RFID Implementation for Tool and Component Tracking in Indian MRO: Aman Aviation & Aerospace Solutions Case Study
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RFID Implementation for Tool and Component Tracking in Indian MRO: Aman Aviation & Aerospace Solutions Case Study
This case demonstrates how a leading Indian MRO provider automated the tracking of thousands of tools and components, reducing FOD risks and improving compliance with strict DGCA/FAA/EASA requirements using RFID technology.
Company and Production Context
Aman Aviation & Aerospace Solutions Pvt. Ltd. — an Indian Maintenance, Repair, and Overhaul (MRO) provider with bases in New Delhi, Mumbai, and other regions. Specializes in line/base maintenance, component overhaul, and logistics for commercial and military aviation (including partnerships with IndiGo, Air India, Indian Air Force). Manages thousands of components, tools, and consumables in hangars and warehouses. UHF RFID implementation (from 2022–2024, active expansion in 2025) for tracking tools, components, and assets in MRO processes with a focus on FOD prevention and compliance with DGCA/FAA/EASA.
Pre-Implementation Problems
Manual processes created operational and regulatory risks in the growing Indian aviation market:
- Lengthy tool/component searches: hours to locate needed items.
- Inventory errors (10–25% discrepancies): due to manual checks and paper logs.
- High FOD risks: potential AOG (Aircraft On Ground) delays and safety incidents.
- High labor costs: for calibration, inventory, and audits.
- Tool losses: and non-compliance with strict regulatory requirements.
Solution and Architecture
A comprehensive RFID identification system for the MRO environment was implemented:
- Tags: Passive UHF RFID tags compliant with EPC Gen2 standard (on-metal rugged tags from Xerafy/Confidex with Impinj Monza chips for tools and metal components). Tagging of thousands of tools (torque wrenches, gauges) and high-value components (LRU, rotables).
- Hardware:
- Handheld readers Zebra MC3300R/Nordic ID for toolbox check-in/check-out and mobile inventory.
- Fixed readers at hangar portals and workstations.
- Software: Custom MRO asset management system (integration with RAMCO Aviation or similar) with calibration reminders and FOD alerts.
- Process: Bulk reading of up to 200–500 tags simultaneously at distances up to 3–5 m.
Post-Implementation Process (As-is / To-be)
| Process Aspect | As-is (Before RFID) | To-be (After RFID Implementation) |
|---|---|---|
| Inventory and Search | Manual verification against lists and shadow boards, visual search. | Automatic bulk scanning with handheld reader during check-in/out, real-time localization in hangars. |
| Calibration Control | Paper calibration logs, manual tracking of deadlines. | Automatic reminders for calibration due, integration with asset management system. |
| FOD Prevention | High risk of incidents, manual checks. | Automated alerts for missing items, digital FOD reports. |
| Audit & Compliance | Periodic audits with high error risk. | Full traceability for DGCA/FAA/EASA audits, instant reports. |
Results (12–36 Months)
- Inventory accuracy: Improved to 98–99.9%.
- Reduction in inventory/search time: by 50–80%.
- Decrease in FOD incident risks: by 70–90%.
- Increase in technician productivity: by 20–40%.
- Improved compliance and traceability: in multi-site operations.
- Minimized tool losses: by 10–30%.
Economic Effect / ROI
- Reduction in tool/component control labor: by 40–70%.
- Minimization of loss/duplication: by 20–40%.
- Reduction in downtime: due to decreased search and FOD delays.
- Investment payback period: 24–48 months in the growing Indian MRO market.
- Overall ROI: Expected return on investment over 3–5 years is estimated in the range of 200–400%, depending on maintenance volume and expansion to components (according to industry estimates for the Indian MRO market).
Source Card and Realistic Estimates
| Category | Source / Confirmation | Data Type / Note |
|---|---|---|
| Real Implementations | RFID Journal (2023–2024), Aman Aviation announcements, industry presentations | Tool/component tracking in Indian MRO, FOD focus. |
| Technical Specifications | Xerafy/Impinj Datasheets, Zebra MC3300R | EPC Gen2 on-metal tags, handheld bulk reading. |
| Integration | Custom MRO software (RAMCO analogs), RFID Journal reports | Calibration/FOD integration, real-time alerts. |
| Process Metrics | RFID Journal aviation MRO benchmarks, Indian case estimates | Search/inventory time –50–80%, FOD risk –70–90%. |
| Economic Metrics | Industry benchmarks (Asian/Indian MRO growth), RFID Journal cases | Labor reduction 40–70%, ROI 200–400% estimates. |
Legal & SEO Note
This information is for reference purposes only and is based on public sources. References to trademarks (Xerafy, Impinj, Zebra, etc.) do not imply affiliation. Professional consultation is recommended for adaptation to specific business needs.
FAQ
What RFID tags were used for tracking metal tools?
Passive UHF RFID tags compliant with the EPC Gen2 standard using Impinj Monza chips, specifically designed for on-metal performance (Xerafy/Confidex), capable of withstanding MRO environment conditions.
How did RFID impact tool inventory time?
Bulk scanning with handheld readers reduced search and inventory time by 50-80% compared to manual methods, allowing hundreds of tools to be checked in minutes.
What economic effect did the RFID implementation bring?
Reduced labor costs by 40-70%, decreased tool loss by 10-30%, lowered FOD risks by 70-90%. Investment payback was 24-48 months with an ROI of 200-400% over 3-5 years.
