Boeing, the largest aerospace company on the planet, builds a lot of planes. The organization manufactures aircraft for airlines and governments in more than 150 countries. And every one of those planes contains thousands of wires that connect its various electrical systems.
These complex webs of wires don't weave themselves, and putting all the parts together is a monumental task. Each week, thousands of Boeing's U.S. workers construct "wire harnesses," or "people-size portions of the electrical systems" designed to help them join the various shapes and sizes of wires, according to Kyle Tsai, a research and development (R&D) engineer with Boeing Research and Technology (BRT), the company's central R&D organization. "Wire harnesses are very complex and very dense, and the technicians have to use what are, in essence, roadmaps to find the attachment points and connector pins," Tsai says. "There are so many that it can be information overload at times."