Overview
When Boeing launched the 777X, a next-generation derivative aircraft, it triggered a cascade of engineering changes across all five major product streams supporting airplane interiors. Each stream required a redesigned or entirely new production system to handle the complexity of new components, increased volume, and integration challenges.
Initiation: Building the Case for Change
As part of the Industrial Engineering team, I supported early program feasibility by helping develop rate plans to assess whether our existing facilities could support the 777X. We confirmed the space could accommodate the program, but significant reconfiguration was needed within each stream. I was assigned to lead the production readiness project for one of the core product streams.
Planning: Designing the Future System
Working cross-functionally with engineering, operations, and tooling teams, I conducted a gap analysis between current capabilities and future program needs. I iteratively developed a system design that aligned with engineering release timelines and business objectives, defining requirements across:
Space utilization
Tooling and equipment
Engineering specifications
Flow and build constraints
This plan laid the foundation for a newly funded production system.
Execution & Monitoring: Navigating Change
As execution began, I managed scope, schedule, risk, and change control in close partnership with engineering and operations teams. I addressed critical roadblocks with data-driven solutions:
Tooling Delay: Our internal tool supplier’s schedule threatened production readiness timelines. I restructured the testing build sequence to align with tool availability, formalized the change, and updated the baseline schedule.
Evolving Engineering Definition: As designs evolved midstream, I led a risk assessment and change impact analysis. After securing cross-functional approval, I coordinated supplier design updates and kept leadership aligned via a tailored communication plan.
The project concluded successfully when the new production system supported the form, fit, and function of the 777X components. Ownership was transitioned to manufacturing, marking a major milestone in the program’s readiness lifecycle.