Tool Control in Aviation

Tool Control

The need for effective tool control measures is paramount to the design of all safe and efficient aircraft maintenance programs. The roots of its implementation must pervade the culture of the maintenance organization to be effective. There are several methods and controls that can be implemented, such as the use of tool chit systems, electronic databases used for tracking tool locations, and foam drawer liners in tool boxes to augment tool inventories. Today we discuss the driving factors behind tool control, how to implement these systems, and finally some of the methods that may be utilized.

Tool control in aircraft maintenance is not just about keeping up with our tools to prevent unnecessary replacement; rather it is about saving lives. If an auto mechanic leaves a wrench under the hood, it will likely fall out on the road somewhere, the only result being a mechanic who is out of a $10 tool. Aircraft mechanics have a whole different world of responsibilities in the tool realm. Left in the wrong place, a misplaced tool can lodge in flight controls or mechanisms, resulting in aircraft damage or the loss of an aircraft and flight crew. It’s not just about wrenches; tool control encompasses all things used by mechanics. A rag left in a fuel cell after in tank maintenance can clog fuel lines causing engine failure. A plug cap left in place and not turned can cause much worse, as in the case of the C-141 where a fuel cell vent cap was not removed, and upon subsequent refueling, the aircraft wing tank burst from pressure, causing the entire left wing to separate from the aircraft on the refuel pad. Lost tools not only endanger lives, they can cause losses in man-hours, missed or late sorties, and reduced overall maintenance effectiveness. Control measures are crucial to safety, but to work, a well thought out program must be in place.

For any system of controls to be effective, there must be clear guidance defining the program,...