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MGMT 580 – FINAL PROJECTCesar A. Marrero
AGENDA
Introduction Popularity of the Boeing 737 Reliability Program Failures of the Boeing 737 Evaluation: Defective Wiring (TWA Flight 800) Conclusion
INTRODUCTION
Boeing 737 – the workhorse for low-fare airlines around the world Easier and less expensive to maintain Fewer parts than older models Quick turnaround at the terminals
BOEING 737 – POPULARITY
Over 7,500 aircraft delivered to date Record-breaking orders of any model in a
single year 1,124 net orders of the next-generation version
(models 700, 800, and 900) in 2012 914 orders for the 737 MAX version
RELIABILITY PROGRAM
Entire System Common components reused in all airframes Unchanged fuselage
Changes primarily to wing structure and engines Airframe is quite cost-efficient Redesigning fuselage would not provide much
improvement Increased costs with two separate production lines
RELIABILITY PROGRAM
Humans in the System Commonality of airframes promotes familiarity Training costs are significantly reduced Employees use a common set of tools and
procedures
RELIABILITY PROGRAM
Maintenance of the System Interchangeable parts Standard technical documentation Longevity efforts
RELIABILITY PROGRAM
Simplicity of Design Greater turnarounds for airline carriers Maximize the use of their fleet Low stance on the ramp
Easier to maintain and load Servicing can be done at ground level Baggage can be loaded from the ground
Last minute cargo/luggage additions
RELIABILITY PROGRAM
Redundant and fail-safe features Two engines per aircraft, even though only one is
needed to fly Two electrical systems Two fuel systems Emergency Oxygen system Triple Rudder system
RELIABILITY PROGRAM
Manufacturing Methods and Purchasing Requirements Assembly line production, similar to the
automotive industry Accelerated production Reduced production costs Fewer order backlogs and customer waiting
times
RELIABILITY PROGRAM
Maintenance of complete product or system performance records Production and maintenance logs
Records failures, replacements, repairs, warnings, field tests, and operating conditions
Influences changes in the airframe Improves manufacturing methods Modifies quality checks Identifies most reliable components
Extensive field testing before components are fielded
RELIABILITY PROGRAM
Communication Valuable collaboration between customers, chief
mechanics, and field service reps Efforts ensure new version of 737 continues the trend
of simplicity, reliability and low cost. Airlines can choose a version of 737 with latest cockpit
displays or commonality with older models
FAILURES OF THE BOEING 737
Events influenced dramatic changes in the inspection and maintenance process TWA Flight 800 – Exploded, killing all on board Southwest Flight 812 – Peeled exterior skin
TWA FLIGHT 800
Exploded 12 minutes after take off Boeing Model 747, not 737 230 on board killed
Cause determined to be faulty wiring Spark caused ignition of fuel fumes FAA ordered Boeing to inspect all airframes,
especially the older 737 model
SOUTHWEST AIRLINES FLIGHT 812
Loss of cabin pressure, caused crew to perform emergency landing
Cause determined to be manufacturing flaws on the fuselage skin Rivet joints not aligned or overlapped, causing
fatigue on external skin Skin peeled off, causing a rapid loss of cabin
pressure Not first time skin peeled-off
EVALUATION OF DEFECTIVE WIRING
Cause and effect diagram:
Aircraft Explodes
PeopleMachinery / Equipment
MaterialsMethods
Different fuel mixture
Failure to detect defective cables
Substandard cables
Insufficient quality control
Missing inspection steps
Inexperienced maintainers
Insufficient testing tools
Inadequate testing tools
MACHINERY / EQUIPMENT
Insufficient testing tools NO tools available to detect fuel leaks
Inadequate testing tools NO tools to detect electrical shortages
METHODS
Missing inspection steps NO instructions on how to inspect for fuel leaks
around electrical wiring
Insufficient quality control NO formal QC oversight when inspecting the
areas where fuel cells and electrical wiring are combined
PEOPLE
Failure to detect defective cables NO training Unable to physically view defective cables
Inexperienced maintainers NO experienced workers/mentors
MATERIALS
Substandard cables Outsourced cables delivered by sub-contractors
Different fuel mixtures Lack of standard fuel operations at airfields
world-wide
CORRECTIVE ACTIONS
FAA ensure corrective actions are complied with
Boeing ensures employees receive immediate maintenance notices
Boeing consider redesigning electrical wiring near fuel systems
Boeing consider improving fuel leak detectors
CONCLUSION
“Reliability, or quality over the long term, is the availability of a product to perform its intended function over a period of time and under prescribed environmental conditions.” (Summers, 2010). Based on this definition, the Boeing 737 has
exceeded these conditions Surpassed their intended function by extending
its lifespan beyond the prescribed maximum of 75,000 flights.
REFERENCESBoeing Website (2013). The Boeing Next-Generation 737 Family --
Productive, Progressive, Flexible, Familiar. Retrieved August 16, 2013 from http://www.boeing.com/boeing/commercial/737family/background.page
Dummeyer, D. (2013). Boeing Quarterly Reports (2Q13). Retrieved August 16, 2013 from http://www.boeing.com/commercial/aeromagazine/articles/2013_q2/pdf/AERO_2013q2.pdf
Brady, C. (1999). Boeing 737 Production. Retrieved August 15, 2013 from http://www.b737.org.uk/production.htm
Irving, C. (2012). Is Boeing’s 737 an Airplane Prone to Problems? - Newsweek. Retrieved August 17, 2013 from Newsweek Magazine at http://www.thedailybeast.com/newsweek/2012/03/19/is-boeing-s-737-an-airplane-prone-to-problems.html
Spicer, K., Angers, S. (2002). Boeing: The Secret Behind High Profits at Low-Fare Airlines. Retrieved August 15, 2013 from Boeing website: http://www.boeing.com/commercial/news/feature/profit.html
Summers, D. (2010). Quality. New Jersey: Prentice Hall