyer Brian Ellis Celestine Jackson Robert Mjelde David Seifert

BOEING FRONTIERS June 2007 39 n MILESTONES

Cathy Sejansky Sandra Snow Richard Svoboda Tracy Turner Larry Weaver Charles Willeford Lee Shaw Joseph Snyder Douglas Swift Gregory Vanhorn Allan Weber Thomas Williams Susan Sheffield John Spencer Gary Talken Gregory Vasquez Duncan Weber David Wilson Matthew Sherman Harold Stancil Gail Taylor-Smith Christopher Velloff Steven Weinstein Allen Wirz Ken Shih Stephen Stecko Kevin Tellier Robert Volk Marvin Wesley Michael Wisniewski Steven Shindle John Steinlage Thomas Tench George Vrabel Glen Wester Phillip Wolff Richard Singleton Stuart Stephenson Scott Teplitz Timothy Wacker Charles White Mark Wolinsky John Sinon Michael Stewart Marvin Thomas Brian Walker Kathleen White Richard Wong Wema Slyter James Stokes William Thompson Janet Ward Lawrence White Joan Woolsey Bryce Smith Susan Stolting Alison Timidaiski Michael Ward Richard White William Wyrick Phyllis Smith Jeffrey Stroud Steve Trejo Thomas Ward Julian Whitley Robert Yung Roger Smith Steven Stuhlsatz Peter Triana Gary Warning Joyce Whittington Sharon Zalabak Roy Smith Holly Susterich Richard Tuck Byron Watts Robin Wicklund William Smith Emmet Sutterer Verna Tucker Douglas Weaver Daniel Wiedman

