AeroTrack Pro – Intelligent Tool Tracking for Airline Maintenance

AeroTrack Pro is an aviation-grade IoT solution built to eliminate tool loss, prevent FOD incidents, and ensure FAA/EASA compliance in aircraft maintenance environments. This professional services offering enables customers to leverage Microsoft Azure services such as Azure IoT Hub, Azure Stream Analytics, Azure Functions, and Azure SQL Database to deploy a scalable and intelligent tool tracking infrastructure.

Through this implementation, customers will get hands-on support to deploy cloud-connected RFID portals, integrate tool movement data with Azure-based dashboards, and use Azure-native services to automate compliance, traceability, and real-time alerts across global MRO operations.

Key Features -

1. Multi-Technology Tool Tracking - Combines RFID (Impinj Monza 6), barcode scanning, and weight-sensing for complete tool visibility—even without network or power.

2. Hangar-Wide Real-Time Monitoring - Entry/exit RFID portals and geo-zones detect unauthorized tool movement, enabling proactive alerts and auditing.

3. Mobile Alerts & Dashboard - App-based alerts notify technicians and supervisors of missing or misused tools. Dashboard displays last known location, usage history, and tool status.

4. Aircraft Clearance & FOD Prevention - Enforces tool return protocols at aircraft access points. Automatically generates FAA/EASA audit logs.

5. Compliance Engine - Cloud-based system tracks tool calibration, assignments, audits, and traceability by tail number, job, or technician.

6. Offline & Hybrid Operation - Data caching supports network outages. Barcode and weight-sensor fallback ensure redundancy.

7. Scalable Architecture - Deployable across single hangars or global hubs. Supports fixed and mobile MRO operations.

Solution Architecture

• Frontend Components:
• Mobile apps for technicians and supervisors
• Real-time dashboards with tool maps and status indicators

Backend Infrastructure:

• RFID portals (entry/exit and aircraft clearance)
• Smart tool cabinets with weight-sensor integration
• Cloud platform (e.g., NexCap) for compliance, audit logs, and ERP integration

Technology Stack

• IoT Hardware: Impinj Speedway R420 readers, smart tool cabinets, RFID portals
• Software: Cloud-based compliance engine (e.g., NexCap), mobile applications
• Integration: SAP, AMOS, Ramco, Inventory & Access Control systems
• Tracking: RAIN RFID, 1D/2D barcode, weight sensors
• Data: Real-time and offline-capable sync, auto logging, and exportable reports

Execution Plan - Phase Duration Assessment & Planning 0–2 weeks Hardware Setup & Integration 2–4 weeks Platform Deployment 4–6 weeks MRO System Integration 6–8 weeks User Training & Go-Live 8–10 weeks

Value Proposition - By deploying AeroTrack Pro on Azure, aviation maintenance teams reduce tool search time by 80%, eliminate FOD incidents, and achieve 100% audit readiness. The Azure-based architecture allows scalable, resilient, and intelligent tool tracking that integrates with enterprise systems and delivers real-time visibility across hangars and maintenance hubs.