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Space Exploration

A Lean+ Future for Space Exploration

Across the Boeing Enterprise, employees are embracing a Lean culture to realize productivity gains, increased resource capacity, and enhanced value to customers. Starting in 2006, The Boeing Company expanded Lean beyond the manufacturing floor to realize potential in all areas of the work environment. Known as Lean+, this effort has since grown to an overarching continuous improvement approach that harnesses best-of-Boeing strategies, tools, and resources.

Boeing is dedicated to further enhancing its Lean+ expertise and applying solutions to NASA's Constellation Program. As we embark on a return to the Moon and beyond, continuous improvement is critical for maximizing safety and performance within cost and schedule constraints. A Lean+ culture, inspired by innovation and employee involvement, enables efficient ground processing and assured mission success.

Explore the examples below to learn just some of the many ways the Lean+ approach has positively impacted The Boeing Company.

Checkout, Assembly, and Payload Processing Services (CAPPS)

The Checkout, Assembly, and Payload Processing Services (CAPPS) team supporting Kennedy Space Center (KSC) is well trained in Lean+ principles and strategies. In 2006, Lean initiatives in the Space Station Processing Facility (SSPF) focused on point of use practices and space reduction, leading to the following results:

  • 80% reduction in prep time by engineers and technicians
  • 79% reduction in product travel
  • 70% reduction in hand tool inventory
  • 25,000 sq. ft. of floor space was cleared

Since 2006, targeted Lean+ initiatives for process improvements have led to significant reductions in inventory and annual cost avoidances. Furthermore, customers often participate in Lean+ events and activities to ensure improvements are most beneficial.

Apache Longbow

Boeing's AH-64D Apache Longbow helicopter program in Mesa, Arizona exemplifies Lean manufacturing with a pulse production line and an embedded culture of continuous improvement. This award-winning site has reduced its rate of lost workdays by 74% and its manufacturing cycle time by 40%. Employees are team-orientated, and adjust their work schedules based on where and when help is needed.

The Ares I crew launch vehicle will lift the Orion spacecraft, the successor to the space shuttle, into orbit. Within NASA's planned Constellation framework, Boeing will pursue the Ares I crew launch vehicle's Upper Stage and Instrument Unit elements.

Ares I Upper Stage

Ares I Upper Stage production is built on Lean+ principles to provide the safest and most reliable Upper Stage, at the lowest-cost to NASA. Boeing's manufacturing process relies on standard work and point of use concepts to maximize efficient use of resources. Practicing binary communication with all customers and suppliers also ensures quality and customer satisfaction.