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When it comes to developing new production tools and assembly processes, it's hard to beat Boeing. The company has always been ahead of the curve implementing new technology on its assembly lines.
In the 1980s, Boeing was on the cutting edge of computeraided design and computer-aided manufacturing. A decade later, Boeing was one of the first companies to adopt lean manufacturing initiatives. Today, it's leading the charge into advanced digital production, predictive analytics and wearable technology.
Boeing is also pioneering assembly automation in the aerospace industry. It's investing heavily in state-of-the-art robotics, intelligent positioning systems and flexible material handling equipment. The goal is to streamline production by eliminating the need for large fixtures and tooling.
For instance, a new Fuselage Automated Upright Build (FAUB) process at the company's Everett, WA, plant will be used to assemble the next generation of 777 jetliners. With FAUB, designed by KUKA Robotics, fuselage sections will be built using automated, guided robots that will fasten the panels of the fuselage together, drilling and filling the more than 60,000 fasteners that have been traditionally installed by hand.
Plant floor innovation is part of Boeing's DNA. Thousands of ideas and inventions over the last 100 years have resulted in easier, safer and more productive tools and methods to build aircraft and spacecraft.
Here's a look at how Boeing engineers have solved assembly problems in the past and how they're addressing some of today's challenges.
Revolutionary Riveting
For decades, riveting has been the heart and soul of aircraft assembly at Boeing. According to a news item in the March 1960 issue of ASSEMBLY, the company purchased 100 million rivets in 332 categories each year.
During the 1940s, 1950s and 1960s, Boeing engineers developed a wide variety of automated equipment to improve productivity and reduce costs as aerospace manufacturing grew increasingly complex.
"Rosie the Riveter has a brand new configuration," proclaimed an article in the July 1958 issue of Boeing magazine. It explained how a major part of the riveting job at Boeing's Wichita plant was being done by four new Drivmatic machines.
The machines were used to assemble wing panels of the B-52G Stratofortress bomber. Applications included riveting aluminum stiffeners to lower wing panels.
"Each of these can handle eight to 10 rivets...