Case Studies

Dyess AFB Tool Automation


Problem:

Man-power intensive tool accountability demands aircraft maintenance personnel spend their time controlling tools rather than fixing aircraft

  • Lack of Focus: The current Tool Accountability System (TAS) and TCMax require too much human interaction, resulting in lack of focus on maintaining aircraft.
  • No Metrics: TAS takes manual inputs and does not allow user to manipulate reports or inventories to fit customers needs.
  • Time Intensive: Tool custodians and maintenance personnel spend large amounts of time during the check-in/out process, at least twice per shift.
  • Manning Loss: 5-10% of aircraft maintenance personnel must be taken out of their primary career field in each Squadron to ensure tool accountability.
  • No Current Solution: No commercial off the shelf (COTS) tool accountability system meets Air Force standards.

Solution:

Partner with the leading identification company, IDZ, to create an automated tool solution viable for Dyess, AMC, and the Air Force

  • Utilize standard tool box and existing knowledge of tool control processes.
  • Integrate passive RFID and standard issue Common Access Card (CAC) for individual item tool control for all Airmen.
  • Automate both check-in/out and calibration tracking processes
  • Incorporate web-base applications and tailored software for greater span of accountability and transparency between shops, Squadrons, and MAJCOMs

Results:

Defined and implemented an automated tool control system (Itelmatic) with feedback from Airmen at all levels of tool control: flightline, backshop, Squadron, Group, Wing, MAJCOM and other AMC bases.

  • 24-hour real-time like item tool accountability
  • Implemented initial 50-tool prototype system on 4 Feb 08. Resulted in 25 hours saved daily
  • Currently expanded to 10 Itelmatics with 14 additional automated boxes in production with a total of over 2,500 individual tools being tracked in real time on the flightline and in the backshops
  • Over 100 pieces of PMEL and equipment items being tracked and controlled
  • 16,500 man-hours saved to date
  • Made low-manned CTK shop a viable and productive shop (Zero Defects in the Fall 2008 LSEP/UCI)

The Way Ahead:

After “complete” Dyess tool automation, AMC plans to expand IDZ solutions to all other AMC bases. IDZ has implemented their solutions in ACC with plans to move into AFMC, other DoD installations, and the commercial aerospace industry.

  • Following expanded implementation, the Air Force will grant IDZ network access for global tool control and equipment oversight through network integration.
  • IDZ is constantly expanding their hardware and software product suite and plan to create a lasting inventory, tool, and equipment control software to integrate into automated and non-automated/”dumb” process controls. IDZ’s hardware will fill specific niches for tool and equipment control and tracking priorities across the DoD and commercial areas.
  • IDZ is capable of interacting with different tool management software such as TAS and TCMax
  • Through Business Case Analysis (BCA), IDZ anticipates that MAJCOM’s and Air Staff will continue to fund automated tool control needs at the base level to ensure that Airmen are focused on their primary duties, fixing and flying America’s combat aircraft.