Boeing Aerospace Manufacturing Facility
Clean Manufacturing Facility Coating Project | Seattle, WA
Project Overview
Boeing's aerospace manufacturing facility in Seattle produces critical aircraft components requiring pristine manufacturing environments. The 950,000 square foot facility required comprehensive coating renewal while maintaining active production schedules. The project demanded absolute Foreign Object Debris (FOD) prevention, stringent contamination control, and coordination with ongoing aircraft assembly operations.
Challenges
- Aerospace manufacturing cleanliness standards requiring FOD prevention
- Active production facility with no shutdown allowance
- Multiple surface types including epoxy floors, concrete, structural steel
- Coordination with ongoing aircraft assembly operations
- Strict particulate control and contamination prevention
- Security clearances and badging for entire crew
Our Solutions
- FOD prevention protocols with daily inspections and tool accountability
- Low-particle generation coating systems and application techniques
- Phased approach working around production schedules
- HEPA-filtered equipment and dust containment systems
- Background-checked crew with aerospace facility experience
- Real-time contamination monitoring and reporting
Results
- Perfect FOD record: Zero foreign object debris incidents throughout project
- Production continuity: No manufacturing delays or disruptions
- Quality achievement: All coating systems passed Boeing quality standards
- Safety excellence: 156,000 man-hours without OSHA recordable incident
- Schedule performance: Completed on time despite complexity
- Recognition: Boeing Supplier Excellence Award for quality and safety
Technical Specifications
Coating Systems by Zone
- Manufacturing floors: High-build epoxy with static dissipative properties (ESD-safe)
- Assembly areas: Chemical-resistant epoxy with light reflective finish
- Structural steel: Low-VOC epoxy primer with polyurethane topcoat
- Concrete walls: High-scrub acrylic coating systems
- Support areas: Durable epoxy-modified systems
FOD Prevention Program
- Daily tool inventory and accountability procedures
- Shadow boards and tool control systems
- Low-lint application methods and materials
- HEPA-filtered spray equipment and dust collection
- Daily inspection and documentation of work areas
- Immediate containment and removal protocols
Client Testimonial
"Moorhouse Coating demonstrated exceptional aerospace facility expertise. Their FOD prevention program was flawless - zero incidents across 20 weeks in an active manufacturing environment. They understood our cleanliness requirements, respected our production schedules, and delivered outstanding quality. We consider them a trusted partner for future projects."
Aerospace & Clean Manufacturing Facility Coatings
We specialize in aerospace, semiconductor, pharmaceutical, and other clean manufacturing environments requiring absolute contamination control. Our team understands FOD prevention, particulate control, and the unique demands of precision manufacturing facilities.