RFID Maintenance ProgramDelta Air Lines
Mike Kotas
Director
Cabin Maintenance
IATA RFID Aircraft
Technical Operations Conference
Toulouse, France
November 13, 2014
Delta Air Lines
Who we are
Delta began flying passengers 85 years ago, and has been committed
to innovation and climbing to new heights ever since.
• Headquarters: Atlanta, Georgia, USA
• Nearly 80,000 Employees Worldwide
• Aircraft: 17+ fleet types, 760+ Aircraft
• Daily Flights: Over 2,950 Mainline Flights
• On-Time Performance: 86.3%
• Serving nearly 165m customers each year
• Recent partnership addition - Virgin Atlantic
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Delta TechOps - Cabin Maintenance
Mission: Protect the Brand
Mission Objectives:
•
Quickly (Fast)
•
Lowest Cost (Cheap)
•
SEA
BOS
MSP
DTW
JFK
LGA
SLC
Minimal Inconvenience (Good)
CVG
LAX
ATL
MCO
NRT
HKG
LHR
MNL
AMS
CDG
SIN
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Rick’s Hair
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Program Timeline
2016
2014
2013
2011
RFID Airframe
Engineering team
established + 34k
tags flying
800+ Aircraft will
be fully RFID
tagged!
RFID Mtc. program
approved by FAA
1st RFID Induction
on B757
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End User of RFID tags
The MECHANIC!
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O2 Generator RFID Scan
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RFID at Delta
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Cargo
ACS
Freight
Baggage
RFID Mtc. Program
TechOps
Airframe
09/13/2014
Logistics
DELTA AIR LINES, INC.
Why RFID at TechOps?
1. Compliance & Configuration:
• Presence
• Expiration
2. Material Yield:
• Material Life (Green time)
• Predictability: Just in Case vs. Just in Time
3. Labor Savings:
• Reduce Time Spent on Date Checks
• Reduce Human Factors Errors
4. Safety
5. Logistics
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Compliance & Configuration
RFID Benefits:
TIME LIMIT OVERRUNS
BY COMPONENT 2010-2013
•
Reduce risk of overrun on life
limited parts
•
Quickly check presence and
expiration of life-limited
components
•
Check security and tamper
evidence to comply with TSA
regulations
Various
2%
Squib
15%
EE
18%
Slide
4%
LIFE VEST
O2 GEN/Mask
O2 Gen
7%
SLIDE
Life Vest
54%
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EE
RFID Mtc. Program
APU/CARGO/ENGINE
BTL SQUIB
VARIOUS
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DELTA AIR LINES, INC.
Human Factors Errors
•
Delta is required to visually check the presence, condition,
security, and expiration of all life limited parts
•
Each part may have manufacture, expiration, service, or packaging
dates, etc. which can introduce human factors errors and
increase labor required
ELT
Water Fire Ext
First Aid Kit
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RFID Mtc. Program
Halon Fire Ext
EEMK
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DELTA AIR LINES, INC.
Material Yield
O2 Generators
8-years
2-years
Visual
RFID
On Shelf
On Aircraft
2-months
On Shelf - Buffer stock for the unknown demand
• High inventory count
• Reduced material life on shelf (avg. 12 months)
Replace - Early replacement
• Replace at avg. 14 months remaining
Example - Waste
• Avg. Cost: $400 /pc
• Avg. Waste: $78 /pc
• Fleet Waste: $130K (*$13K/AC x 10 A/C)
Potential Fleet Waste Reduction:$110K
*Estimate: life on shelf 3 month in Inventory & 2 month life remaining
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Just in Case to Just In Time
RFID Mtc. Program
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Labor Productivity
Visual Inspection vs. RFID Scan (B777)
Hrs
14
12
Life Vests
• Visual: 12 hrs
• RFID: 35 min (2 min to scan)
95%
Improvement
10
93%
Improvement
8
6
83%
Improvement
4
62%
Improvement
2
0
Life Vest
Life Vest
Security
Seals
Emergency
O2
Generator Equipment
Visual
Potential:
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RFID Mtc. Program
RFID
Life Vest Security Seals
• Visual: 45 min
• RFID: 17 min (2 min to scan)
O2 Generators
• Visual: 8 hrs
• RFID: 32 min (2 min to scan)
Emergency Equipment
• Visual: 4 hrs
• RFID: 40 min (10 min to scan)
22.7 Labor Hrs/ Aircraft!
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Labor Productivity Annualized
Visual Inspection vs. RFID Scan
Potential:
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RFID Mtc. Program
26 FTE reduction
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DELTA AIR LINES, INC.
Operator Needs
1.
Ultimate customer – the line/shop maintenance technician
• All uses not created equal
• Flexibility -
2.
Good, Cheap, and Fast
Proper Industry Standards
• Low Memory Tag Standard
– Expendable parts
• High Memory Tag Standard
– Used for parts pooling (Loans/Borrows)
Average 777 A/C Tags
Low Mem: 902 (98%)
High Mem: 24 (2%)
1. Tag simplification – Don’t want/need 40 different tags
2. The right tag for the right usage
3. Readers/Software that read all tags
4. Standardized coding
– Testing Standards
– Conformity
– Read/Write standards
5. Physical tag maintainability
6. Parent/Child master data (Server based data vs tag based data)
7. Data security
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So, What’s Next?
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Continue Our Climb
Next RFID Targeted Items:
Current
Next
Life Vest
A/C Registration Certificate
Life Vest Container Security
Seal
Galley Cart/Carriers/Waste
Container
O2 Generator
Chillers/Coffee Makers/Oven
Emergency Equipment
Cushion & Leather
APU/Cargo/Engine Squibs
Rotable Parts
Crew O2 Masks
Landing Gear
Tablet Solution: Paperless operation, Information at your fingertip!
• e-document
• e-signature
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Thank You
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Questions?
For more Information
Please contact:
Mike Kotas
Director – Cabin Mtc, IFE, Engineering
mike.kotas@delta.com
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Eri Hokura
RFID Program Manager
eri.hokura@delta.com