David Waind Aircraft Engineer Business Development Manager * STAHLWILLE Germany

1. David Waind Aircraft Engineer Business Development Manager * STAHLWILLE Germany

2. Where does the name Stahlwille originate?

3. Wuppertal Solingen Remscheid Where is the Company Located?

4. A Tradition of Quality and Innovation Since 1862 Today as back in 1862, the products we manufacture are without exception MADE IN GERMANY

5. 143 Years of Tool Manufacturing Expertise

6. Who are we now?… Family owned business run as a publicly traded company (AG) Managed by non family members (day to day and Board of Directors) Over 750 employees in the Stahlwille Group More than 60% of all revenues are generated through export Wholly owned European subsidiaries 5 production centers in Germany 10 complete groups of Hand and Specialty tools (4500 products) Close cooperation with industry leading OEMs (Aerospace, Automotive & Industrial Worldwide) The first tool company to be certified to DIN EN ISO 9001 (not 9002 as most other Tool manufacturers) in 1989

7. Who Belongs to the Stahlwille Group?

8. What is in the Stahlwille Product Range? A complete program of over 4500 individual hand tools and storage solutions

9. A Tradition of INNOVATION - Quick Release - Tool Control Systems - HPQ and Cold Forging

10. Tool Control Standard „Catalogue“ Solutions TC Socket Sets 97/6 KM 806/9 TCS

11. Tool Control Standard „Catalogue“ Solutions 97/8 KM

12. Tool Control Custom & Customer Specific Projects

13. 144X TPI New Products - Aerospace 13220 Boroscope Plug Tool for EJ200 PH / PZ 440MJ Toothed Spline Adapters The World’s Finest Lockwire Pliers

14. Aerospace References

15. STAHLWILLE UK

16. FOD PREVENTION STRATEGIES RISK vs. BENEFITS More than just a Safety Strategy? Risk or Reality?

17. FOD ($ £ €) RISK Which carries more weight? Risk or Cost?

20. The Realities of FOD - a need for Tool Control UK CAA Maintenance MORs Analysis (1992)3 The UKCAA published a list, in 1992, of frequently recurring maintenance discrepancies, based on Mandatory Occurrence Reports. The problems, in order of frequency of occurrence, were: Maintenance MORs (CAA 1992) • incorrect installation of components • fitting of wrong parts • electrical wiring discrepancies (including cross-connections) • loose objects (tools, etc) left in aircraft • inadequate lubrication • cowling, access panels and fairings not secured • landing gear ground lock pins not removed before departure Professor James Reason reports a further breakdown of these figures as: • Fastenings undone/ incomplete (22%) • Items left locked/ pins not removed (13%) • Caps loose or missing (11%) • Items left loose or disconnected (10%) • Items missing (10%) • Tools/spare fastenings not removed (10%) • Lack of lubrication (7%) • Panels left off (3%)

21. (£ $ €) RISK Aside from the risks why bother?? 1) Government Regulation Environmental Issues Health and Safety Regulation 2) Technical Requirements for Efficient / Safe Operation 3) Insurance Requirements 4) Social and Moral Obligations

22. FOD Government Regulation Environmental Issues Health and Safety Regulation Just what is formally required?

23. FOD Government Regulation EASA 145.A.40 Equipment, tools and material (a) The organisation shall have available and use the necessary equipment, tools and material to perform the approved scope of work. 1. Where the manufacturer specifies a particular tool or equipment, the organisation shall use that tool or equip- ment, unless the use of alternative tooling or equipment is agreed by the competent authority via procedures specified in the exposition. 2. Equipment and tools must be permanently available, except in the case of any tool or equipment that is so infrequently used that its permanent availability is not necessary. Such cases shall be detailed in an exposition procedure. 3. An organisation approved for base maintenance shall have sufficient aircraft access equipment and inspection platforms/docking such that the aircraft can be properly inspected. (b) The organisation shall ensure that all tools, equipment and particularly test equipment, as appropriate, are controlled and calibrated according to an officially recognised standard at a frequency to ensure serviceability and accuracy. Records of such calibrations and traceability to the standard used shall be kept by the organisation. d) The practical training element shall cover the practical use of common tooling/equipment, the disassembly/assembly of a representative selection of aircraft parts and the participation in representative maintenance activities being carried out relevant to the particular Part-66 complete module.

