RFID in the Lufthansa Technik Group – Technology for ... Supply Ch… · Technology for Logistics...

RFID in the Lufthansa Technik Group –

Technology for Logistics and Maintenance Processes

Lufthansa Technik styleguide for presentations23 February 2010, Copyright © 2010 Lufthansa Technik AG. All rights reserved. Subject to restrictions and disclaimer on last page.

RFID in the Lufthansa Technik Group February 21st, 2012, Seite 2Copyright © 2011 Lufthansa Technik Logistik Services. All rights reserved. Subject to restrictions and disclaimer on last page.

Agenda

Company Profile

RFID Approach

Permanent Parts Marking

Current use-cases of RFID

Upcoming Applications



The Lufthansa GroupFive business segments.

Passenger Transportation

Catering

Maintenance, Repair, Overhaul

Air Freight

IT Services




CompanySpeaking aviation as native language.

� Being a 100% subsidiary of Lufthansa Technik, 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 for all logistics

concerns of the Aviation / MRO industry

Maintenance Engine ServicesComponent

Services

Landing Gear

Services

VIP & Executive

Jet Solutions

Product Divisions:


Logistics for MRO needs

Overhaul



Agenda

Company Profile

RFID Approach






2005 2006 2007 2008

Aircraft

Maintenance

Services

Aircraft

Component

Services

RFID in the Lufthansa Technik GroupApproach to using RFID technology



RFID in the Lufthansa Technik GroupFocusing on repairable spare parts

Internal

Repair-ShopAirline

unserviceable parts

serviceable partsExternal

Repair-Shop

Supplier



LHT Component ServiceLRU pooling

The Lufthansa Technik Component-Pool:

� Approx. 120.000 Units in stock (Reserve)

� 20.000 different Part numbers

� Value: approx. 1,2 Bill. Euro

Smoke Detector Coffee Maker

Multipurpose Control Display

Flight Management Guidance & Envelope Computer

Aircraft Battery

Galley Oven



Reasons for permanent RFID markingSimplification of data collection



� Supporting on-board processes� Aircraft Configuration Management

� periodic checks for 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

Reasons for permanent markingRFID directly on parts promises high potential



Current RFID usage Marking accompanying paper with smart labels

� Type: Rafsec DogBone

� Frequency: UHF, 860 MHz bis 960 MHz

� Producer: UPM Raflatac

� Storage capacity chip: 96 bit, re-writeable

� Stored Data: 15-digit smart label-ID

� Smart: unambiguous smart label-ID

offered as rfid-number und barcode



Agenda

Company Profile

RFID Approach






Process benefits of RFID enhancement

� automatic identification of packed parts at the central

transition point

� no sight-contact / unwrapping needed

� electronic / no media conversion

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. 35.000

Result

� lead time reduction between aircraft removal and repair

shop by 70 %

Current RFID usageTransition Point between Aircraft removal and Repair Shop

Part identification with RFID



Current RFID usageTransition point between aircraft removal and repair shop



Process benefits of RFID enhancement

� bulk reading of all parts when crossing an RFID-

Gate

� immediate, automatic booking into available stock

and therefore disposability for 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. 100.000

Result

� lead time reduction between repair shop and

availability in our warehouse by 70 %

Current RFID usageRFID enhanced Pre-Storage

RFID enhanced pre-storage

RFID-Tag identifying the carrier RFID-Gate with touch screen



Agenda

Company Profile

RFID Approach






� 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 for new parts at

MFR

Permanent Parts MarkingDocument tagging vs. Permanent Parts Marking



Size• Approx. 10 x 40 x 5 mm • beveled sides to reduce the risk of shearing tag off the component

Chemical Resistance• Kerosene, • Skydrol, • Hydraulic Oil, • Acetone, • Solvents,• …

Mechanical / Temperature Resistance

• vibration• operational shocks• humidity• altitude: 220hPa• temperature: -65 – 160°C• flammability

Standard Interoperability• SAE AS5678• Class IP 69K• ISO 18000-6c• EPC Class1 Gen2• ATA Spec 2000 Chap. 9-5

