Process

1. Define: Technical Research

   Production system design began alongside the final stages of wing product design. I partnered with subject matter experts to understand the product requirements, environmental and electromagnetic safety constraints, and ergonomic challenges.
   Tools: Engineering Drawings, EME Specs, Historical Data Analysis, SME Interviews

2. Define: User Research
   I led sprint-based workshops with expert mechanics and engineers to gather job data (sequencing, time estimates, tools, materials, and training). I also conducted field studies to understand pain points from current seal mechanics working on 777 wings. Activities included: observing sealers in real-world conditions, participating in new-sealer training, and capturing ergonomic and workflow frustrations.
   Tools: On-Site Interviews, Contextual Inquiry, Field Notes, Workflow Diagrams

3. Define: System Framework
   Using the collected insights, I developed a series of manufacturing planning deliverables to define and visualize the full system scope. Outputs included: ergonomics scores, value stream maps, wing maps with job data, sequencing diagrams and placement maps, and risk/opportunity registers and crew cycling plans
   Tools: Excel, Visio, Shop Floor Diagrams, Risk Registers

4. Ideation & Prototyping
   To validate early concepts, we created physical and virtual prototypes to simulate work conditions and test layout, tooling, and crew cycles. Prototypes created: full-scale plywood wing box mockup, CAVE virtual reality 3D environment, and Aurora modeling software for crew cycling
   Tools: CAVE VR, Aurora, CAD, Physical Mockups

5. Testing: Usability & Ergonomics
   I ran multiple usability tests with seal mechanics using ergonomic tools (robotic arms, jigs, supports), and measured performance, pain points, and system friction. Outcomes: identified critical stress points in overhead work, evaluated setup inefficiencies, and used findings to drive both quick fixes and R&D initiatives
   Tools: Ergonomic Testing Protocols, Video Logging, Manual Timing, Usability Logs

6. Iterate: Design Refinement
   We implemented rapid iteration cycles to incorporate feedback and solve for major ergonomic and operational pain points. I led a sub-team focused on overhead work mitigation, resulting in a 50% reduction in ergonomic risk. Examples of improvements: delayed fixture installations, U-shaped setup flow for tool collection, refined crew cycling patterns, and adjusted capital equipment quantities for cost avoidance
   Tools: Six Sigma Analysis, Process Flowcharts, Cost-Benefit Analysis

7. Final Testing & Implementation
   A full-scale wing mockup was used to validate the complete end-to-end process. The first production wing using the new system was delivered on time and within budget, with continuous improvements tracked post-implementation.
   Tools: Full-Scale Prototypes, Schedule Logs, Pilot Metrics