24. FOD Government Regulation EASA AMC 145.A.40(b) Equipment, tools and material 1. The control of these tools and equipment requires that the organisation has a procedure to inspect/service and, where appropriate, calibrate such items on a regular basis and indicate to users that the item is within any inspection or service or calibration time-limit. A clear system of labelling all tooling, equipment and test equipment is therefore necessary giving information on when the next inspection or service or calibration is due and if the item is unserviceable for any other reason where it may not be obvious. A register should be maintained for all precision tooling and equipment together with a record of calibrations and standards used. 2. Inspection, service or calibration on a regular basis should be in accordance with the equipment manufacturers' instructions except where the organisation can show by results that a different time period is appropriate in a particular case.

25. FOD Government Regulation EASA Part M.A.402 Performance of Maintenance (a) All maintenance shall be performed by qualified personnel, following the methods, techniques, standards and instructions specified in the M.A.401 maintenance data. Furthermore, an independent inspection shall be carried out after any flight safety sensitive maintenance task unless otherwise specified by Part-145 or agreed by the competent authority. (b) All maintenance shall be performed using the tools, equipment and material specified in the M.A.401 maintenance data unless otherwise specified by Part-145. Where necessary, tools and equipment shall be controlled and calibrated an officially recognised standard. (c) The area in which maintenance is carried out shall be well organised and clean in respect of dirt and contamination. (d) All maintenance shall be performed within any environmental limitations specified in the M.A.401 maintenance data. (e) In case of inclement weather or lengthy maintenance, proper facilities shall be used. (f) After completion of all maintenance a general verification must be carried out to ensure the aircraft or component is clear of all tools, equipment and any other extraneous parts and material, and that all access panels removed have been refitted.

26. Government Regulation - Just what is required????? (f) After completion of all maintenance a general verification must be carried out to ensure the aircraft or component is clear of all tools, equipment and any other extraneous parts and material, and that all access panels removed have been refitted.

27. FOD Technical Requirements for Efficient / Safe Operation Manufacturers Sub-Contractors Service Providers Warranty Implication Compliance = Costs ($) or Savings?

28. FOD Health and Safety Loss of Life Serious Injury A cut Finger A slight Headache !! Management = Costs ($) and to whom?

29. FOD Insurance The Generic Reason for implementing FOD Prevention… ? Corporate Protection / Liability reduction = Costs ($)

30. FOD Social and Moral Responsibility Human Factors Clear FOD Preventative Strategy Good Working Practice Good Working Environment Continuous Training Quality Control Human Resources = Costs ($)

31. FOD CAN A COMPANY PROFIT FROM THE IMPLEMENTATION OF A TOOL CONTROL STRATEGY ?

32. FOD Costs & Savings 1) Lean Engineering 2) Six Sigma 3) Kaizen 4) Continuous Improvement 5) Just in Time 6) 5C’s Implementation = Cost to develop and launch strategy

33. FOD Costs & Savings 1) Lean Engineering – reduced inventory – reduced FOD hazard 2) Tool Control System – FOD prevention technique / labour cost reduction 3) Asset Management – secured assets 4) Reduced Consumable Spend – reduced consumption 5) Capitalisation of small tooling.. +++ ..future benefits Implementation of TOOL CONTROL = Reduced Direct Costs (-$) + Improved Balance sheet Implementation = Cost Reductions ($) ?? Prerequisite: Solid strategy and high grade products

34. FOD Cost Reduction Lean Engineering

35. FOD Cost Reduction Lean Engineering - simple case study

36. FOD Cost Reduction Tool Control System – FOD Prevention Technique

37. FOD Cost Reduction Tool Control System – FOD prevention technique

38. FOD Cost Reduction Labour Cost Reduction

39. FOD Cost Reduction Asset Management Asset administration Asset reduction through multi-user kits

40. FOD Cost Reduction Asset Management RFID Transponders GSM / RFID Asset tracking

41. FOD Cost Reduction Reduced Consumable Spend – reduced consumption

42. FOD Cost Reduction Capitalisation of small tooling.. +++ ..future benefits vs. Tool Purchase one time and repeating expenditure Capital Asset Acquisition long term commercial strategy

43. FOREIGN OBJECT DEBRIS Conference Message Tool Control Systems deliver not only FOD prevention measures but also cost saving benefits to Manufacturing, MRO’s, Operators and works services departments. There should be no cost barrier to implementation. Non-Mandatory FOD procedures should be reviewed by those in authority and improved FOD incident reporting should be encouraged to help improve future preventative strategy.

44. Have a good conference…… www.stahlwille.de www.stahlwilleaerospace.com