Using existing resources to solve new workplace challenges

Mark Rehberg has always had a creative side to him, from building airplane and rocket models, to capturing award-winning photography.

He also gets to flex his creative muscles in his job at Boeing, working in the Moonshine shop.

Alcohol is not involved. But like the old-timey distillers, Boeing’s Moonshine team finds inventive ways, using existing resources, to solve problems – often related to workplace ergonomics.

“We work with tons of people from the factory who bring us various challenges,” explained Mark. “After finding the root of the problem, we’ll use our resources to design and fabricate a solution.”

Those resources include 3D printers, water jets, lathes, welding tools and much more.

Recently, mechanics brought forward a process that required a stepstool and awkward body extension in order to drill an airplane part.

Rising to the occasion, Mark designed a rolling table that raises and lowers, outfitted with mounting brackets that hold the part in place at a comfortable height, making the work safer and more efficient.

Other recent Moonshine projects include a 3D-printed, handheld prybar that saves mechanics’ fingers from repeatedly popping open temporary clamps on wiring bundles, and a mirror that clips to flashlights to aid inspections in tight spaces.

“These projects aren’t always big and flashy,” said Mark. “But they’re impactful. I really enjoy being able to help mechanics do their work more efficiently with these tools.”