It’s never just a tool - How a Boeing airframe tool is brought to life
Line maintenance, base maintenance, aircraft modifications or AOG situations do not only need ground support equipment, including tripod-jacks or axle-jacks, they also require special tools tailored to every single aircraft model. No matter if you are an MRO shop or an airline that does their own aircraft maintenance: Every time a new aircraft model enters service, you have to equip your hangars with the appropriate tools. What matters is that you have all the different tools, that can be up to 250 unique tools for a single aircraft, available and ready for use.
Just how is a Boeing tool created exactly? What are the fine points and the differences? Just how is a Boeing tool brought to life exactly? And how do I make sure that it operates its entire life?
In the beginning, there is a drawing
The drawing is the start for a new tool. All aircraft manufacturers have the drawings for the tools needed for their aircraft. Boeing does, too. They make these drawings available to various suppliers. The quality of the drawing extends from mere sketches that are several decades old to completely finalized 2-D or 3-D drawings. Are all specifications required for manufacture contained in the drawing? Are all the measurements specified in the suitable system of units to be used for manufacture (metric or imperial)? Depending on the quality of the drawing, preparation of the drawing in advance is necessary. All tooling must be made to latest revision of Boeing drawings. Customers need to be notified of any tooling changes that happen before delivery.
All unanswered questions that come up during the drawing preparation phase are tracked in a ticket system and coordinated with the manufacturer.
In the end, the customer expects a functioning tool regardless of the drawing's quality.
HYDRO for instance, always delivers to the latest standard drawing. They can only do this by being fully licensed by Boeing and having proper processes in place to update drawings.
The tool is brought to life during production
Is the tool produced in-house or at another subcontractor? If additional subcontractors are involved, many years of experience and the corresponding supplier network are necessary to achieve the quality desired at the end. In this process, supplier quality engineers, a strategic supplier management system, supplier development and regular supplier assessments, among other factors, play a large role worldwide. In short: Well-rehearsed processes must be used.
Airframe tools are not manufactured in large volumes but they do have large variance.
Whether coming from the supply chain or in-house: The individual parts are produced, purchased and assembled to the finished tool in final assembly stage. In this phase, precise work is necessary. After final assembly, the tool undergoes a functional test.
Now the new tool is ready to go.
HYDRO, for example, delivered more than 11,200 Boeing tools to its customers in 2019. These included just under 800 tools with different part numbers.
What does the customer expect? The right quality the first time
Boeing expects that the intended product quality will be provided from the outset.
For this reason, after production of a tool, a quality check uses the latest instruments such as laser test systems to make sure that the tool matches the drawing. Are all the specified measurements correct? Did the tool function under a proof load with an appropriate safety margin?
Quality Assurance also makes sure that all test certificates, calibration certificates and COCs are completed and accompany the product. Tools used in the European market also get a CE marking where necessary.
The quality inspector is the final gate keeper who makes sure that only tools that are 100% on quality will be delivered to the customer.
HYDRO, for instance, gives an extended warranty period of 3 years because they stand behind their work.
Delivery to the customer: A new airframe tool is born
The customer expects that all tools will be supplied in packaging that is intended to last the lifetime of the tool and to provide superior protection.
What really counts is that the tool will be delivered on time to the customer. Because time is money, and every single tool counts. If only one tool is missing, a maintenance task can’t be finished and the Boeing model stays on the ground. This is why delivery reliability is so important and differentiates the various suppliers on the market.
For instance, Boeing tools from HYDRO include free packing for freight by HYDRO USA, as well as logistics planning and coordination with the customer’s carrier of choice.
How to keep the Boeing tool going
However, the life of the tool does not end when delivered to the customer. After-sales care makes the difference here. For example, this includes tool recertification, any necessary repairs or the implementation of tooling revisions. Everything needed to keep the tool in use for decades and to keep it ready to function whenever it is needed.
HYDRO, for example, has a global network of 11 service centers so we are always near the customer and can stand by every single tool for its whole life.
Interested in Boeing Airframe tools from HYDRO? Contact your local Area Sales Manager