Best Practices for Tool Control: Reducing FOD Risk and Improving the MRO Process and Supply Chain. Robert Holmes / WinWare, Inc.

Transcription

1 Best Practices for Tool Control: Reducing FOD Risk and Improving the MRO Process and Supply Chain Robert Holmes / WinWare, Inc.

2 Agenda The Challenge of FOD Programs Evolution of Tool Control Why Passive RFID for Tool Control Technology Urban Legends Technology for Tool Control Making a Program Work

3 You Are Not Alone FOD programs for tool control are challenging Many principles go against human nature

4 Future Airplane Mechanics

5 Clear Runway

6 Littered Runway

7 FOD Incident

8 FOD Incident = FOD Damage

9 A Little More Costly Courtesy of FODNews.com

10 Tool Control Evolution Manned Toolcrib Punch Cards Toolboxes at POU Log Sheets Shadowboxing Chit Systems

11 Why Passive RFID for FOD? Technology is on a fast track Visibility beyond a cabinet or other storage

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13 Why Passive RFID for FOD? Technology is on a fast track Visibility beyond a cabinet or other storage Ability to locate a tool if lost

14 Story after Story

15 Why Passive RFID for FOD? Technology is on a fast track Visibility beyond a cabinet or other storage Ability to locate a tool if lost Visibility beyond drawer and location

16 What does the Press Report? Managing Automation, RFID Inside, June 2008 "We've demonstrated a reduction in lost tools and delinquent tools," Klein says, without quoting dollar figures. But the system's integration into the larger enterprise has created even greater savings, he says. A primary goal of deploying the RFID-based technology, Klein says, was "the creation of a system that allows us to provide a higher level of confidence that we're not leaving something in an airplane that's going to be pulling the turns with the G-forces that these aircraft do." The integrated CribMaster RFID system allows workers to check in tools somewhere other than their point of origin in another building, for instance. The system identifies the tool as safe and secured, and pings the appropriate personnel to collect and return the tool to its home. Creating that level of visibility in the previously manual world of tool tracking would have been difficult.

17 Technology Urban Legends RFID is not accurate enough

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19 Technology Urban Legends RFID is not accurate enough Tags fall off

20 Double secure methods approved by All FOD departments

21 Technology Urban Legends RFID is not accurate enough Tags fall off Tags are too big

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23 Technology Urban Legends RFID is not accurate enough Tags fall off Tags are too big Tags don t work on metal

24 Technology Urban Legends RFID is not accurate enough Tags fall off Tags are too big Tags don t work on metal No proven system all science projects

25 What does the Press Report? Managing Automation, RFID Inside, June 2008 At Lockheed's facilities in Palmdale, CA; Marietta, GA; Fort Worth, TX; Meridian, MS; and Clarksburg, WV, RFID-based CribMaster technology from WinWare is helping the aerospace giant to more intelligently construct fighter jets, such as the F35 and the F16, as well as carrier airplanes, such as the C5 and C130. The system earns its keep in a myriad of ways, according to Denis Klein, Lockheed's senior manager of production distribution processes. First, it keeps costs in check by preventing the loss of tools. When workers know the system is tracking each tool that they check out anything from a screwdriver to a wrench to a socket they're less likely to lose a tool or leave the plant with it.

26 Not Proven?

27 Technology for Tool Control Keys for a Successful System Single System One Software Application One database Link Facilities Easy Integration into other systems and processes Ease processes not create more FLEXIBLE support for continuous improvement Where can we go from here???

28 Technology Truths Requires Authentication Establishes Accountability Easy to Use Multi-levels of Kitting Provides Proper Information Sharing Is Secure

29 Technology Truths Software

30 Technology Truths

31 Technology Truths RFID ToolBoxes

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34 Technology Truths RFID Cabinet

35 Technology Truths LPR

36 Technology Truths LPR

37 Technology Truths Scanners & Software

38 Challenges of a Program Lots of processes to document Information flow Personnel accountability Internal buy in 100% Tool Accountability No Less Tracking Locating

39 Making a Program Work Have to define current processes and be honest about what is working and what is not There must be someone or some team accountable for the success of the project You must have the right team in place and all departments who will be affected represented (management, engineers, mechanics, IT, etc.)

40 Making a Program Work You must have internal buy in at all levels - You must work to create that buy-in - You must make everyone understand that this will help them - Have a training plan and why the change should be a part - Find away to make everyone a part of the change - Promote the change

41 We have done it ourselves

42 Contact & Questions Robert Holmes Marketing Director WinWare, Inc. The makers of CribMaster Phone: x robert.holmes@cribmaster.com

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