Fulfilling ATA Customer Mandates to Commission High Memory Tags

Lloyd Whiting Principal Business Integration Analyst, Service and Asset ManagementRockwell Collins © 2012 Rockwell Collins. All rights reserved.

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About Rockwell Collins

• A global company operating from more than 60 locations in 27 countries on 6 continents

• A balanced business across markets we serve— $4.8 billion in sales (2011)— Government – 58% of sales— Commercial – 42% of sales

• 20,000+ employees on our team

• Leader in avionics and communications solutions

• Key differentiators— Innovation and diversity— Quality and customer trust— Industry collaboration

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ATA Involvement

• Air Transport Association (ATA) eBusinessProgram– Global commercial aviation industry

collaboration (including Rockwell Collins)– Standards for information exchange – Spec2000 addresses materiel management

• Chapter 9-5 covers RFID standards– Consistent with nameplate data dictionary– Governed by RFID on Parts Project Team

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The business need…

Airbus requires high memory (RFID) tag use in parts tracking of all serialized,

replaceable, and repairable parts of the A350

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Existing Technology Infrastructure

Multi-tier architecture across 5 continentsServer Infrastructure (mostly virtualized) Wintel with multiple domainsUnix (Netweaver / SAP)

Windows based PC clients

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Existing Technology Infrastructure

Single SAP instanceWireless (in most locations)

(No) RFID standardsTagsReader

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Technological Requirements• Must meet industry specifications

– ATA Spec2000, Chapter 9-5• Birth records• Part history records

– EPC Global, C1G2• Airbus requirements

– A350 XWB; Serialized, Repairable, Life limit• Environmental conditions

– SAE AS5678– Both pressurized and unpressurized

• High memory– RFID vs. CMB

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RFID vs. CMB

• Contact Memory Buttons (CMB)– Pro: small, durable, high memory– Con: proprietary technology, touch access

• RFID– Pro: standards-driven, no line-of-sight– Con: high memory chips not mature, cost

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What we did…

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Phased Project Approach

• Phase 1: Birth record writing via bar code• Phase 2: Birth record writing via WiFi• Phase 3: Part history record writing

– Includes service center process– Postponed until service contracts in effect by

late 2013• Other phases de-scoped to meet deadlines

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Project Time Frame• ATA birth record capability

– Kick-off lean event: February 2010– Requirements elicitation– Customer benchmarking (Airbus visit)– Solution development– Solution implementation– Project closed: September 2011

• ATA part service history record capability– Kick-off: Fall 2012

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Solution Development• Source system components• Map birth record data fields to SAP• Design SAP data output (printout & XML)• Connect RFID hardware to wireless LAN• Add RFID tags to assembly drawings• Define process flow

– Develop RFID process triggers– Identify user groups

• Write and publish system documentation

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RFID Partners• Maintag FLYtag®

– Uses high memory TegoChipsTM

– Two sizes available• Rectangular 49 x 24 x 5.5 mm• Circular 14 mm Ø x 5 mm

• Motorola MC9090Z Handheld– Ruggedized, one-piece design– Features

• 2D barcode imager/reader• WiFi enabled

• OATSystems®– Software provider and solution integrator– History with Airbus and Rockwell Collins– Scalable, SAP-integratable

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RFID Birth Record Requirements

TEI Cod

e

Description Mandatory/ Conditiona

lMFR Manufacturer Cage Code MSER Unique Serial Number MPNO Original Part Number MPDT Part Description MDMF Date of Manufacture MHAZ Hazardous Material Code CPML Modification Level at Birth CTDN Airworthiness Certificate Tracking No. C

• Stored in “User Memory” section of tag• “Perma-locked”

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RFID Data Retrieval• Phase 1 (Bar code)

– Faster development of birth record capability

– Reduce risk of missing delivery schedule

– Back-up system if wireless LAN goes down

• Phase 2 (WiFi)– Avoids printing data sheet– Data keys

• Part number• Serial Number

– Data files sent over wireless LAN via web services

LANSAPOAT

WiFiD

ata

Key

s

Dat

a R

ecor

d

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RFID on Parts Flow for New Builds

LRU Build

Attach RFID

Tag per Drawing

LRU Test

/Inspect

Finished Goods

Finished Goods

Encode Birth

RecordPack Inspect Ship

Additions to Original Process

Process Trigger

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First RFID-enabled Airbus Deliveries

• August 2011

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Lessons Learned• Scope of “Enterprise RFID”

– 18 months spent on - what does it mean?– Tried to accomplish too much

• RFID infrastructure • Birth Record tagging• US DoD Shipping Labels• Service History

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Lessons Learned• Implementation

– Bleeding edge technology…• RFID chips not ready• Middleware & a moving target of standards

– Commitment dates - Internal & External– Money NOT an issue?!?!– Success

• Met Requirements • On-time • Under budget

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Questions?For more information, visit www.rockwellcollins.com