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Streamline Aerospace MRO Operations with RTLS + Smart Tool Control
Optimize MRO Efficiency with
Digital Twin + RTLS in Aerospace
Drive zero-error production, slash turnaround times,
and lower FOD risks with automated real-time asset tracking.
The LocaXion Difference: Why RTLS + Digital Twin in Aerospace
RTLS answers the "where," Digital Twins answers the "when" and "what if." In MRO and Aerospace, this means moving from simple asset visibility to Live Operational Sync- transitioning from reacting to AOG (Aircraft on Ground) events to preventing them through predictive simulation.
- Real-time tracking of tools & GSE (Ground Support Equipment)
- Historical tool movement playback
- Zone-based FOD (Foreign Object Debris) alerts
- Manual cycle counts of spare parts
- Basic reporting on tool utilization
- Static safety boundaries around test cells
- Predictive Availability: Forecast GSE shortages 24 hours ahead of heavy maintenance checks to zero-out wait times.
- Hangar Simulation: Test different aircraft parking and maintenance staging scenarios digitally to minimize Turnaround Time (TAT).
- Autonomous FOD Prevention: Uses real-time tool status to ensure tools are accounted for before aircraft release.
- Reality-Based Logistics: AI insights that auto-replenish consumables based on real-time hangar consumption rates and upcoming work orders.
- The Digital Thread: Automated end-to-end component history linking physical location data to digital maintenance records to support FAA/EASA audit compliance.
- Predictive Maintenance (PdM): Uses digital twin models to detect potential failures earlier and reduce unplanned downtime.
Real-World Example: Tier-1 Commercial MRO Facility
How RTLS + Digital Twin slashed Turnaround Time (TAT) and enforced FOD compliance
The Challenge
A six-bay heavy maintenance hangar (850,000 sq. ft.) faced chronic delays during C-checks due to inefficient Ground Support Equipment (GSE) management. With over 12,000 serialized tools and stands shared across multiple aircraft, mechanics spent an average of 45 minutes per shift searching for specific torque wrenches or hydraulic jacks. Furthermore, manual "chits" at the tool crib created bottlenecks during shift changes, and the facility faced two near-miss FOD (Foreign Object Debris) incidents caused by tools left inside cowling areas.
The Implementation
Phase 1 - RTLS Deployment: A hybrid BLE/UWB infrastructure was deployed to support RTLS in aerospace hangar environments. Critical GSE (jacks, stands, tugs) and calibrated tools were tagged, with location-based zones defined across aircraft bays, the tool crib, and the calibration lab for real-time visibility and movement tracking.
Phase 2 - Digital Twin Integration: A live view of the hangar was created by linking real-time location data with the facility’s MRO system (such as Trax or Maintenix). This gave teams a clear picture of where tools were, whether they were cleared for use, and which maintenance tasks they supported, forming a practical aerospace digital twin of daily hangar operations.
Measurable Results
94% Reduction in Tool Search Time (dropped from 45 mins to <3 mins/shift)
12% Improvement in Turnaround Time (TAT) (faster aircraft release)
100% Calibration Compliance (zero usage of expired tools)
$650k Annual Savings in Lost Tool Replacement
The ROI Breakthrough
While RTLS solved ‘where is the jack?’ problem, the digital twin technology in aerospace enabled more proactive compliance controls. The system now automatically flags any tool entering an aircraft zone that is within 48 hours of calibration expiration, alerting the floor manager before work begins. Additionally, the Twin supports structured FOD checks by allowing managers to verify that all tools assigned to a specific aircraft have physically returned to the crib before release. This reduced rework risk, strengthened maintenance sign-off confidence, and improved overall safety and audit readiness.
Critical Aerospace MRO Challenges
Tool search time was cut by 94%, Turnaround Time (TAT) improved 12%, and calibration compliance hit 100% with RTLS and Digital Twin predictive intelligence.
Foreign Object Debris (FOD) Risks
Unaccounted tools remain one of the most serious safety concerns in aerospace maintenance. Manual tool control methods rely on human checks, which typically carry a 3-5% error rate, especially during shift changes or high-pressure maintenance windows. When a tool cannot be accounted for, operations may pause for inspections, increasing downtime and cost while elevating safety risk.
Technician Utilization & Walking Waste
In large hangars, technicians often spend a considerable part of their shift walking to retrieve tools, parts, or documentation. When work assignments do not account for the physical location of required resources, productive maintenance time can drop by 20-25%. Poor staging and manual coordination further increase fatigue and inefficiency during complex maintenance checks.
Digital Thread & Compliance Gaps
Proving that a specific task was performed with a verified, calibrated tool is a paperwork nightmare. During FAA and EASA audits, most facilities find gaps between physical execution and digital maintenance records. These gaps extend inspection timelines, increase manual reconciliation effort, and complicate compliance with Part 145 and AS9100 requirements.
Proven RTLS Solutions for Aerospace MRO
From tool accountability to hangar safety, RTLS in aerospace combined with digital twin
capabilities supports efficient, compliant MRO operations.
Why Aerospace MRO Leaders Trust LocaXion
Proven expertise in delivering RTLS + Digital Twin solutions across the global aviation and MRO industry.
100+
RTLS and Digital Twin projects
delivered globally
98%
Customer satisfaction and
long-term engagement rate
Built for Metal Manufacturing Environments
RTLS + Digital Twin technology designed for extreme conditions and unique
challenges of primary metal production
Extreme Environment Hardware
Ultra-wideband (UWB) tags rated for high-heat (>200°C), high-dust, and high-vibration zones typical of foundries and melt shops. Sub-meter accuracy even with steel interference.
Metal-Specific ERP Integration
Pre-built connectors for SAP S/4HANA (Mill Products), PSI Metals, and other metal manufacturing systems. APIs for legacy integrations.
Compliance-Ready Reporting
Automated data capture for ISO 45001 (safety), ISO 14001 (environmental), and EN 1090 traceability requirements.
Ready to Optimize Your MRO Operations?
See how RTLS and Digital Twin integration can improve tool accountability, reduce delays, and strengthen safety and compliance across your hangar operations.
Frequently Asked Questions
Everything You Need to Know About Implementing RTLS in Aerospace Industries
RTLS provides real-time visibility into tools, equipment, materials, and workflows on the shop floor, helping aerospace manufacturers improve coordination, traceability, and operational control. This makes rtls in aerospace a foundational layer for execution visibility.
RTLS asset tracking in aerospace focuses on continuously locating critical assets such as tools, GSE, and components to reduce search time, prevent loss, and support maintenance planning.
RTLS supplies live location data from the physical environment, while a digital twin uses that data to model workflows, constraints, and dependencies. Together, they form a practical digital twin in aerospace that reflects actual shop-floor conditions.
Yes, a digital twin helps visualize restricted zones, personnel presence, and hazard exposure to support safer operations. By linking physical movement with rules and context, a digital twin in aerospace industry strengthens safety oversight and supports compliance with operational and regulatory requirements.
A digital twin becomes necessary when teams need more than location visibility and must understand sequence, timing, and operational impact. In these cases, an aerospace digital twin helps translate RTLS data into actionable operational insight.
RTLS data is validated by correlating location events with work orders, personnel records, and maintenance logs to ensure consistency. When integrated correctly, digital twin technology in aerospace supports traceable, review-ready audit evidence.
Workflows involving tool control, GSE usage, FOD prevention, parts staging, and safety monitoring benefit most from RTLS adoption. In these areas, improved visibility directly impacts operational performance and compliance.