767 | 777 | 787 Integration
The Boeing Company
Everett, WA

Wood Harbinger created an intuitive method of identifying the needs of each stakeholder, assessing their relationships to other user groups and visualizing each of their competing interests.

The team satisfied Boeing’s goal of seamlessly shifting the production of 767 aircraft from one location to another without any delay or schedule extensions.

The 767/777/787 Factory Integration project consisted of three combined projects all corresponding with each other. Wood Harbinger, serving as Prime A/E, accomplished this integration through an innovative design utilizing the most current technologies, efficient construction and design management, and effective communication.

767 – The 767 Relocation project included moving the 767 production line from building 40-024 to 40-032; which is the first production line to roll out airplanes from the north side of the Everett factory.

The design and construction schedules had aggressive requirements in order to keep the production of the 767 on-going without interruptions. Due to our successful coordination, the job was completed on schedule, and Boeing was able to relocate the production of the 767 airplane to building 40-032 within hours and continue the production without any time lost.

The overall project required significant modifications to architectural, structural, mechanical, and electrical systems. The mechanical utilities in the new trenching system consisted of: compressed air, hydraulic, high-blow air, cold water, and sanitary sewer.

The new electrical requirements of two 767 airplane positions in the 40- 032, two substations were upgraded to 1,000 kVA to meet the increase in load power. The existing 480 V electrical distribution system consisted of multiple distribution boards, branch panels, transformers, and busways in trenches

For the first time, the floor of the production line building was completely coated with an epoxy that provides skydrol resistant flooring, a smoother surface for the movement of tools with an air bearing system.

777 – This task provided a fully-functional overflow assembly position for the 777 including hydraulic systems testing connections for both the 777 and 747 airplanes. Utility upgrades included a hydraulic test console and controls, hydraulic piping, filtered compressed air, low-pressure air system, water and drain piping, electrical power connections and receptacles, articulated quick-disconnect fittings, and surface hatch cover assemblies. Electrical upgrades also included shop-floor office and equipment power connections (including 400Hz), VESDA, and system shunt-tripping.

787 – The 787 Surgeline project included modifications to existing utilities and systems in the 40-024 building to construct a temporary assembly line for the 787 Dreamliner.

The mechanical and electrical utility upgrades for the aircraft assembly includes three trenches located under the assembly area. The point-of-connection for all utilities are inside the trenches including compressed air, potable water, condensate drain, and pumped process waste.