Technical Requirements• at least 512 Bit User Memory• no battery• operation in UHF (860 – 960 MHz)• must work on metal

Other• Read range >2m in EU & US

on 2 Watt ERP• possibility for password protection

��

��

��

No available tag covering the needs of the aviation industry

��

Permanent Parts MarkingRequirements of an MRO capable permanent tag



Permanent Parts Marking with avio.tagAlternative Mounting Methods



Component Specification

Requirements for the testing of LHT Permanent Tag,

Version 1

ComplianceMatrix

Qualification Test Plan

(QTP)

Qualification Test Report

(QTR)

DOA 21/JForm 1

Permanent Parts MarkingTag Development and Qualification

Standard Interoperability

• FAA AC No. 20-162

• EASA Policy on passive RFID Devices

• SAE AS5678

• ATA Spec 2000 Chap. 9-5

• ISO 18000-6c / EPC Class1 Gen2

Technical Characteristics

• Operability on metal

• 512 Bit user memory

• No battery = passive

• Frequency band UHF (860-960 MHz)

Airworthiness and MRO-Capability

• Thermal resistance

• Mechanical resistance

• Chemical resistance

• Electromagnetic compatibility (EMC)

Dimensions

• 11 x 41 x 5,2 mm

• beveled sides to reduce the risk of

shearing tag off the component



Marking of accomanying Docs with Smart Label

Today


Future

Permanent RFID-Tag for Aviation

Development accomplished

Mounting with adhesive foil + and/or Edge

Sealer

Alternate Fixing and Safety Methods

Development today

Permanent Parts MarkingFurther Development of Aviation Tag



Agenda

Company Profile

RFID Approach






Still to come…Cabin Equipment Check

Business Case: Quick and accurate check for 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. 63.000 ea. ca. 250 Doctor‘s Kits ca. 25.000 ea.

ca. 700 First-Aid-Kits



Still to come…Cabin Equipment Check



Still to come…Visibility & Compliance through real-time change information

u/s

s/a

Additional

Information

1

2

Workorder

3

6

5

4

Back-End IT Systems

Correctness Check

Documentation

Start Following Process

7



Facing challenges…

Expiration date

Data quality Time & Effort

Tracking & TracingShelf life monitoring

Single Labelling

investigate

searchinglubricious

Audits

dirty

sticky

soiled

Product diversitydispose

Identification

Localization

lack of standardization greasyAuthority requirements

Storage diversity

Data layout

New Concepts: Automatic Check of Expiration DateRFID Tagging of Consumables



New Concepts: Automatic Check of Expiration DateRFID Tagging of Consumables

� 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.

7-21 days (yellow) before

� usage of products with

exp. > 21 days (green)

Proof of Concept within a testpilotInitializing of product data and shelf life control application

� Tagging of all

items in designated

department

� Partial tailoring of Smart

Labels for metal and extremly

small surfaces

Selection and proof of RFID-technologyTesting of various Smart Label and Handheld Hardware

RFID-Process

Weekly check

of all items

Identifying of critical items

Localizing of critical items

Storage of tagged items

Disposing ofcritical items



Auto-ID in Maintenance ProcessesLocalization technology for a transparent Supply Chain

!?



!

Attention!

Flight LH400 delayed!

Engine Transport HAM - JFK

0

1

2

3

4

5

6

7

G-Force Monitor

Phone calls

question search

investigate

online

Time stamps

manuell

HAM

FRA

NUE

Where is AOG # 3675?

Auto-ID in Maintenance ProcessesLocalization technology for a transparent Supply Chain



Thank you for your attention.

Copyright © 2011 Lufthansa Technik Logistik Services GmbH. All rights reserved.

The information contained in this presentation is proprietary to Lufthansa Technik Logistik Services (LTLS) and is disclosed in

confidence. The presentation and the information 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 for LTLS, its subsidiaries and affiliates but is for information purposes only. Accordingly, LTLS its subsidiaries and

affiliates neither expressly nor conclusively accept responsibility or liability for the actuality, accuracy and completeness of the

statements and information contained in this publication.

RFID in the Lufthansa Technik Group – Technology for ... Supply Ch… · Technology for Logistics...

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