OCTOBER 2015 | VOLUME 14, ISSUE 06 | BOEING.COM/FRONTIERS Frontiers Automation innovation Robots, lasers and other advanced manufacturing tools help Fabrication employees safely meet rising production rates OCTOBER 2015 01 TABLE OF CONTENTS 07 LEADERSHIP MESSAGE 26 08 SNAPSHOT 09 QUOTABLES 10 WHAT WE DO 12 H ISTORICAL PERSPECTIVE Seventy-five years ago this month, a sleek new combat aircraft from Boeing heritage company North American Aviation took off for the first time—and flew into history. The P-51 Mustang PHOTO: JOSHUA DRAKE was an engineering masterpiece and became one of America’s best-ever fighters. 16 LIGHT ’EM UP! Boeing’s Compact Laser Weapon System 30 is small and light enough to be set up by two soldiers, and it is highly effective at detecting, debilitating or destroying enemy unmanned aerial vehicles. 18 TRANSFORMERS From Washington state to Australia, Boeing Fabrication employees have embraced automation and other new advanced manufacturing tools that reduce repetitive-motion injuries—and help them keep up with fast-paced production rates. 26 GROUND-FLOOR INNOVATION Boeing employees have been inventing and improving on designs, ideas and tools since the company began building airplanes nearly a century ago. And some of the most valuable inventions come from employees on the factory floor. 29 CUSTOMER PROFILE 30 CLIMBING HIGHER PHOTO: BOB FERGUSON | BOEING More than 1,900 Boeing employees, most with Defense, Space & Security or Commercial Aviation Services, work in the state of Colorado on programs that range from missile defense to providing precision aero charts and navigation services worldwide. 38 38 RISING STAR The Republic of Korea is a rising economy in a dynamic part of the world and presents new commercial and defense opportunities for Boeing. 44 TRAILBLAZERS 47 MILESTONES PHOTO: RON BOOKOUT | BOEING 51 IN FOCUS 02 BOEING FROntIErs Cover: Mac “Duke” Maravel, a tool- and die-maker for Auburn (Wash.) Tooling Services, positions a superplastic forming die for cleaning by a robotic laser ablation tool (rear). BOB FERGUSON | BOEING Photo: Jonathan Jorgenson, left, metal structures technician apprentice, and project manager Cesar Viray adjust automated drilling equipment on the 737 MAX Heat Shield robotic pulse line in Auburn, Wash. BOB FERGUSON | BOEING OctOBER 2015 03 FRONTIERS STAFF ADVertisements Tom Downey The stories behind the ads in this issue. Publisher This new ad highlights the value of Brian Ames Boeing’s experience and continuity on Editorial director 05 Ground-based Midcourse Defense, Paul Proctor a highly complex and vital national Executive director SAFE AND SECURE, security priority. It is running in James Wallace AS IT SHOULD BE. trade publications. Editor Vineta Plume 11.375 in. Bleed 11.375 10.875 in. Trim 10.875 in. Managing editor 9.875 in. Live Cecelia Goodnow Showcasing the F/A-18E/F Super Commercial Airplanes editor 06 Hornet, this recruitment ad emphasizes Ground-based Midcourse Defense (GMD) is on alert around the clock protecting the homeland. Since 1998, Boeing has provided continuous leadership in the development, execution and sustainment of this vital opportunities Boeing employees have Diane Stratman national security asset. The Boeing team’s more than 30 years of experience and expertise in homeland defense ensures GMD readiness and reliability against any long-range ballistic missile threat. to continually look for ways to build Defense, Space & Security editor products bigger, smarter, faster, stronger SPECIAL INVENTION AWARDS selects finalists on the basis of technical innovation, degree of implementation, internal Junu Kim businessand value to Boeing,better. business value to customers, The and licensing valuead to Boeing. primarily will run in TECHNICAL EXCELLENCE. ENGINEERING ACHIEVEMENT. Patrick L. Anderson Barry A. Fetzer Melinda D. Miller Paul G. Vahey Engineering, Operations & Henry L. Beaufrere Matthew D. Fevergeon John T. Monahan Paul M. Vijgen 7 in. Live career fair program guides at recruiting, Douglas H. Berry Jason L. Firko Elizabeth T. Montague Steven R. Walton 8 in. Trim Jeffrey D. Blanch Richard Fraker Julio A. Navarro Miles A. Webb Bruce L. Blaser Mark D. Fuller John B. O’Connell Gregory J. Werner 8.5 in. Bleed Technology editor Congratulations. Richarddiversity N. Bostwick Jonathan W. Gabrys andPradip G.college Parikh Eric Whinnem events. Mark J. Boyer Patric Gillies Arthur G. Powell Richard L. Williams Job Number: BOEG_BDS_GMD_3304M_A_R2Hien T. Bui Paul S. Gregg Wes Quigley Jay K. Yoshinaga John M. Caddick Todd M. Harris Manuel F. Rivera Our Special Invention Award and TechnicalClient: Boeing Product: Boeing Defense Space & Security Approved Randy C. Camp Date/InitialsPeter T. Heisen Seiya Sakurai Len Vraniak Date: 9/18/15 GCD: P. Serchuk