WEIGHT CONTROL RESPONSIBILITY, WEIGHT CONTROL RESPONSIBILITY, AUTHORITY, and ACCOUNTABILITY (RAA)AUTHORITY, and ACCOUNTABILITY (RAA)

Presentation at the67th Annual Conference

of theSociety of Allied Weight

Engineers, Inc.Seattle, Washington

17-21 May, 2008

Kenneth LaSalle787 Weight EngineeringThe Boeing Company

Weight Control RAAWeight Control RAAAgendaAgenda

Importance of Weight Control

Weight Derivation Ingredients

Roles & Responsibilities

Weight Control Engineering Attribute Overview

Summary

Weight Control RAAWeight Control RAA Q: Why is weight efficiency important to airlines?

A: Weight affects 2/3 of the airplane operating cost

Weight Control RAAWeight Control RAAHow is the airplane weight, at Entry Into Service, derived & improved through design process (structural perspective)?

Weight = f f Configuration + Aerodynamics + Loads + Stress + Design

Weight is the result of the released design. To influence the airplane weight, the weight control engineer must influence the design process.

• Mission req’ts

• 3-View

• Planform

• Integration

• Functionality

• New Technology

• Etc.

• Airfoil Type

• Sweep

• T/c

• Aspect ratio

• Span

• Etc.

• External

• Preliminary

• Design

• MLA

• Internal

• Thermal

• Combined

• Etc.

• Strength

• Fatigue

• Stiffness

• Criteria

• Min Gage

• MS

• Etc.

• Producibility

• Layouts

• Ply maps

• Buy to Fly

• Detailed Part Modeling

• Integration

• Noise

• Design Growth

• Etc.

Product Development

“Design Sensitive” Tools/Parametrics

Firm Concept

Parametrics + LCPT Initial Sizing

Detail Design

Fully Released MBDs / Actual Weights

Weight Control RAAWeight Control RAA

Roles and Responsibilities (or RAA) Ensure the weight efficiency & weight compliance of our company’s

products Provide airplane weight estimates given “any” level of design definition Documented weight estimations w/all assumptions defined Articulate differences between new design concept and existing fleet Proactive design influence (must integrate ourselves into the design community)

Lead airplane weight optimization effort (New, Derivative, or Sustaining) Company leadership’s “primary” resource for weight efficient project planning Provide technology & weight optimization roadmap (Chart the course w/ R&D

Team) Lead weight reduction planning activities (Idea collection thru implementation)

Required Weight Control Engineering Attributes Big Picture / Vision / Strategy Focus Teamwork Technical Competence Personal Attitude / Challenge / Development

Big Picture / Vision / StrategyBig Picture / Vision / Strategy

Commercial Airplane Business Unit (Investment in enhanced performance?) Conditions affecting airlines

High fuel prices? Passenger expectations (more comfort or direct flights)

Company fleet condition (aging or gaps in family?) Launched Programs (competing resources)

787 Family, 777 Freighter, 747-8 A380, A350

Airplane Performance Organization (How Do We Balance Risk?) Engine Performance (SFC) vs. Weight (OEW) vs. Aero Performance

(L/D)

Weight Engineering Organization Communicate frequently to the design team

What is the airplane weight level (understand all assumptions) Where the airplane level is going (forecasting) Why we are pursuing target weight level How we are going to achieve target weight level

Teamwork Teamwork (Establish Trust & Dependability)(Establish Trust & Dependability)

Establish Network Leadership (First-line to program level) Configuration & Engineering Analysis (C&EA) Design Stress Loads Manufacturing Finance Global Supplier(s)

Build Relationships… More than just requesting information

Provide Data On time (meet commitments) Accurate (fidelity required, list & discuss all assumptions)

Team Player Ask trade study team to request missing disciplines’ participation Represent airplane level interests, not just Weight Engineering

Technical CompetenceTechnical CompetenceDetermine Mission Requirement Design ImpactsDetermine Mission Requirement Design Impacts

Range (wing planform & loft size, fuel capacity, low speed devices)

Passenger count (fuselage length & diameter, wing center section width)

Passenger Accommodations (higher humidity, lower cabin alt pressure, large windows)

Speed (wing sweep, airfoil depth, etc.)

