Every tool accounted for, every shift — and FOD risk designed out.
A line- and base-maintenance operation needs auditable proof that every tool leaving a cabinet returns before an aircraft is signed off. Manual shadow-boards are slow and miss items — and foreign object debris (FOD) is a safety and cost problem industry-wide.
What the programme delivered.
Reduction in FOD incidents with RFID tool control.
Typical payback from efficiency & FOD avoidance.
Tool accountability checks per shift.
Client identity withheld under confidentiality. Figures reflect outcomes from comparable RTLS/RFID deployments; your own numbers depend on use case, environment and execution.
The challenge
FOD costs the aerospace industry an estimated $4 billion a year, and a single damaged part repair can exceed 20% of its original value. Manual tool control can’t keep pace with shift changes, AOG pressure and AS9110 evidence requirements.
Our approach
- Map the tool inventory and define accountability points (cabinet, zone, aircraft).
- RF site survey for UHF RFID smart cabinets / roller cabinets in the hangar RF environment.
- Define check-out / check-in logic with missing-tool alerts before sign-off.
- Wire tool events into the MRO / maintenance system for audit evidence.
- Pilot on one bay, prove read-rate and accountability, then scale.
Technology & integration
Stack deployed: UHF / RAIN RFID smart cabinets, fixed readers, ruggedised tags; optional UWB for high-value asset location.
Integration: MRO / maintenance management, AS9110 tool-control evidence, work-order systems.
Related: RFID consultant · Aerospace RTLS · Impinj vs Zebra