Harold S Haller & Company worked with the Boeing Military Airplane Company to improve their manufacturing process. Raw material savings and improved process control resulted in a savings of $83 million per year.

1. A significant phase of the construction of airplanes involves the riveting of the skin to the air frame. The problem facing BMAC was how to avoid having to invest in extremely expensive rivets and still obtain the high quality surface finish demanded by customers. Using Haller & Company's D-optimal design of experiments software, EDO(c), a plan was developed in which four factors were investigated:

1. Two types of rivets
2. Three airframe locations
3. Three different drill bit lengths
4. Two methods to align the drill when boring holes for rivets

Analysis of the data from these experiments indicated that the critical factors affecting the surface quality were the use of the proper drill bit length and the use of a jig to align the drill when boring holes for rivets. Since the type of rivet had no effect on the quality of the surface finish, the purchase of very expensive rivets was avoided.

2. Government contract work can be very frustrating, particularly when military inspectors are required to authorize all additional tasks for a given project. Part of this frustration comes from delays waiting for the military officer in charge to come to the work site, inspect the proposed work, and render a judgement as to whether or not the proposed work is covered by the contract. Analysis of the history of the proposed work and judgements rendered on 747 modifications indicated that BMAC should perform the work needed as soon as it is detected rather than wait for the military inspector to arrive on site. The cost of idling the work force while waiting for the inspector's visit exceeded the cost of the proposed work.