International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 11 Issue: 09 | Sep 2024
p-ISSN: 2395-0072
www.irjet.net
Six Sigma Report: Boeing 787 Dreamliner Battery Issue Analysis and Improvement S. Abishek1, J. Sruthiharan2 1 UG Student, Department of Aerospace Engineering, Hindustan Institute Of Technology and Science,
Chennai, India
2 UG Student, Department of Aerospace Engineering, Hindustan Institute Of Technology and Science,
Chennai, India ---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - The Boeing 787 Dreamliner faced critical
The DMAIC approach is used in this following report to consolidate the data. It includes:
operational challenges shortly after its launch due to issues with its lithium-ion battery system, leading to fleet groundings and significant financial losses. This report applies the Six Sigma methodology to analyze and resolve these battery-related problems. The analysis focused on two major battery fire incidents that grounded about 50 aircraft globally. Six Sigma tools, such as Pareto charts, Fishbone diagrams, and histograms, were utilized to identify the root causes—thermal runaway and short circuits—which accounted for 90% of the failures.
1) Define 2) Measure 3) Analyze 4) Improve 5) Control
1.1 Research Methodology
The Six Sigma DMAIC (Define, Measure, Analyze, Improve, Control) framework was used to address the issue systematically. The Define phase outlined the project scope, aiming to eliminate battery failures and enhance safety. Measurement revealed a defect rate of 4%, with substantial financial implications. Root cause analysis in the Analyze phase pinpointed thermal runaway and manufacturing defects as the primary issues.
The battery-related problems of Boeing 787 Dreamliner were approached methodically with extensive usage of the Six Sigma methodology. The different pivotal phases included in the research framework were: 1. Define: The preliminary phase involved a clear definition of the scope and purpose of the research project. This included the listing of specific issues pertinent to the battery system such as incidents of batteries catching fire, their impact on aircraft safety and operations, and the related financial losses. Key stakeholders were engaged to allow for a proper understanding of the problems and determination of the aims of the project.
Corrective actions in the Improve phase included redesigning the battery for better insulation, containment, and cooling, as well as improving manufacturing controls and supplier audits. These changes reduced the defect rate to less than 0.1%, with no further incidents reported. In the Control phase, real-time monitoring and periodic audits ensured the long-term sustainability of these improvements.
2. Measurement: In this step, data were collected to ascertain the extent of the problems with the batteries. The process involved determining the rates of defects, incident records, and analyzing financial implications. Tools like process maps and data collection forms were used to collect relevant information related to performance and failure rates for the batteries.
This report demonstrates how Six Sigma tools can be applied to complex engineering challenges, yielding significant improvements in safety, reliability, and cost savings for the Boeing 787 Dreamliner.
1. INTRODUCTION
3. Analyze: Thorough analysis was made to identify the root causes of battery failures. Various Six Sigma tools were used; these included:
The Boeing 787 Dreamliner represents a significant leap forward in aerospace technology, combining advanced materials and innovative design to enhance fuel efficiency and passenger comfort. First introduced in 2011, the Dreamliner is renowned for its use of composite materials, which reduce weight and improve fuel economy, as well as its state-of-the-art avionics and
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*Pareto Analysis: To prioritize the most significant issues contributing to the battery failures * Histograms: To understand the distribution of battery defects and identify patterns or trends.
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