The Boeing 787 program revolutionized many aspects of commercial airplane production. One of the unique aspects of its global production system is that the major 787 structure components are transported via a small fleet of freighter airplanes. These freighter airplanes, called the Large Cargo Freighter (LCF), fly among five production sites to transport the 787 components forward and return their respective carrying tools back to their original sites. Simulating and optimizing LCF logistics related factors is an art as much as a science. This presentation depicts a Six Sigma approach combined with simulation modeling to improving existing tools and methods of the 787 LCF logistics. It is often difficult to start and conclude a LEAN Six Sigma project using simulation modeling. This presentation aims to share the valuable lessons learned through the practice of LEAN Six Sigma using simulation modeling.
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