Takt Flow Assembly Work Cell for Boeing 777 Business Class Seating

Zodiac Seating secured the contract for Boeing 777 seating production, delivering the Aura Lite shipsets to the Turkish Airlines Boeing fleet of B777 aircraft. To avoid penalties and ensure future work prospects, Zodiac had to meet the stringent aero quality requirements and shipset delivery plans outlined by Boeing. 

To facilitate this, Zodiac appointed a manufacturing engineer as the project lead tasked with designing and implementing efficient manufacturing processes for the shipsets. Recognizing the necessity for consistency and meeting deadlines, the manufacturing engineer chose to adopt the lean methodology of Takt Flow Assembly, utilizing a predetermined Takt Time and implementing a single-piece pull system for material.

Previously, Boeing 777 seating production utilized single cell builds, with start to finish operations managed by one man per cell, lacking sequencing and inter cell coordination. The high variety of component parts was traditionally delivered through an MRP style call-in system, presenting a bulk 'sweet shop' approach that resulted in no reconciliation, leading to high loss and damage. This approach wasted time as operators moved around the work cell searching for parts and tools, while also managing the disposal of part protection packaging. Additionally, contracted high skilled labor was expected to perform all jobs, contributing to inflated labor costs. There was a significant lack of visibility regarding the status of jobs in WIP, as well as material shortages and how they affected progress, highlighting the need for lean methodology to optimize manufacturing processes in Zodiac Seating production.

The manufacturing engineer engaged all stakeholders to design the Takt Flow work cell for Boeing 777 seating production, ensuring it met customer expectations while utilizing existing resources as effectively as possible. 

Establishing and setting up a sub-assembly line to feed the main Takt Flow, the team introduced a self-governing Kanban card replenishment system, adhering to lean methodology principles. Additionally, single point resourcing centers were introduced to carry all necessary tools on shadow boards, bulk-issue stock, and workstation-specific instructions, focusing on bite-size work station delivery within the Zodiac Seating production processes. 

Proof tested and implemented material handling solutions using Creform, dedicated handling apparatus were introduced to enhance workflow, presenting parts ready for use. The team calculated Takt Time and balanced the line to align with customer demand. Moreover, Kanban Kit Cages were incorporated to pull material from stores, with two cage sets supporting the six-station work cell.

Zodiac Seating successfully delivered the Aura Lite shipsets for the Turkish Boeing 777 fleet by implementing lean methodology through the Takt Flow single-piece assembly method. The organization and coordination of man, machine, material, and innovative manufacturing processes significantly improved visibility of progress against plans, management of WIP, and coordination with stores. This approach also led to a reduction in waste and fostered greater interpersonal accountability, enabling the team to deliver in sync with the Takt beat. All shipsets were delivered as planned.

If you have a project that involves Boeing 777 seating production and require expert guidance through similar manufacturing processes, contact the manufacturing engineer to arrange an initial conversation and leverage lean methodology to start the ball rolling.