Trial name: Support for monitoring and management of tools tracking.
Manufacturing Sector: Helicopter OEM
Keywords: Safety, FOD, Training
The AW Final Assembly Line (FAL) in Vergiate plant is the location in which the trial has been tested. The FAL is the location in which helicopters are manufactured and it is responsible for creating processes that canter around reliability and efficiency, both in the supply and management of materials and in guaranteeing Quality during the assembly and delivery to the final customer. During FAL and maintenance operations the FOD (Foreing Object Debris) avoidance is very relevant and strictly related to the correct management of tools. Tools FOD is a serious danger caused by tools left inside the helicopter after manufacturing or servicing. To prevent and avoid FOD risk and improve efficiencies to be sure all tools have been removed from the Helicopter, maintenance and manufacturing teams have dedicated strict tool control procedures and use of dedicated training courses and different instruments for their tracing and checking too, such as toolbox, tagged tools.
The goal is to support the monitoring managing of tracking of tools in case of not return in the boxes with the use of new technologies and a new system of taking control of tools localisation for safety purpose and to have a dedicated DB referring to tools be used for training material scope.
Innovative Services and Functionalities
- Collect data from Smart tool box relevant to tool usage. Selected a specific period of time to be monitored, the following information are provided:
- the last date in which the event happens (tool );
- the typology of event (for example not correct position of tool in the smart tools box at the end of activity);
- the tool connected / associated to the logged event;
- the number of time that the event linked to the selected tool happens (this is linked to the entire chronology, starting from the first use of the toolbox and referring tools).
All these information are collected in a report is used by stakeholder involved in FOD (Foreign Object Debris) prevention to better define and tailor training courses to be provided to technicians as prescribed by regulations for all workers employed in the aviation industry (for example taking into consideration events that occur more frequently, tools most forgotten, etc.). The aim is to keep high the awareness on safety that, in all its forms, is essential for the avoidance of risk to helicopter’s users (passengers and crew).
Impact and Benefits
One KPI has been taken into account:
PI6 Report of tools use tracking useful for preparation of tailored training material linked to Tools FOD prevention. This is a Qualitative Indicator whose validity has been approved by the instructors involved in the preparation of the courses to be delivered to BCW. The knowledge of the situations in which tools were not stored (shift change, the evening hours, etc.), the frequency of events, the type of tools are essential information to customize courses towards those aspects of human factors useful for FOD prevention.
Safety is a must in all aeronautical activities also in Final Assembly Line where many complex operations are performed during the mounting of a helicopter. As a consequence to encourage workers to a positive attitude towards safety and to discourage unsafe behaviour and practices is a best practice. To achieve this goal, it is important to train workers on the procedures to be followed in carrying out his activities and on the aspects of human factors; knowledge of human factor helps to avoid potential risk situations. A special focus should be taken on Foreign Object Debris (FOD) prevention. In the “as is” situation, periodically the BCW are required to attend refresher courses relevant to Human Factor generic topics.
The business objective is to improve the effectiveness of training. The system, interfacing the new Smart Tool Boxes that AW is installing at the FAL / LiVo, makes possible to monitor the tracking of tools gathering a lot of data. This information is used to identify the cause of wrong behaviour that could be more highlighted in the training materials in order to have a continuous improvement of FOD awareness.
Technical Challenges & Trial Platform
The GE (Generic Enabler) /SE (Specific Enabler) / TSC (Trial Specific Components) used to develop the Digital platform for the trial are:
- SE – trigger
- GE: IoT. Gateway.Datahandling – Esper 4 Fast Data
- GE: IoT.Backend.IoT Broker (NEC)
- GE: IoT. Backend.Conf Man (Telefonia I+D)
- TSC: events DBs
Moreover the following Trial Integration Components have been developed:
- Simulated data from Smart Tool Box Snap Source
- Web Application for visualize and export the data
- Event Admin GUI (Graphical User Interface)
- Periodic report with relevance to Tools events
AgustaWestland was created by the merger of two helicopter Companies, both with long and rich histories dating back to the formative days of aviation manufacturing in the early 20th century. Agusta’s and Westland’s pedigrees as helicopter manufacturers dates back to the 1950s. The two Companies first collaborated in the 1960s when Westland began producing the Agusta AB47G, known as the ‘Sioux’, under licence. From 1964 Westland built 250 of these small helicopters at Yeovil, UK. The relationship between the two Companies continued to evolve for more than 20 years through collaboration on the development and production of the 16-ton multi-role EH101 (now AW101) helicopter. This association enabled Agusta and Westland to integrate quickly and smoothly when Finmeccanica S.p.A. of Italy and GKN Plc of the UK signed an agreement for the formation of a 50:50 joint venture company named AgustaWestland in 2001. In December 2004 Finmeccanica acquired GKN’s 50 per cent stake in AgustaWestland.
AgustaWestland is leader in the global helicopter industry. It offers a wide commercial/military product range encompassing all main weight categories that can perform a full variety of missions such as offshore, passenger and VIP transport, air ambulance, law enforcement, SAR or utility missions. The advantage of this family of helicopters is that they share a common design approach, common parts, common training and the same maintenance philosophy. In the military sector, AgustaWestland has the most capable helicopters in production today for naval, attack, utility and combat SAR missions.
Research and Development is an essential part of the business, and represents the Company’s commitment to improving existing products as well asto developing innovative solutions. AgustaWestland is particularly focused on providing customers with effective logistic and maintenance support to increase their operational capabilities, whilst reducing overall operating costs.The worldwide headcount at AgustaWestland exceeds 13,000, with major manufacturing facilities located in Italy, UK, Poland and USA. Revenues in 2013 stood at €4,076 million with a cumulative order backlog amounting to almost €12 million, and new orders worth €4,384 million.
Point of contacts for FITMAN
Mrs. Elena Rossi
Mr. Roberto Sanguini
TXT e-solutions is the FITMAN coordinator.
Founded in 1989, TXT e-solutions is an international software products and solutions vendor, leader in “Strategic Enterprise Solutions”. The company has been listed on the Italian Stock Exchange – STAR segment (TXT.MI) – since July 2000 and has about 600 employees. Consolidated 2014 revenues are € 55.9 million. TXT is based in Milan and has branches in Italy, Paris (F), Lyon (F), Wynyard (UK), Leicester (UK), Chemnitz (D), Halle (D), Barcelona (E), Toronto (CDN) and Sydney (AUS).
TXT is specialized in the most dynamic and agile markets with the highest degree of innovation and renewal that require state-of-the art solutions, where process and business play a fundamental role in growth and competiveness. To answer to customer’s needs TXT has always invested in technology and in business processes innovation, making this a cornerstone on which to build its success. Research and Development therefore holds a primary role in TXT, with important investments in both business areas:
- TXT PERFORM: End-to-end solutions for Fashion, Retail, Consumer Goods and Manufacturing sectors;
- TXT NEXT: advanced Software Engineering Services for companies in the Aerospace, Automotive, High-Tech and Banking sectors.
Point of contacts for FITMAN
Mr. Michele Sesana