Tool control is an essential part of preventing avoidable aviation accidents, helping to keep both passengers and crew of commercial and private aircraft safe whilst in flight.
Many major countries operate tool control policies precisely for this reason, so it’s vital that aviation engineers take the necessary steps to ensure the tools they use are always accounted for after completing routine maintenance or aircraft repairs.
Shadow foaming is just one of a handful of aircraft tool control systems that aviation operators use to keep tabs on their tools day-to-day.
Here, we take a look at how this simple method of tool accountability works and why this system of tool control in aviation maintenance is favoured by so many aviation professionals.
What is tool control policy in aviation?
In the aviation industry, a tool control policy regulates how aviation tools, such as those used to service or repair an aircraft, are stored, logged, and maintained.
The purpose of a tool control policy is to ensure that all tools that come into contact with an aircraft are in a perfect state of repair (I.e., not damaged nor broken) and that each tool can be accounted for when the job is complete.
This is to ensure that no tools are accidentally left in the vicinity of the aircraft, where they could potentially cause damage to the aircraft before it takes flight or once it’s in motion.
Why is tool control important in aircraft maintenance?
Never underestimate the importance of tool control in aviation. If unaccounted for, loose tools can easily damage an aircraft and render it unsafe for travel.
This can occur if a tool gets sucked into the engine, as was the case when a screwdriver tip got lodged in an Airbus A320 in Australia.
Similar aviation incidents have involved a torch jamming the landing gears of a Boeing 747 and a pair of cutting pliers preventing the undercarriage from retracting, also on a 747.
Some instances have resulted in catastrophic failure and mass fatalities. Having a robust aircraft tool control system, therefore, is essential in helping to prevent these avoidable accidents from occurring.
Shadow foaming: Efficient tool control in aviation
Custom shadow foaming, a service we offer at Red Box Tools, is a form of tool control that’s extremely popular in the aviation sector. It involves each tool having its own bespoke space in a piece of laser-cut foam, usually consisting of two contrasting colours.
This system not only makes it obvious to see when a tool is missing, it also offers a storage solution where each tool is neatly organised and protected, thereby minimising tool damage.
Benefits of shadow foaming and tool etching for tool control solution in aviation
- Timesaving
Forget foraging around frustratingly in your toolbox, trying (and failing) to track down the precise sized screwdriver, wrench, or key you need. With shadow foaming every tool has its place, so you can always find exactly what you’re looking for in seconds, without having to sift through loose tools each time.
- Security (FOD – Foreign object debris)
Using a shadow foaming system is the perfect way to prevent Foreign Object Debris. The two-colour foam makes it easy to identify and report any tools that are missing, so you can always ensure that all tools are put back where they belong and safely stored out of harm’s way.
- Tool accountability
Shadow foaming is also a great way to keep aerospace engineers and other operatives accountable for the tools they take out. The system makes it easy for maintenance and service teams to keep track of tools while they work and easily inventory tools at any given moment.
- Tool etching with custom code
For additional tool control, you can also combine shadow foaming with custom tool etching. This is a great way to add another layer of accountability, by assigning each tool a unique code. Not only does this help with proof of ownership in the event the tools are stolen, but you could also set up a system where each tool is logged in and out during use, making them traceable to a specific engineer in your team.
Conclusion
Shadow foaming is a perfect solution for complying with tool control regulations in aviation environments. The system is one of the easiest to set up and because each element is bespoke it offers total flexibility.
To prevent operational disruption on the ground, each tool can be individually scanned on-site at your premises by our technicians, rather than in our own studio. What’s more, our high-quality CNC tool foams can be sized to any specification, so you won’t even need to upgrade your existing tool storage if you don’t want to.
For industries where safety is paramount and a lack of organised tool control puts lives at risk, shadow foaming offers a proven solution to ensure your operation is compliant and your team executes its duties to best practice industry standards.
