A leading aircraft maintenance, repair, and overhaul (MRO) provider, serving a global network of airlines, required a more efficient solution to track and manage its extensive inventory of maintenance tools and equipment. With a commitment to delivering high-quality MRO services, the company sought to enhance operational efficiency by replacing its manual and barcode-based tracking system with an advanced asset tracking system.
Given the complexity of MRO operations and the critical nature of tool availability, the company needed a solution that would provide real-time visibility into asset movement, improve workflow efficiency, and enhance security with RFID access control and automated tracking.
Problem
Managing a vast inventory of MRO tools and equipment was becoming increasingly challenging. The reliance on manual tracking and barcode scanning created inefficiencies, including delays in locating tools, inventory discrepancies, and increased paperwork. Key challenges included:
- Lack of real-time visibility into the location and status of tools.
- Inefficiencies in manual tracking, lead to misplaced tools and delays.
- No automated system for monitoring calibration and maintenance schedules.
- Increased risk of unauthorized tool usage or removal due to limited access control systems.
- Ineffective supplier management and replenishment processes, leading to stock shortages.
To streamline MRO asset tracking and improve operational efficiency, the company partnered with TracTeck, a leader in identification technology and enterprise solutions. TracTeck implemented an industry-leading MRO asset tracking system powered by RFID access control and asset tracking software to automate tool tracking and management.
The Tool Tracking & Management System (TT&MS) was designed to provide real-time visibility into the location and usage of tools while eliminating manual tracking inefficiencies. Key features of the solution included:
- Automated Tool Tracking – The system enabled real-time tracking of assets as they moved in and out of maintenance stores, ensuring accurate inventory records.
- RFID Employee Badges for Access Control – Technicians and maintenance staff were assigned RFID-enabled badges, allowing controlled access to tools and preventing unauthorized usage.
- Calibration and Inspection Monitoring – The system provided automated alerts for scheduled calibrations and inspections, ensuring compliance with maintenance standards.
- Mobile RFID Scanning for On-Demand Tools – Toolkits were delivered directly to flight bays using handheld RFID scanners, reducing retrieval time and improving workflow efficiency.
- Smart Replenishment & Supplier Management – Automated monitoring of expendable and durable items ensured timely reordering and supplier performance tracking.
- Seamless Integration with Existing Systems – The solution was designed to integrate seamlessly with the company’s existing MRO asset tracking and ERP systems for centralized visibility.
Results & Benefits
By implementing TracTeck’s asset tracking system, the MRO provider significantly enhanced efficiency, reduced tool misplacement, and improved overall inventory management. Key benefits included:
- Increased Operational Efficiency – Automated tracking reduced time spent searching for tools, improving workflow and minimizing downtime.
- Enhanced Inventory Accuracy – Real-time tracking and automated data capture eliminated stock discrepancies and ensured up-to-date inventory records.
- Improved Access Control & Security – RFID-based access control systems ensured that only authorized personnel could access tools, reducing the risk of unauthorized usage.
- Streamlined Compliance & Audit Readiness – Automated calibration tracking and inspection alerts ensured that tools met safety and maintenance standards, improving audit readiness.
- Optimized Stock Management – Smart replenishment systems reduced stockouts and ensured continuous availability of critical maintenance tools.
- Faster Turnaround Time – Improved tool availability and streamlined workflows reduced maintenance delays, leading to faster aircraft turnaround.
Conclusion
The successful implementation of TracTeck’s RFID access control and asset tracking software transformed the MRO provider’s tool management process, eliminating manual inefficiencies and enhancing operational control. By leveraging warehouse automation systems and MRO asset tracking technology, the company achieved greater efficiency, improved compliance, and strengthened its maintenance operations.
With a future-ready asset tracking system in place, the company continues to optimize its MRO processes, ensuring seamless operations and delivering superior service to its airline partners worldwide.