The following employees retired in April from Douglas Montgomery, 31 Years David Serpas, 24 Years RETIREMENTS: The Boeing Company. Ronald Moon, 50 Years Dennis Shackleford, 42 Years Edward Moore, 34 Years David Simmons, 28 Years John Ackland, 26 Years Orvilla Damschen, 27 Years Richard Hummel, 22 Years Mattie Moore, 29 Years Herbert Singleton, 38 Years Harold Alexander, 41 Years Delpha Danks, 10 Years Tommy Ingalls, 27 Years Luis Moreno, 36 Years Sweeney Skinner, 19 Years Hagop Aliksanian, 28 Years Gerald Darnell, 11 Years Wendy Jackson, 15 Years Scott Morgan, 30 Years Stanley Slaven, 22 Years Coletta Allen, 19 Years John De Leon, 28 Years Richard Janicki, 14 Years Lynne Morris, 18 Years Dana Small, 25 Years Lars Andersen, 34 Years Cathy De Walt, 21 Years Karen Jewell, 31 Years Robert Morris, 24 Years David Smith, 9 Years Raymond Anderson, 30 Years James Delaloye, 39 Years Carl Johnson, 21 Years Dan Morrow, 27 Years Richard Smith, 11 Years William Anglin, 29 Years Robert Dell-Imagine, 32 Years Donald Johnson, 29 Years David Mosakewicz, 17 Years William Smith, 17 Years Lauren Anstead, 34 Years Margaret Dempsey, 23 Years Jaun Johnson, 18 Years David Moulton, 37 Years Gary Snyder, 32 Years John Applegate, 10 Years Joseph Dinneen, 14 Years Melvin Johnson, 19 Years David Mullens, 21 Years John Solis, 26 Years Paul Barringer, 20 Years Robert Downey, 19 Years Glyn Jones, 23 Years Gerald Muraida, 33 Years Jack Speigner, 36 Years Randolph Baseler, 32 Years Sharon Downie, 39 Years John Keeton, 25 Years Sharon Murphy, 28 Years James Steckler, 41 Years John Bates, 32 Years John Dye, 13 Years Ray Keith, 19 Years Robert Murrill, 21 Years John Steffan, 41 Years Alisa Becker, 15 Years Connie Edmonds, 23 Years Clinton Kingsley, 16 Years Gary Musselman, 41 Years Linda Stoneback, 22 Years David Bellin, 34 Years Mark Ellis, 29 Years James Kirk, 20 Years Hattie New, 11 Years John Strong, 21 Years Gary Benson, 24 Years John Errea, 26 Years Cleo Koehler, 27 Years Mamie Nguyen, 10 Years Fred Struck, 38 Years Michael Bingham, 32 Years David Fall, 38 Years James Koenig, 29 Years Katherine Nichols, 23 Years Daniel Summers, 23 Years Mary Blumenshein, 20 Years Douglas Fanning, 10 Years David Krug, 41 Years Stuart Nicol, 43 Years Richard Sutherlund, 20 Years Burl Bolerjack, 28 Years Michael Farmer, 25 Years Richard Kruse, 21 Years Freddie Nieto, 21 Years Robert Swenson, 24 Years Marianna Bolman, 22 Years Kenneth Farnell, 18 Years John Lackey, 37 Years David Nix, 33 Years Giok Tan, 21 Years James Boster, 39 Years Raymond Fernandez, 23 Years Kenneth Larsen, 27 Years Sanae Noda, 27 Years Betty Taylor, 39 Years John Boutin, 22 Years Russell Ford, 19 Years Michael Lebow, 20 Years Richard Nolan, 22 Years Terry Taylor, 22 Years Brian Boyer, 40 Years Michael Foster, 23 Years Randy Ledermann, 28 Years Donald Obermann, 20 Years Gregory Thompson, 32 Years James Bozich, 26 Years Robert Foust, 10 Years Jeannie Ledford, 28 Years Charles Odess, 38 Years Gregory Thompson, 0 Years