1571. 757 Payloads Weight Optimization

Paper

Abstract

The 757 Program efforts toward obtaining minimum weight design have been extremely effective for the passenger cabin interior and cargo systems. Early in the 757 design development (mid 1978), the payloads design group and Walter Dorwin Teague Associates, interior consultants, established the general architecture for the 757 interior. At the time program go-ahead was announced, the interior received acceptance and the interior design estimated detail weights were established, reviewed and approved by the design package team. Defined in the baseline weight were what the weight staff believed to be realistic goals, achievable with energetic weight control. What actually occurred during the next three years was a surprising weight reduction that far exceeded the targets of our tightly budgeted base. The majority of the components investigated for weight reduction required study for degradation of noise attenuation, material properties, loads, etc., to assure management that program goals and guarantees were not compromised. An example of the weight reduction evolution is the overhead bin stowage design. The initial baseline was similar to the 727 carry-all in installation and mechanism, but with a new envelope and architecture. The resultant weight reduction for the stowage bin design was accomplished by changing construction to a single piece stowage bin, extensive use of Kevlar, refinement of operating mechanisms, and minimizing use of foam. The conditioned air outlet extrusion underwent ten separate design changes before the final configuration was fixed. We also convinced our suppliers of the advantages of aggressive weight control. An option for the 757 is the Air Cargo Equipment (A.C.E.) in-plane baggage system. By joint efforts of Boeing and A.C.E. personnel, the system weight was reduced and the detail component design was improved. The weight and cost reduction success we achieved on the 757 payloads system must be credited to all levels of employment, including drafters, technical aids, managers, engineers, and shop mechanics. Few of the small detail changes and only some of the large advanced items would have been incorporated if not for the aggressive attitude and family atmosphere projected by the management and the dedicated cooperation of the individual design package team members.