Abstract:
This thesis delves into the external supply chain operations of Boeing's Tooling Manufacturing Business Unit, specifically examining the provisioning of form dies for the 737-700 and 737-800 aircraft. An initial review of the 737-700 form die package highlighted metrics related to cost, quality, and schedule. Subsequently, a team at Boeing implemented a preferred supplier strategy, fostering closer collaboration with a reduced number of form die suppliers. This approach yielded significant benefits for both Boeing and its preferred partners, primarily through enhanced information exchange, shared knowledge, and aligned incentives. A trial implementation of this preferred supplier model on the 737-800 form die package demonstrated tangible improvements, including a $32,000 reduction in die procurement cost, an additional $46,000 savings from reduced tool tryout time, the elimination of die rework, and improved schedule performance. Furthermore, increased trust within the supply chain facilitated valuable learning. This successful strategy holds potential for broader application across other tooling types and general parts provisioning. In a separate yet crucial component of the project, the study critically evaluated the design methodology for accounting for springback in stringer dies. Current design practices involve a constant 15% overbend. However, a comprehensive Finite Element Analysis (FEA) of the stringer forming process revealed that greater overbends are more appropriate for larger and more slender joggles, thereby directly leveraging advanced simulation to refine design principles. The FEA results were rigorously validated against empirical measurement data obtained from parts formed with the modeled dies, ensuring the accuracy and applicability of the simulation outcomes. This improved design approach, informed by the Finite Element Analysis, is now being integrated into future die packages, anticipating a direct benefit of reduced die rework due to more precise springback compensation.
