RFID in the Lufthansa Technik Group Technology for Logistics and Maintenance Processes

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1 Technology Logistics and Maintenance Processes

2 Agenda Company Profile RFID Approach Current use-cases of RFID Permanent Parts Marking Upcoming Applications 2 2 Copyright AG. Logistik All rights Services. reserved. All rights reserved.

3 The Five business segments. Passenger Transportation Air Freight Maintenance, Repair, Overhaul Catering IT Services 3 3 Copyright AG. Logistik All rights Services. reserved. All rights reserved.

4 Company Speaking aviation as native language. Maintenance, Repair, Overhaul Product Divisions: Maintenance Overhaul Engine Services Component Services Landing Gear Services VIP & Executive Jet Solutions Maintenance, Repair, Overhaul Logistics MRO needs Being a 100% subsidiary of, we combine the experience and the capabilities of a global logistics provider with the trusted knowledge of the aviation industry Specifically designed and optimized solutions all logistics concerns of the Aviation / MRO industry 4 4 Copyright AG. Logistik All rights Services. reserved. All rights reserved.

5 Agenda Company Profile RFID Approach Current use-cases of RFID Permanent Parts Marking Upcoming Applications 5 5 Copyright AG. Logistik All rights Services. reserved. All rights reserved.

6 Approach to using RFID technology Aircraft Maintenance Services Aircraft Component Services Copyright AG. Logistik All rights Services. reserved. All rights reserved.

7 Focusing on repairable spare parts Supplier Airline Internal Repair-Shop External Repair-Shop serviceable parts unserviceable parts 7 7 Copyright AG. Logistik All rights Services. reserved. All rights reserved.

8 LHT Component Service LRU pooling The Component-Pool: Approx Units in stock (Reserve) different Part numbers Value: approx. 1,2 Bill. Euro Multipurpose Control Display Galley Oven Flight Management Guidance & Envelope Computer Smoke Detector Aircraft Battery Coffee Maker 8 8 Copyright AG. Logistik All rights Services. reserved. All rights reserved.

9 Reasons permanent RFID marking Simplification of data collection 9 9 Copyright AG. Logistik All rights Services. reserved. All rights reserved.

10 Reasons permanent marking RFID directly on parts promises high potential Supporting on-board processes Aircraft Configuration Management periodic checks completeness and expiration date Supporting maintenance processes parts identification while installed and w/o line of sight simplifying handling and documentation of parts w/o serialization Supporting logistics processes accelerated receipt at delivery points proactive notification about upcoming parts Standardization of parts processes simplification of quality & certificate checks assisting & promoting paperless processes liquidation of cross media transactions Copyright AG. Logistik All rights Services. reserved. All rights reserved.

11 Current RFID usage Marking accompanying paper with smart labels Type: Frequency: Producer: Storage capacity chip: Stored Data: Smart: Rafsec DogBone UHF, 860 MHz bis 960 MHz UPM Raflatac 96 bit, re-writeable 15-digit smart label-id unambiguous smart label-id offered as rfid-number und barcode Copyright AG. Logistik All rights Services. reserved. All rights reserved.

12 Agenda Company Profile RFID Approach Current use-cases of RFID Permanent Parts Marking Upcoming Applications Copyright AG. Logistik All rights Services. reserved. All rights reserved.

13 Current RFID usage Transition Point between Aircraft removal and Repair Shop Process benefits of RFID enhancement automatic identification of packed parts at the central transition point no sight-contact / unwrapping needed electronic / no media conversion Part identification with RFID Implemented application start-of operation in 2008 on our site in Hamburg Roll-Out on our sites in Frankfurt and Munich in 2009 number of parts per annum: approx Result lead time reduction between aircraft removal and repair shop by 70 % Copyright AG. Logistik All rights Services. reserved. All rights reserved.

14 Current RFID usage Transition point between aircraft removal and repair shop Copyright AG. Logistik All rights Services. reserved. All rights reserved.

15 Current RFID usage RFID enhanced Pre-Storage Process benefits of RFID enhancement bulk reading of all parts when crossing an RFID- Gate RFID enhanced pre-storage immediate, automatic booking into available stock and theree disposability maintenance actions Implemented application on our main workshop-site Hamburg in November 2007 Roll-Out on our site in Frankfurt in 2009 number of parts per annum: approx Result lead time reduction between repair shop and availability in our warehouse by 70 % RFID-Gate with touch screen RFID-Tag identifying the carrier Copyright AG. Logistik All rights Services. reserved. All rights reserved.

16 Agenda Company Profile RFID Approach Current use-cases of RFID Permanent Parts Marking Upcoming Applications Copyright AG. Logistik All rights Services. reserved. All rights reserved.

17 Permanent Parts Marking Document tagging vs. Permanent Parts Marking Document tagging Ident-Tag (LHT-Proprietary) Smart-label (passive) Content: reference to Ident-Tag ID Customized bought and applied on document printing in LHT workshops or on goods receiving Permanent parts marking LRU, pool parts only permanent tag (passive) Content: master data, e.g. SNR, PNR, MFR (corresponding to ATA SPEC 2000) Applied on parts in the LHT workshops and new parts at MFR Copyright AG. Logistik All rights Services. reserved. All rights reserved.

