Case Study · Aerospace & Defence

Aerospace Tool Tracking

Tata Boeing

Impinj R420 UHF ReadersTimes 7 UHF AntennasHexaIoT RFID HubStack-light & Buzzer SystemTouch-screen KiosksMetal-mount UHF Tags

95%

Tool loss reduction

90%

Audit time reduction

Zero

FOD incidents

+22%

Technician productivity

Business Challenge

Strict FOD (Foreign Object Debris) compliance required 100% tool accountability across the aircraft fuselage assembly facility in Hyderabad. Manual sign-out boards and shadow-board audits could not keep pace with multi-shift operations, causing audit risk and production delays.

Solution

Deployed a complete HexaHash RFID Tool Tracking Zone covering the assembly bays — UHF RFID tags on every tool, in-zone antennas continuously reading tool presence, kiosks at each bay for authorized issue / return, and stack-light + buzzer alerts for instant FOD response. Integrated with the customer's ERP and quality systems.

Outcomes

Delivered measurable impact across 4 KPIs with full integration into the customer's existing technology stack.

Technology stack

Edge Sensors

Readers / Anchors

HexaHash Middleware

HexaRTLS Platform

Customer ERP / MES

Live Dashboards

Implementation milestones

1Discovery & site survey
2Architecture & PoC
3Pilot deployment
4Full rollout
5Hypercare & optimization

Customer outcomes

Tool loss reduction
95%
Audit time reduction
90%
FOD incidents
Zero
Technician productivity
+22%