How To Manage Tools & Calibrated Equipments in Aviation

 Abstract

Tool management and control are of paramount importance in aircraft maintenance to ensure the safety, efficiency, and reliability of aircraft operations. Proper tool management and control practices are critical to maintaining the integrity of the aircraft, adhering to regulatory standards, and minimizing the risk of errors or accidents.
The most comprehensive Digital Transformation Software solution for The Transformation of  Aircraft maintenance repair & overhaul (MRO) industries   is "AMC Athena" from AMC Aerospace Technologies.  Athena www.amcaero.com is a proven ERP software built with cutting edge technologies to manage the  Enterprise Digital Transformation  functions of Large/ Medium enterprises.

Introduction

With effective tool control, it becomes possible to ensure that all tools are issued against an aircraft check & /or task to ensure all tooling is returned at the end of the check. Ensuring the integrity of tooling & equipment used for measuring is of critical importance particularly within the aviation industry.

1)Safety: Aircraft maintenance involves complex procedures, and using the wrong tool or improper tools can lead to errors that compromise safety. Accidents caused by tool-related mistakes can result in injuries, damage to aircraft, or even loss of life. Effective tool management ensures that only authorized and properly calibrated tools are used, reducing the risk of accidents.

2)Regulatory Compliance: The aviation industry is highly regulated to ensure the highest standards of safety. Regulatory agencies, such as the Federal Aviation Administration (FAA) in the United States or the European Union Aviation Safety Agency (EASA) in Europe, have strict requirements for aircraft maintenance processes. Proper tool management is essential to comply with these regulations and maintain the necessary documentation for audits.

3)Precision and Accuracy: Aircraft systems are intricate and precise. Using incorrect or poorly calibrated tools can result in incorrect adjustments, installations, or repairs. This could lead to suboptimal performance or malfunction of critical systems, jeopardizing the aircraft's operational capability.

4)Efficiency: Efficient tool management ensures that mechanics and technicians have easy access to the required tools, reducing downtime during maintenance operations. Well-organized tool storage systems and proper tracking of tool locations save time and improve overall workflow efficiency.

5)Preventing Foreign Object Debris (FOD): Foreign object debris, such as loose tools or hardware, can pose a significant threat to aircraft safety. Tools left behind during maintenance can get lodged in critical areas, potentially causing damage to engines, control surfaces, or other components. Strict tool control procedures help prevent FOD incidents.

6)Cost Savings: Mismanaged tools can lead to tool loss, duplication, or premature wear and tear. Implementing proper tool control practices can help track tools, reduce loss, and extend the lifespan of tools, ultimately saving costs for replacement and procurement.

7)Documentation and Accountability: Effective tool management involves creating and maintaining records of tool usage, calibration, and maintenance. This documentation establishes accountability, aids in tracking tool history, and supports compliance with regulatory requirements.

8)Training and Competency: Integrating tool management into training programs ensures that technicians are aware of proper tool usage, storage, and maintenance practices. This contributes to a culture of competence and responsibility within the maintenance team.

9)Quality Assurance: Consistent tool management enhances the quality of maintenance work. When mechanics have access to well-maintained and properly calibrated tools, the likelihood of accurate repairs and installations increases, ensuring a high standard of work.

The key features that will help the tool cribs to manage general tools and calibrated tools/ test equipment are given below:

1)Part Definition

 

Define the part details in the item master and update all the required information. The user has the option to upload photographs and documents.

2)Asset Manager

Define assets within the asset master and generate QR-coded asset labels. These labels can be affixed to tools/equipment and can be easily scanned to record tool issuance and returns.

3)Maintenance Activities Definition 

Define the maintenance activities and establish their applicability and frequency of occurrence. The calibration activity can be defined for the tools using this feature.

4)Maintenance Work Completion

The planner is capable of creating and generating work orders for technicians to complete the assigned tasks. Additionally, it can generate completion/calibration certificates to fulfill regulatory requirements, along with generating the necessary reliability data.

5)KPI and Dashboards

KPI dashboards are instrumental in tracking equipment availability and serviceability. These KPIs can be established at the departmental or organizational level. Additionally, the reliability dashboard plays a crucial role in enhancing equipment reliability.

6)Forecasted and maintenance plan

The system formulates the maintenance plan by considering the frequency of activities, equipment usage, and calendar days as criteria.

7)Tool Issue & Return Tracking

The tool accounting is very important in a shop/hangar where the aircraft/engine/rotables are repaired/maintained. The tool issue and return feature allows the tool cribs to easily track the issuance and return of tools to technicians. It allows verification if all the tools have been promptly returned before releasing the aircraft to avoid FOD incidents.

Conclusion

Tool management and control play a vital role in maintaining aircraft safety, efficiency, and regulatory compliance. By implementing rigorous tool management practices, aviation organizations can mitigate risks, improve maintenance processes, and uphold the highest standards of operational excellence. Often it is a laborious task managed on paper by the employees. A cutting-edge software solution like AMC Athena can be used for managing the Enterprise Digital Transformation tasks. It is essential to adopt the new age Digital Transformation products like Athena to improve the organizational efficiency and effectivity.