18 Permanent Parts Marking Requirements of an MRO capable permanent tag Size Approx. 10 x 40 x 5 mm beveled sides to reduce the risk of shearing tag off the component No available tag covering the needs of the aviation industry Technical Requirements at least 512 Bit User Memory no battery operation in UHF ( MHz) must work on metal Chemical Resistance Kerosene, Skydrol, Hydraulic Oil, Acetone, Solvents, Mechanical / Temperature Resistance vibration operational shocks humidity altitude: 220hPa temperature: C flammability Standard Interoperability SAE AS5678 Class IP 69K ISO c EPC Class1 Gen2 ATA Spec 2000 Chap. 9-5 Other Read range >2m in EU & US on 2 Watt ERP possibility password protection Copyright AG. Logistik All rights Services. reserved. All rights reserved.

19 Permanent Parts Marking with avio.tag Alternative Mounting Methods Copyright AG. Logistik All rights Services. reserved. All rights reserved.

20 Permanent Parts Marking Tag Development and Qualification Dimensions 11 x 41 x 5,2 mm beveled sides to reduce the risk of shearing tag off the component Standard Interoperability FAA AC No EASA Policy on passive RFID Devices SAE AS5678 ATA Spec 2000 Chap. 9-5 ISO c / EPC Class1 Gen2 Technical Characteristics Operability on metal 512 Bit user memory No battery = passive Frequency band UHF ( MHz) Airworthiness and MRO-Capability Thermal resistance Mechanical resistance Chemical resistance Electromagnetic compatibility (EMC) Component Specification Compliance Matrix Requirements the testing of LHT Permanent Tag, Version 1 DOA 21/J Form 1 Qualification Test Report (QTR) Qualification Test Plan (QTP) Copyright AG. Logistik All rights Services. reserved. All rights reserved.

21 Permanent Parts Marking Further Development of Aviation Tag Today Development accomplished Development today Future Marking of accomanying Docs with Smart Label Permanent RFID-Tag Aviation Alternate Fixing and Safety Methods Permanent Parts Marking Mounting with adhesive foil + and/or Edge Sealer Copyright AG. Logistik All rights Services. reserved. All rights reserved.

22 Agenda Company Profile RFID Approach Permanent Parts Marking Current use-cases of RFID Upcoming Applications Copyright AG. Logistik All rights Services. reserved. All rights reserved.

23 Still to come Cabin Equipment Check Business Case: Quick and accurate check presence and expiration date of e.g. Emergency Equipment in terms of labour and processes. Life Vests First-Aid- / Doctor s Kit Oxygen Generator ca ea. ca. 250 Doctor s Kits ca ea. ca. 700 First-Aid-Kits Copyright AG. Logistik All rights Services. reserved. All rights reserved.

24 Still to come Cabin Equipment Check Copyright AG. Logistik All rights Services. reserved. All rights reserved.

25 Still to come Visibility & Compliance through real-time change inmation Workorder 3 Back-End IT Systems Correctness Check Documentation Start Following Process 2 s/a u/s 6 Additional Inmation Copyright AG. Logistik All rights Services. reserved. All rights reserved.

26 New Concepts: Automatic Check of Expiration Date RFID Tagging of Consumables Facing challenges Authority requirements lack of standardization greasy Single Labelling lubricious searching Shelf life monitoring Tracking & Tracing Localization dirty Data quality Time & Eft dispose soiled Data layout Product diversity investigate Expiration date Auditssticky Identification Storage diversity Copyright AG. Logistik All rights Services. reserved. All rights reserved.

27 New Concepts: Automatic Check of Expiration Date RFID Tagging of Consumables Selection and proof of RFID-technology Testing of various Smart Label and Handheld Hardware Proof of Concept within a testpilot Initializing of product data and shelf life control application Tagging of all items in designated department Partial tailoring of Smart Labels metal and extremly small surfaces Transfer of required data and Verification of successful storage on Smart Label Weekly check with RFID- Handheld Application Dispose products with Exp. <7 days (red) Use products with Exp days (yellow) bee usage of products with exp. > 21 days (green) RFID- Process Storage of tagged items Weekly check of all items Identifying of critical items Localizing of critical items Disposing of critical items Copyright AG. Logistik All rights Services. reserved. All rights reserved.

28 Auto-ID in Maintenance Processes Localization technology a transparent Supply Chain?! Copyright AG. Logistik All rights Services. reserved. All rights reserved.

29 Auto-ID in Maintenance Processes Localization technology a transparent Supply Chain Engine Transport HAM - JFK! G-Force Monitor 7 Attention! Flight LH400 delayed! Phone calls question Time stamps investigate search online manuell Where is AOG # 3675? NUE FRA HAM Copyright AG. Logistik All rights Services. reserved. All rights reserved.

30 Thank you your attention. Copyright 2011 Logistik Services GmbH. All rights reserved. The inmation contained in this presentation is proprietary to Logistik Services (LTLS) and is disclosed in confidence. The presentation and the inmation contained herein shall be kept strictly confidential and shall not be used, disclosed to others or reproduced without the express written consent of LTLS. Nothing contained in this publication shall constitute any warranty, guarantee or liability LTLS, its subsidiaries and affiliates but is inmation purposes only. Accordingly, LTLS its subsidiaries and affiliates neither expressly nor conclusively accept responsibility or liability the actuality, accuracy and completeness of the Copyright statements and inmation contained AG. Logistik All rights Services. in this reserved. publication. All rights reserved.

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