April 19, 2005 1

Requirements for Machine-readable Technologies to Identify Commercial

Airplane Parts

Kenneth D. PoradThe Boeing Company

April 10, 2005

Airline Customers and Automated Identification and Data Capture

• Since 1994, our customers were labeling repairable and time-controlled parts with unique identification (bar codes) to support• Airworthiness Directive compliance monitoring.• Warranty claim processing.• Rogue parts identification.• Repair history including upgrade modifications.• Part flight-hours and landings tracking.• Inventory control and spares pooling.

• Boeing and Airbus were asked to provide leadership.

The Air Transport Association PlanSPEC 2000 e-business Standard

• Defines a standard format for Automated Identification and Data Capture (SPEC 2000 chapter 9)• Developed by industry task force• Uses bar code and radio frequency identification

technologies to enhance data collection• Provides a common tracking ID, using part number,

serial number, and manufacturer code• Allows the industry to take the next step of sharing

the databases that contain product history information (SPEC 2000 chapter 11)

Rockwell Collins Sample Bar Coded Nameplate

Direct Part Marking

• 2D Data Matrix bar code symbology

MFR 12345 SER ABC123PNR 100200300400A

What Our Engine Manufacturers Are Doing

• Continuous dialogue with propulsion systems manufacturers since early 1999• Pratt & Whitney• GE Aircraft Engines• Rolls-Royce• CFM International

• All have agreed to implement permanent bar code parts identification• Line-replaceable units• Internal engine components

What Our Engine Manufacturers Are Doing

0.1”

We Have Received Broad Airline Interest

United AirlinesUnited United AirlinesAirlines

American AirlinesAmerican American AirlinesAirlines

Southwest AirlinesSouthwest Southwest AirlinesAirlines

Continental AirlinesContinental Continental AirlinesAirlines

DeltaAir LinesDeltaDeltaAir LinesAir Lines

US AirwaysUS AirwaysUS Airways

NorthwestAirlinesNorthwestNorthwestAirlinesAirlines

Trans WorldAirlinesTrans WorldTrans WorldAirlinesAirlines

BritishAirwaysBritishBritishAirwaysAirways

ScandinavianAirlines SystemScandinavianScandinavianAirlines SystemAirlines System

LufthansaLufthansaLufthansa

Air FranceAir FranceAir France

Japan AirlinesJapan Japan AirlinesAirlines

All Nippon AirwaysAll Nippon All Nippon AirwaysAirways

CathayPacific AirwaysCathayCathayPacific AirwaysPacific Airways

Qantas AirwaysQantas Qantas AirwaysAirways

FedExFedEx

Initial Considerations for Deploying Machine-readable Technology

• Line replaceable• Repairable• Recommended as a spare• Frequency of removal• Spares price• Dispatch criticality• Life-limited or time-controlled part

•Airplane Boeing Proprietary Supplier Equipment*Model Part Numbers Parts per Airplane Part Numbers Parts per Airplane

717 19 33 209 431

737 382 401 683 1,174

747 373 445 728 1,150

757 366 397 522 1,025

767 314 364 536 1,253

777 406 453 725 1,960

* Approximately 500 different suppliers

Aircraft Readiness LogTypical Parts per Airplane

Today’s Requirements for Suppliers

• ATA SPEC 2000 compliant nameplates or direct part marks

• Symbology shall be code 39, code 128, or Data Matrix• Select appropriate label material for each application• Minimum bar coded elements are:

• part number (PNR)• serial number (SER)• CAGE code (MFR)

• Serial numbers must be unique within CAGE code• Regulatory approval, or drawing changes, if required, are the responsibility of the supplier

Bar Code Versus OtherAutomated Identification Technologies

• Other identification technologies considered• Passive radio frequency identification• Active radio frequency identification• Contact memory buttons

• We previously focused on bar codes based on• Drawing changes not required.• Proven applications in airborne environment.• Successful pilot program on the Next-Generation 737.• Recognized bar code standards with international

acceptance.• Preferences of airline customers and suppliers.

Radio Frequency Identification (RFID)

• RFID is an automated identification and data collection technology that uses radio frequency waves to transfer data between a reader (interrogator) and items that have tags (transponders) affixed

• Similar to bar code• RFID tag stores data ~ bar code label• RFID reader ~ bar code reader• Radio waves ~ light waves

• RFID advantages compared for commercial aviation• No line of sight required• Dynamic read/write capability• Simultaneous reading and identification of multiple tags• Tolerant of harsh environments

RFID Factory Applications

• Receiving• QA / Inspection• Work In Process• Tool Crib• Container Tracking• Cross Dock• Case Load Shipping• Plant To Plant

Federal Aviation Regulations (FAR)

• Radio and electronic equipment, controls, and wiring must be installed so that operation of any one unit or system of units will not adversely affect the simultaneous operation of any other radio or electronic unit, or system of units...

• The occurrence of any failure condition which would prevent the continued safe flight and landing of the airplane is extremely improbable, and…

Because passive RFID devices:

(1) Have no on-tag power source and no active transmitter, and

(2) perform a ground operated, non-essential function, and

(3) are not potential sources of interference or susceptibility, and

(4) are FCC-certified for unlicensed use.

The FAA and JAA should agree that passive RFID devicescomply with applicable regulations and do not impactform, fit, or function of installed systems and equipment.

Boeing Position on Passive RFID Tags

Boeing Enterprise RFID Charter

• Utilize the collective resources of the Boeing Enterprise to enable RFID technology through:• Coordinating research and development to evaluate

RFID technology. • Constructing business information to evaluate the cost

effectiveness of the technology. • Ensuring optimal standards for RFID within the

enterprise via representation on industry committees.• Leveraging the aggregate demand for RFID equipment

in the hardware acquisition process.• Communicating lessons learned where the technology

has been deployed.

Simplified View of Standards Activity

Mark It.

Radio Frequency Identification of Tools and Parts

Permanent Bar Code Identification of Parts

Track It.

Delivery Records: Aircraft Readiness Logs; Aircraft Inspection Reports

Automated Data Capture and Management

Share It.

Aircraft Reliability and Maintenance Data Exchange

XML Repository and Secure Web Data Transmission

ATA SPEC 2000 Chapter 9

ATA SPEC 2000 Chapter 15

ATA SPEC 2000 Chapter 11

Incr

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Tech

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Increasing Integration

Automated Identification and Data Capture In Practice

Boeing Operations/QA data

Schedule interruptions,flight hours & landings

Logbook complaint created

Component removaloccurs

Shop repair activity

Single, user-friendly, electronic resource

Boeing RFID Focus Areas

Via the Boeing Automated Identification SolutionsCenter, focus on the following:

• Shipping labels and packing slips to support commercial airplane production and spares delivery.

• Permanent airplane parts identification utilizing smart labels.

• Totally integrated automation of our airplane final assembly process.

• New after-market products and services.

Thank You for Your Attention

Contact: Kenneth D. PoradBoeing Commercial Airplanes

Telephone 206-662-6160Fax 206-662-7168

kenneth.d.porad@boeing.com