Dolores Brender, 21 Years Walter France, 34 Years Kristie Leighton, 28 Years Marcia Olson, 22 Years Richard Thompson, 22 Years Jeffry Brewer, 29 Years Rodger Fraser, 26 Years Geneva Lenik, 16 Years Patrick Oswald, 28 Years Sherry Thompson, 39 Years Thomas Brittain, 21 Years Barbara Friant, 35 Years Edward Lewis, 28 Years Joseph Pannon, 27 Years Melvin Thorpe, 28 Years Donna Brown, 18 Years Terry Gaddis, 30 Years Gary Lewis, 30 Years Ernie Parziale, 10 Years Arthur Tonga, 10 Years Joseph Burnett, 19 Years Jeffrey Gase, 18 Years Chong Lim, 26 Years Nelia Penalosa, 26 Years Antonio Torres-Skerrett, Billy Burroughs, 35 Years Dorothy Gauthier, 19 Years Willa Link, 10 Years David Petcu, 38 Years 22 Years Andrew Button, 14 Years Richard Gertken, 30 Years William Lokken, 40 Years Dang Pham, 16 Years Melinda Vanden Brink-Smith, Joseph Cardenas, 44 Years John Giffel, 25 Years Quan Luu, 21 Years Jimmy Pippin, 18 Years 22 Years Robert Carlsen, 31 Years Andrew Gill, 22 Years Stanley Malm, 35 Years William Porter, 25 Years Jay Vannest, 30 Years Raymond Carolus, 43 Years James Goldade, 28 Years Clara Marbutt, 15 Years Tyrone Prevost, 18 Years Don Vansteenvoort, 20 Years Dennis Carstensen, 44 Years Robert Graf, 35 Years Diana Martin, 16 Years R.C. Quartararo, 28 Years Martha Wangeman, 40 Years Robert Cartwright, 14 Years Bessie Gratton, 35 Years Arthur Martinelli, 16 Years Mikel Randleman, 17 Years Timothy Wherry, 32 Years Koreen Choe, 20 Years Mary Greenreich, 28 Years Ronald Martinez, 28 Years Roger Records, 23 Years William Whitford, 32 Years Darlene Christensen, 19 Years Robert Gwinn, 33 Years Linda McAskill, 27 Years Virgil Redman, 11 Years Larry Whitt, 25 Years Walter Chrush, 38 Years Michael Hansen, 22 Years John McBee, 36 Years Arnold Reimer, 24 Years Jack Willis, 27 Years Joseph Cline, 41 Years Jeffrey Harrison, 27 Years David McClure, 5 Years Richard Richards, 8 Years David Wisniewski, 19 Years James Coan, 16 Years Julius Harry, 43 Years Janet McGee, 28 Years Grant Riggs, 12 Years Richard Wolbach, 42 Years Steven Coe, 32 Years Dean Henniger, 31 Years Gregory McGuire, 16 Years Dean Robbins, 41 Years Frank Woolston, 24 Years Lynda Colombo, 18 Years Ricardo Hernandez, 32 Years Robert McNally, 10 Years Ronald Rogers, 21 Years Douglas Wright, 10 Years Joseph Congialdi, 22 Years Richard Hernandez, 32 Years Howard Mead, 21 Years Jonathan Roh, 28 Years Russell Wyatt, 41 Years Craig Conyers, 21 Years Marvin Herrod, 24 Years Eleanor Merritt, 21 Years Raymond Sanchez, 26 Years Michael Yohe, 30 Years Phillip Corelli, 38 Years John Hilaman, 32 Years Steven Metz, 29 Years Anthony Scavo, 32 Years Thomas Zigrang, 38 Years Ruth Cox, 20 Years Joseph Hine, 46 Years Michael Mitchell, 20 Years Dean Schafer, 35 Years Louis Zimmermann, 44 Years Robert Cummings, 35 Years Donald Hofferber, 35 Years Stephen Mogan, 27 Years Monty Searcey, 10 Years Milton Zlatic, 34 Years Philip Curry, 28 Years Robert Holcomb, 12 Years Harry Montague, 26 Years Alan Seraphine, 39 Years