Replication Award 2015 winners. Philip W. Chung Herbert L. Hoffman Mike M. Scheiern BOEG_BDS_GMD_3304M_A_R2 File Name: BOEG_BDS_GMD_3304M_A_R2 Creative Director: P. Serchuk Fred M. Cruz Frank S. Holman Paul H. Shelley Output Printed at: 100% Art Director: K. Hastings Date: 09.18.15 71907ID02r2_A.indd Mark A. Dahl Nathaniel T. Horton Harold P. Soares DIGITAL PROOF SPECS. DIGITAL FILES SPECS. Fonts: Helvetica Neue 65 Copy Writer: P. Serchuk SCREEN ANGLES DOT SHAPE LINE SCREEN DMAX RESOLUTION PDF Angelica Davancens Brian B. Kim Nathaniel J. Stenberg YEL MAG CYAN BLK Line : 2400 RSR 133 280 x1a Media: Frontiers Print Producer: Human Resources and 90˚ 45˚ 105˚ 75˚ Graphic : 300 Account Executive: MarkD. McAuliffe R. Davis John Koppelman Frederick M. Swanstrom 3C Space/Color: Page — 4 Color — Bleed YEL MAG CYN BLK PMS PMS 50K Client: Scott Boeing A. Davis Dennis M. Lewis Jimmy S. Takeuchi 50C Live: 7 in. x 9.875 in. 4C 41M Proof Reader: Stephen L. Fahley Jia Luo Matthew G. Trudeau 41Y Trim: 8 in. x 10.875 in. Celebrating technical excellence and Legal: Administration editor Bleed: 8.5 in. x 11.375 in. Traffi c Manager: Susan G. Gutter: 0 25 50 75 100 Digital Artist: Production Artist: S. Bowman Art Buyer: Retoucher: 14 Vendor: Colorengineering Inc. achievement is the theme TECHNICAL REPLICATION AWARDS PUBLICATION NOTE: Guideline for general identifi cation only. Do not use as insertion order. Material for this insertion is to be examined carefully upon receipt.highlights the most successful projects where cross-enterprise collaboration, learning Beriah Osorio If it is defi cient or does not comply with your requirements, please contact: Print Production at 310-601-1485. andof replication this have driven productivity,ad growth as and program Boeing execution. congratulates Frontline Communications Partners 1880 Century Park East, Suite 1011, Los Angeles, CA 90067 Shared Services Group editor Deric A. Babcock Jerry G. Fox Matthew T. Lakebrink Kevin Puterbaugh Blairwinners J. Basom Franklin B. French of theStephen T. LeDoux 2015Michael R. ScherrSpecial Invention Kevin M. Bell Mark F. Gabriel Daniel T. Long Christopher J. Senesac Robert A. Brandt John R. Heidmiller Ken MacGregor Jake Strait Andrew W. Cary John L. Henroid Steven E. Malarkey Dave A. Treiber Eric Fetters-Walp StephenAwards R. Chaney William Herling andMori Technical Mani Dean R. VanDeLaare Replication John H. Clark Jonathan N. Hotra Keith G. Massey Jeffrey S. Veselovsky Richard E. Clark Dave P. Irving Paul McEldowney William E. Ward Staff writer Andy J. Dorgan Vladimir Karakusevic William D. McGarry Chad M. Winkler WilliamAwards, Dumont Mike Kegley whichGlenn A. Patterson will be presented at a Jerry A. Esrig Brian S. Kornegay Shane T. Peterson Joe Fatta Randy J. Krohn Nikoli E. Prazak Dan Raley Johnceremony D. Ferguson John A. Ladd thisMatthew Prokopowicz month. Staff writer 286518_SIA_TRA_Frontiers_Spread.indd 2-3 9/17/2015 12:10:45 PM PHOTOGRAPHY Part of Boeing’s Middle East “Together” Bob Ferguson 52 campaign, this ad highlights Boeing’s Photo director investment in education for the future in Saudi Arabia. Translated, the text ART reads: “Together we innovate. As Katie Sheahan a founding member of the KAUST Designer Industrial Collaboration Program, Boeing is dedicated to educating مـعـًا، نـبـتـكـر تفخر شركة بوينج بدعم جهود جامعة الملك عبد اهلل للعلوم والتقنية ONLINE PRODUCTION لتطوير مهارات الشباب السعودي في مجال األبحاث والتكنولوجيا والهندسة. and training the future generations of شراكة ترتقي إلى الريادة اكتشف المزيد عبر Wendy Manning boeing-me.com/together Web manager Saudi youth in the fields of technology, Michael Craddock engineering and aerospace.” Web designer Lynn Hesby Web developer Tina Skelley Information technology consultant FSC LOGO CONTACT INFORMATION Email: [email protected] Address: Boeing Frontiers SUBSCRIPTIONS MC: 5003-0983 Go to boeing.com/subscribefrontiers.html to receive an email notification 100 North Riverside Plaza and links whenever a new edition of Frontiers is available online. Chicago, IL 60606 ETHICS QUESTIONS 866-473-2016 Phone: Contact the Office of Ethics & Business Conduct at 888-970-7171; Website: boeing.com/frontiers fax: 888-970-5330; website: ethics.whq.boeing.com. 04 BOEING FRONTIERS SAFE AND SECURE, AS IT SHOULD BE. 11.375 in. Bleed 11.375 10.875 in. Trim 10.875 in. 9.875 in. Live Ground-based Midcourse Defense (GMD) is on alert around the clock protecting the homeland. Since 1998, Boeing has provided continuous leadership in the development, execution and sustainment of this vital national security asset. The Boeing team’s more than 30 years of experience and expertise in homeland defense ensures GMD readiness and reliability against any long-range ballistic missile threat. OCTOBER 2015 05 7 in. Live