It’s no secret that the world of FOD prevention is complicated and confusing. Tool tracking and tool control in high-accountability areas at the point of use can be overwhelming and can even seem mysterious. With FOD prevention, the “now-you-see-it, now-you-don’t” disappearing act of tracking tools is no longer acceptable. In fact, lost or misplaced tools in aerospace and nuclear environments are considered a safety hazard and if not found or returned properly can result in some serious consequences.
To make tool control more confusing, there is an array of technologies available. There are systems that use digital imaging, “chit” methods, RFID, barcode scanning, the honor system, and so on. Which systems truly consider the human factor of tool usage? After all, we do make mistakes. In an effort to finish a task, even the most seasoned technician could misplace a tool, return it to the wrong cabinet, or accidentally not return it at all.
While it is not intentional, technicians have misplaced tools and later found them in unusual places such as trash cans, a locker, in the pocket of a pair of jeans, or more importantly, areas of an aircraft that could lead to major safety risks or a catastrophic incident. Searching for a lost tool becomes a guessing game that can cause costly completion delays, aircraft tear-down, and/or FOD-compliancy violations.
A complete tool control solution takes into consideration the human factor of tool usage. So, what exactly does ‘complete’ mean? As defined in the dictionary, ‘complete’ means having all the necessary parts, components, or steps. What are the components of a complete tool control solution? There are 5 components and they are: software, RFID-tagged tools, heavy duty steel cabinet(s), Last-Point-Read (LPR) Monitors, and RFID scanners.
Component #1: The software. It provides critical information such as who took it, where it was used, and when it was returned. Beyond just monitoring whether tools are in or out of the cabinet, it also monitors gauge calibration, tool inspections, expiration dates, and mechanic and/or tool certifications. If a tool is returned to a different cabinet other than where it originated, a transfer notice is automatically sent via email to a supervisor. Likewise, if a kit is returned with a missing tool, an electronic inspection notice is automatically sent to ping the appropriate personnel.
Component #2: RFID-tagged tools. Each tool is individually tagged non-invasively with a RFID tag by using a double secure method approved by all aerospace FOD departments. This method utilizes both durable adhesives and special polymer coatings to securely wrap the bonded RFID-tagged tool.
Component #3: The Cabinet. All the RFID-tagged tools and RFID-monitored tools are housed in a secure, heavy-duty constructed, modular drawer system or cabinet. After the employee authenticates by scanning his/her employee badge, the cabinet unlocks and the user removes the needed tools from neatly organized foam cut-outs inside each drawer and goes back to work. The cabinet re-locks and calculates what was removed. An “Items Out” icon appears on the touch screen monitor indicating missing tools from the cabinet.
Component #4: The LPR Monitors. When placed at choke points such as entrances or walkways, the LPR’s can track the movement of the tool throughout the facility. Each time a tool passes the LPR’s, a transaction is sent back to the software indicating where the tool was last seen. This drastically narrows the search area if and when a tool does go missing.
Component #5: The RFID Scanner. To now locate the missing tool, the RFID scanner with “find” software is used. After typing in the serial number of the missing tool, the scanner is waved systematically in the area and begins to beep when it sees the tag on the tool. This greatly reduces the time to retrieve the missing tool.
With FOD-prevention, knowing critical data such as tracking when a tool is removed and when it is returned from the cabinet are vital components of any tool control system, but this is only part of the solution. Achieving positive tool control is only done with a complete system that has all five of these previously mentioned components. It must have the ability to reach beyond the cabinet itself to locate a tool if and when one does go missing.
What then is the real secret to unlocking a positive tool control solution? It’s not complicated, confusing, or even mysterious. The real secret is simple. It starts with software.