40 June 2007 BOEING FRONTIERS n MILESTONES/AROUND BOEING

IN MEMORIAM AROUND BOEING The Boeing Company offers condolences to the families and friends of the following employees, whose deaths recently have been reported. Time to learn, share Bruce Barton, interiors fabrication and assembly mechanic; service date Nov. 21, 1987; died April 17 to productivity improvement; to seek more Common tools, best commonality in our tools, processes and Gary Benson, aircraft structures and surfaces mechanic; service date July 17, 1982; died practices key to taking language; and then eliminate the nonstan- April 30 dards,” said Schnettgoecke. “Our custom- James Cashen, tool crib operator; service date Lean to next stage ers deserve it and they are counting on it.” April 15, 1982; died April 11 Conference highlights included ad- Nancy Cox, occupational manager; service date dresses from Boeing Chairman, President Sept. 3, 1974; died April 22 o take Lean to the next level, Boeing and CEO Jim McNerney; Boeing Lean John Elliott Jr., manufacturing planner; service employees and teams need to get leaders; Clay Jones, chairman, president date July 5, 1977; died April 17 Tbehind the Lean+ companywide and CEO of Rockwell Collins; and Ron Glen Ellis, manufacturing change management growth and productivity initiative and Ritter, special assistant for Air Force Smart specialist; service date Feb. 27, 2000; died standardize tools. Operations to the Secretary of the U.S. Air April 22 That was the message presented to par- Force, and deputy director of the Air Force James Erikson, field and service mechanic; ticipants last month at Boeing’s semiannual Smart Operations Office. service date March 4, 1981; died May 6 Lean+ Conference in Costa Mesa, Calif. The conference also featured Employ- Ramon Garcia, technician; service date Aug. 18, The conference challenged participants to ee Involvement team leaders from five 1975; died May 16 take hold of Lean+ principles. It also asked Boeing sites who participated in a panel Larry Huot, structural mechanic; service date attendees to learn and share knowledge and Sept. 20, 1989; died April 28 discussion. Additionally, during breakout best practices across Boeing—and with sup- John Jonas, refrigeration and air conditioning sessions, 19 employees from multiple sites mechanic; service date Feb. 16, 1979; died plier partners and customers—to improve shared how the engagement and empow- April 19 and solve problems together. erment of people have helped work teams Patrick Kailey, quality system specialist; service Bill Schnettgoecke, vice president and within operations, office environments date May 12, 1986; died May 15 Lean+ leader, told the audience of more and from a business unit and site perspec- Douglas McArthur, manufacturing planner; than 850, including Boeing employees, tive. Educational sessions and tours at lo- service date May 9, 1995; died April 28 customers and industry partners, that cations where Lean+ activities are making Patrick Maples, field and service electrician; Boeing must do more to help customers a difference were also included. service date April 19, 1971; died May 11 through their business challenges. The next Lean+ Conference will be held Cheri Medley, office administrator; service date “Making Boeing the industry bench- Oct. 30 to Nov. 1 in Tacoma, Wash. To learn July 6, 1987; died May 20 mark for productivity will require each of more about Lean+, visit http://leo.web. Timothy Mitsch, electrical technician; service us to align with Lean+ as our one approach boeing.com on the Boeing intranet. n date Feb. 11, 2005; died May 7 Timothy Murphy, industrial hygiene and safety specialist; service date June 21, 1978; died May 21 Boeing Chairman, President and CEO Jim McNerney talks to attendees at the recent Lean+ Ronald Primm, utillty worker; service date March Conference in Costa Mesa, Calif. McNerney delivered one of the addresses at the event. 21, 1966; died May 13 Tony Romero photo Neil Richards, product data management engi- neer; service date Oct. 13, 1969; died April 21 Rebecca Richards, office administrator; service date Oct. 26, 1991; died April 20 George Rosenblatt, manufacturing planner; service date Sept. 17, 1973; died April 26 Cathy Treser, material handling dispatcher; service date Oct. 18, 1978; died May 19 Geraldine Trout, system design integration man- ager; service date Aug. 18, 1967; died May 14 Lawrence Voightsberger, mechanic; service date July 5, 1978; died April 24 Evelyn Volz, system engineer; service date Sept. 9, 1996; died April 29 Jerry Wickard, manufacturing change manage- ment specialist; service date Feb. 16, 1978; died April 25

BOEING FRONTIERS June 2007 41 n SPOTLIGHT K en G raeb photo Long Beach Center of Excellence

our hours end-to-end. That’s the vision for Commercial Airplanes’ Material Management organization, of which we are a part. It means a spare part is on the Boeing shipping dock ready to be delivered to a customer within a four-hour time- Fframe. To best serve customers who need parts that are not immediately available from Boeing, we’re creating a Center of Excellence in Long Beach, Calif. We handle customer requirements for nonstocked spare parts for both Boeing and McDonnell Douglas commercial airplanes. Our challenge is to improve productivity and exceed customer expectations by providing the customer a firm fixed price and schedule for delivery of nonstocked parts within four hours of a request. Nonstocked parts are not part of the normal spares inventory and are typically a challenge to price and acquire on short notice. Through Lean processes, we’ve been engaged to drive productivity improvements to meet the Material Management vision. The work is organized in several specialized cells that address the immediate challenges encountered when a part is not available. We’re tearing down walls—literally. And to maximize teaming and communication, we’ve implemented new seating arrange- ments, by cells. Employee engagement has already resulted in productivity improvements that have reduced the cycle time for processing a purchase order from days to minutes. The team effort also extends to our supplier partners who are engaged in our Lean journey. They are equally committed to fulfilling customer needs. We’re well on the path to being the Center of Excellence for nonstocked parts. It’s clear from employee enthusiasm that the journey has just begun.

From left

Deb Robson Kristi Aguilar Liz Aponte Mindie Carroll Procurement agent Logistics specialist Procurement agent Logistics specialist

42 June 2007 BOEING FRONTIERS

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