rfid applications in boeing aircraft production and...
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Copyright © 2012 Boeing. All rights reserved. 1
RFID Applications in Boeing Aircraft Production and Maintenance
Anil Kumar and Rebecca Shore, Boeing
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Automated Identification Technology at Boeing
• Automated Identification Technology
• (Bar code, Active & Passive RFID, GPS)
• Common across many programs
• Distributed across multiple sites
FLYAWAY NON-FLYAWAY
Aircraft Part Marking & Tracking
Asset Tracking & Location System
QUALITY, PRODUCTIVITY, AFFORDABILITY(Information system enabling visibility and traceability of assets and parts)
CAS RFID Integrated Solutions
Time & Temperature
Sensing SystemWork In Process
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Tracking and tracing of aircraft parts in production and maintenance phase brings value to all stakeholders in the aviation ecosystem
Value Proposition | Aviation Industry
Supply Chain
MaintenanceProduction
• Improved accuracy of the “As Built” and “As Delivered” configuration – Aircraft Readiness Log (ARL) parts
• Helps us provide an expanded ARL list to the airlines• Improving situational awareness due to shared data
environment• Accelerate decision-making capability
“Airplane-Out” data back to
the OEM• Automated management of
parts delivery and distribution• Optimization of inventory due
to improved end-end visibility• Historical lifecycle data from
the operators• Accurate status of part
condition from the field• Common process across
different customers
• Alternative and highly efficient method of ICA compliance
• Fast and reliable configuration management
• Supply chain visibility and inventory reduction
• Maintenance cost reduction
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Quality | Improvement in accuracy
• Data collection with RFID readers reduces chance of errors in transposing data – applicable to Supply Chain, Airlines, Production– Collected data automatically updated to a centralized database
• On-the-spot verification and validation of the collected data minimizes error propagation
Local Server
Little manual data entry – minimizes “fat finger” errors
ERPFixed or Mobile
RFID Reader
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Productivity | Flow time reduction
• Ability to collect data from a distance
–Non-line-of-sight propagation
–Parts installed behind panels
• One example in production environment:
Printed ARL
Manual process
Hand-held RFIDReader
Automated Inspection
Significant benefit in flow time reduction for all the stakeholders
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Maintainability | Consistent and Reliable Data
• Performance– RFID tags comply with SAE AS 5678 standards to ensure
consistent quality of the tags deployed in harsh environment• Interoperability
– Data stored on the RFID tags conforms to ATA Spec 2000 data encoding standards
• Maintenance– Update and maintain parts history during operation– Easy access to “back-to-birth” records– Minimizes effort in leasing and transfer of ownership process
Reduction in maintenance cost to airlines
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Next steps
• Production– Boeing continues to research and carry out extensive studies
for how RFID technology can provide benefits to the aviation industry.
• Aftermarket– Commercial Aviation Services has developed and tested a
service offering for operators that helps to further amplify the benefit in the aftermarket.
All the key stakeholders of aviation industry need to work together to realize the maximum potential
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Forward
• On-airplane RFID use involves unique environmental constraints and regulatory requirements.
• Boeing is offering an RFID-based, centrally managed maintenance program which:– Significantly reduces maintenance lead times,
configuration defects, redundant tasks and cost– Provides stable and reliable component and
configuration data supported by a comprehensive technology platform
– Can be tailored to specific operator requirements– Is fleet-agnostic
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RFID Integrated Solutions
A comprehensive solution including:
• Centrally Managed RFID-Based Maintenance Program
• Maintenance Procedures
• Training
• Hardware
• Software
• Retrofit Guidance
• Technical Oversight• Continued Support and Post-Retrofit Services
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Alaska Airlines Validation
• Developmental partner since the program inception
• Worked together to co-develop, test and validate the first five applications
• Results of operational testing have exceeded expectations
• Alaska will have contributed ~4000 hours of technical evaluation and validation support
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• 10 ASA M&E organizations reviewed and approved all product development documents including:
• ~5000 pages of document review
– Business and systems requirements
– Operational scenarios
– Technical procedures
• 167 revisions made
Validation of Business and Technical Assumptions
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System Performance
• Performed system interference checks
• Confirmed that there will be no EMI / EMC interference between RFID and airplane systems in any ground-based configuration
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• Fujitsu high-memory RFID and MacSema contact-memory technologies exceeding technical performance expectations
• RFID and CMB exceeded thermal cycle and min/max thermal equilibrium expectations
• Distance and speed of low-memory interior tags exceeded read range and distance expectations
In-Service Tests
B737 Main Landing Gear
CFM-56 Integrated Drive Generator
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Typical Aviation Results
• 737 Life Vest Check
– Before: 1 hour
– After: < 2.5 minutes
• 737 Oxygen Generator Check
– Before: 4 hours
– After: <1.5 minutes
• Demonstrated usability and effectiveness:
– End-user acceptance; AMTs performed all UAT procedures
– 100% reliability
• 99% lead time reduction
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Conclusion
• Aviation use of RFID is different from other industries and has unique
challenges.
• Boeing has developed a specific aviation solution to help our
customers harness the power of RFID technology.
– Not a technology solution but an alternative maintenance
program which is enabled by technology
– A comprehensive solution, centrally managed by Boeing
– An adaptable solution configured to the operator’s requirements
– A fleet-agnostic solution
– A method of compliance with instructions for continued
airworthiness
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Thank you!