Abstract

The Boeing Company is in an evolution toward a benchmarked process of Safety Through Design. Historical data in the presentation will touch on the 777 Program, our first trial, and how the 777 was benchmarked from all other airplanes. Once the 777 was documented, we began developing processes that have since proven themselves on the Next-Generation 737, and continuously improved on the 757–300. The paper will explore our lessons learned. The submitted data will detail the safety professional's role and responsibilities to the design phase. Focus will center on a concurrent engineering model utilized in airplane design. The description details engineering design criteria, who and what constitutes concurrent engineering, problem solving within concurrent engineering, and subsequently, how the safety professional works within this dynamic.

Further, the relationship between produceability and maintainability is explored, with empowerment of Engineering to reduce/eliminate risk and how the safety professional supports Engineering. Finally, what future applications and processes exist.

Introduction

Safety Through Design is a proactive approach to safety during the design phase of airframe and subsequent system configuration, as well as tooling and facilities development. This approach addresses safety in terms of loss potential by identifying the primary sources of hazards and implementing actions to effectively preclude the hazard development. A cooperative interaction and effective communication with the integrated product team [IPT] framework (Concurrent Design Process) is required to efficiently identify hazards and to provide timely resolution to issues in the concurrent engineering and build environment.

The vision of Safety Through Design is to eliminate accidents and injuries and to meet or surpass employee safety and health regulatory requirements, as well as company standards.

The mission of the safety professional and of Safety Through Design is (1) to achieve long-term gains in safety based on design team support (i.e., reduction in workplace injuries and illnesses) and (2) to encourage a proactive approach to safety by instilling ownership of the design and processes in the factory customer as well as all engineering disciplines.

The safety representative takes on several roles: to participate in the IPT process with a focus on safety; to provide safety input by reviewing product and process development and submitting analyses as requested or as required; to develop and recommend alternative measures that reduce risk inherent in the build process; to provide timely information to Program and Division management to apprise them of status and potential problems; and to track and document status of safety improvements.

The safety representative is expected to be well-versed in Boeing Safety Health & Environmental Affairs (SHEA) policies and state and federal safety and health codes. Beyond safety, the representative is also expected to have a thorough knowledge of engineering, that is, problem-solving processes, design criteria, business plans, and organizational structures. The safety representative also requires familiarity with manufacturing operations and processes.

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