Take off & landing performance (i.e. icy runway conditions, field length)

Family plan (weight impacts due to commonality)

Interior architecture (New vs. Derivative vs. Existing Fleet) Interior flexibility impacts Overhead space utilization (Crew rest compartments, OCAS, etc.) Option strategy (what to make basic vs. options)

Cost (NR & Recurring)

Noise - Environmental & Passenger Maintenance and reliability enhancements Aviation authority requirements (FAA or EASA)

Entry into service goal

Technical CompetenceTechnical Competence Understand Schedule & Key Design GatesUnderstand Schedule & Key Design Gates

Product Development Firm Concept Systems Architecture Initial Loads Preliminary Loads Aerodynamic Lines Freeze Firm Configuration Firm Interior Architecture Detail Design Phase Final Loads Flight Testing Entry Into Service (EIS)

Weight Reduction Opportunity

1000’s of pounds

10’s of pounds

Tim

e

Technical CompetenceTechnical CompetenceUnderstand Work Package DefinitionUnderstand Work Package Definition

Structures– Ensure clear understanding of: Part-level definition Primary vs. secondary structure Integration structure (splices, sealant, fastener type & size, etc.) Attachments (composite – bolts in lieu of rivets) Interfaces (systems to structures, eccentricities, etc.)

Systems – Ensure clear understanding of: Systems architecture definition (fuel, high lift, hydraulic, electrical, etc.) Systems separation Bomb blast Engine/APU blade off/rotor burst

Loads (determine which ones are critical, how close is next condition) External (static – 2.5G flaps down, dynamic – gust) Internal (buckling, combined loading, thermal, etc.) Systems (fan blade out, voltage, heat, power, , flow, rpms, psi, etc.)

Materials Allowables (A-basis vs. B-basis, criteria effects, etc.) Density (areal weight, density, etc.) Sizing criteria (choose most efficient material, i.e., for fatigue or strength or

durability) Application (CFRP… ply orientation/optimization, etc.) Cost (Titanium vs. Aluminum)

Technical CompetenceTechnical CompetenceUnderstand Weight, Cost, Schedule RelationshipUnderstand Weight, Cost, Schedule Relationship

Determine significant technical weight drivers Material selection Planform (Wing & Empennage) Body cross-section Airfoil technology High lift systems Load alleviation Architecture Integration Supplier base System’s performance requirements (Temp, flow, power, pressure,

etc.)

Determine large cost drivers (typically compete with large weight drivers)

Advanced materials (procurement cost, manufacturing, etc.) Advanced build technology (new facilities, tooling, etc.) New Technology (high-pressure hydraulics, fiber optics, advanced

magnetics, etc.)

Balance weight vs. performance vs. cost vs. schedule

Ask questions & compare existing fleet data What requirements and objectives guide the design? What advisories are circulating that affect the design? Study or create “Tops Down” charts to compare fleet data

Challenge decisions and criteria Requirements Commonality designs Material selections Production Constraints

Inspectable Preferred materials and standard parts Handling constraints (envelope, weight, robustness) Assembly techniques & tooling

Architectural or layout arrangement Loads, stress and design assumptions (Conservative?)

Provide Feedback Positive & negative Say “thank you”

Technical CompetenceTechnical CompetenceAsk Questions / Challenge DecisionsAsk Questions / Challenge Decisions

Personal Attitude/Challenge/DevelopmentPersonal Attitude/Challenge/Development

Having a positive and optimistic outlook and approach enables: Strong design team working relationships - trust, integrity, ethics More cross-functional participation resulting in accumulation of known and

unknown information Mentoring & friendship opportunities

Developing weight control attributes takes repetition working through new designs

Learning to be inquisitive, while providing appropriate support, is necessary

Communication skills are an essential asset

Implementation of short- and long-term career development plans needs to occur early

SummarySummary

Weight Engineering is a diverse and technical field

Weight control engineering is proactive

Roles and responsibilities change as program progresses through design cycle

Communication, both verbal and written, are key

It takes a lengthy period to become an adept weight control engineer