New Breed Manages Inbound Logistics Flow to Support Manufacture of the Boeing 787 Dreamliner
Situation
The Boeing 787 Dreamliner is the world's best-selling new commercial aircraft. To support aggressive manufacturing goals, Boeing's production team sought a partner to help create an automated, efficient inbound logistics process for the new aircraft. Boeing chose New Breed Logistics to manage receipt, storage and delivery of parts, tools, and supplies to designated locations within Boeing's Everett, Washington assembly facility.
Strategy
Boeing and New Breed Logistics teams began work literally years in advance on the systems and logistics processes to be used in final assembly and delivery (FA&D) operations. Some processes leverage New Breed's experience in lean manufacturing support for Boeing Rotorcraft and other large-scale manufacturing operations. As a testimonial to New Breed's performance in support of the 787 program, Boeing chose New Breed to support a second production campus in Charleston, SC. Services include:
- Inventory management. New Breed Logistics systems integrate with four Boeing systems to give Boeing complete visibility to supply chain activities, including inbound material from suppliers. More than 800 Boeing staff use New Breed Logistics' online data portal for instant status on orders and inventory. All items, including tools and consumables, can be tracked to the serial number level. It's a completely automated process for real-time capture of shipment and receipt of goods.
- Kit assembly. Most components are delivered to the assembly point as part of a kit of parts and tools that are used together during assembly. New Breed Logistics builds close to 1,400 kits at the supply warehouse, each containing an average of 34 components per kit. These kits improve manufacturing efficiency and production by eliminating time assemblers would spend looking for and unpacking components.
- Just-in-time delivery. New Breed Logistics uses 1,200 milk runs per month to deliver component kits to designated points in the assembly facility.
New Breed's facilities supporting the 787 program are certified to the AS9100 aerospace standard for quality.
Results
This manufacturing support program exemplifies the success that can be derived from customer and 3PL collaboration during the initial phases of program development. Boeing and New Breed Logistics process engineers, system engineers, and program management personnel spent months working together to develop and implement this industry-leading program - yielding unprecedented process, efficiency, and production gains.
