RFID Tool Tracking Zone for FOD Prevention & Control
Business Challenge
The customer operates a high-volume aircraft assembly facility where Foreign Object Debris (FOD) is a zero-tolerance risk. Manual tool sign-out boards and shadow-board audits could not keep up with multiple shifts, parallel assembly lines and stringent AS9100 audit requirements. A single misplaced torque wrench or gauge could trigger a costly grounding event or compliance failure.
Solution Deployed
HexaHash deployed a complete RFID Tool Tracking Zone covering the assembly bays. Every tool — torque wrenches, sockets, micrometers, drill bits, gauges and consumables — was tagged with a ruggedized UHF RFID tag. Overhead and cabinet-mounted antennas continuously monitor tool presence, while kiosks at each bay handle authorized tool issue and return.
RFID Equipment Used
- Impinj R420 fixed UHF RFID readers
- Times 7 UHF RFID antennas (slim-line, in-zone)
- HexaIoT RFID Hub (edge gateway with offline buffering)
- Stack-light and Buzzer System for visible / audible FOD alerts
- Industrial touch-screen kiosks for technician self-service
- Metal-mount UHF RFID tags engineered for shop-floor tools
- HexaTrack tool lifecycle software with AS9100 reporting
Implementation Process
- Discovery & site survey across assembly bays and tool cribs
- RF site-survey, tag selection and bay-level antenna design
- Tagging of full tool inventory with photo, owner and calibration metadata
- Cabinet, trolley and kiosk installation; reader and HexaIoT Hub commissioning
- Integration with the customer's ERP and quality management systems
- Operator training, SOP rollout and hyper-care across three shifts
Outcomes Achieved
Outcomes reported by the customer's plant engineering and quality teams across the first 12 months post go-live.