Schedule

1. Responsible: B. Kearns Status Date: 8/13/12 Approved by: S. Przybelinski R R GTG: Is / Was 118 Eng & Tools 5X5 Kickoff AP 82 Incr Pullup 5X5 Sback KHI eng Pull-up Test Pullup Anal. stress visit C-clamps Schedule BOEING PROPRIETARY ECCN 9E991

2. CS260 door surround manipulator sketch Phase 1 Design reviews in process Unloads FAJ, provides transport and 6 axis manipulation. Also need c-clamp tools with load cells. Phase 2 KHI style door surround manipulator Provides manipulation, strong back, and pullup Simple manipulator + calibrated c-clamp Boeing Proprietary

3. BSC | Section 47 Door Frame Installation Executive Owner: K. Heitkamp Focal: B. Kearns Updated: Aug 13, 2012 777 Program Level Risk - Risk Summary Grid Report Issue Description (5): • Door surround/edge frame installations have excessive gaps at barrel interface. This results in lost flow days due to shim fabrication and/or NCR processing to fill gaps and overall installation will not meet rate requirement. Impact: • CS260 JBS and flow impact, traveled work to CS270 and CS280 • Inability to meet 4 day and 3 day rate requirements Drivers: • Poor barrel IML profile • No engineering requirement for 5x5 at door • Door surround/edge frame installation profile • Engineering allowable for pullup is limited to 10# per foot Mitigation Actions (Interim): • Initiate engineering change for increased pullup – longwave central region pull up (M. Berden, ECD 6/28) 8/9 update - stress will require 5x5 so this change moves to AP118 incorp. Matt Berden is requesting MPH for AP118 to AP126 and change at AP127. • DE to start the discussion with LE about MPH process on ~AP118, (M. Berden) ECD 8/23 • DE to confirm KHI engineering allowables for shim and pullup (M. Berden), ECD 7/16 Complete 8/9. KHI is limited to 5# per foot by engineering. KHI uses power clecos so team doe not understand the process. • Issue ELR to add 5x5 requirement at doors (ME/Jamie Bigley) ECD 6/22 • 403Z5019, complete ELR 075686, meeting 6/28 with BSC and Everett DE, AP127 incorporation on plan • MPS and sanding, improved check tools – identify AP incorp. (Indelicato)APxx • Modify bar charts/assign MTs to increase hours on rework (IE/Rehn) ECD TBD. Need to bring this to CF SAM for approval of additional work • Improve tool used to check 5x5 quality (Tooling/Don Craig), ECD 8/14 • Sec48 crown was first prototype of new tool - arrived 7/12 and buyoff 80% • Door surround check tools – design ECD 8/1, LUT ECD 8/14 • ME and tooling to meet to simplify calibrated c-clamp to improve lead time (Norman / Bigley), complete – new ECD 9/14 ready for use • IE to determine the critical path flow save (IE/Novotny/Lynch) ECD 8/23 • Engineering changes for 5x5 requirement & increased pullup (DE/Matt Berden) ECD 8/24 • Hard tooling changes to achieve 5x5 (LE/ME/BRT) Complete, AP118 Mitigation Plan – med/long term • Design action for strong back/manipulator, complete • Design action for strong back/manipulator + pullup, need more benchmarking • Verify max additional pullup allowance as required with analysis. Initial stress feedback is that 20# per foot would be acceptable with 5x5 improvements, a defined sequence, a distributed load, and 0.005 gap-closure. • Complete per Matt Berden on 7/12. Stress has analysis and 50# per 6” is approved with validated assembly process. • 7/30 update – Stress and DE will require 0.005/5” IML quality to approve any additional pullup to current 10# per foot allowance. • 7/31 update – Stress is re-evaluating 5x5 prerequisite • 8/9 update – Two separate changes Help Needed • This project moved out past 3 day requirement due to stress 5x5 requirement. Need new rate enablers to get to 3 day.