Software-controlled intelligent fasteners: that's what Textron Fastening Systems (TFS) has achieved with its new Intevia latching system. Using a powered, radio-controlled microprocessor electrically connected to a piece of shape memory alloy in a wire form, an Intevia fastener can be remotely commanded by sending a small amount of current into the metal. As this happens, the alloy changes shape. When physically linked to a mechanical latch, this shape change can be used to trigger it open or shut.

Not surprisingly, the implications of a remotely controlled latching system are profound for the aviation industry. Instead of spending 20 to 30 minutes unscrewing a conventional access panel, an Intevia-fastened panel could be opened in seconds. "The time savings for maintenance crews would be substantial," said Chris Marks, TFS's vice president of aerospace sales. "The same would be true for the OEMs who build this equipment."

The downside? For non-authorized third-party MROs and repair stations, not having access to the Intevia codes could prevent them from servicing Intevia-equipped aircraft. Granted, federal safety rules require such panels to be manually openable. However, just because a non-authorized MRO might be able to open an Intevia-fastened hatch, doesn't mean that they can close it again.

One thing is certain: "The OEMs are very interested in Intevia technology," said TFS executive vice president of technology Seshu Seshasai. Small wonder: an Intevia-equipped aircraft would be far quicker to manufacture, maintain, and reconfigure, from removing hatches and avionics to changing out the seats. As well, the security advantages of an Intevia-equipped aircraft versus one that uses screws and bolts are undeniable. They are as different as a door equipped with an electronic security access system and one with no lock at all.

Then there's the issue of space: Intevia-controlled overhead bin latches can be flush-mounted, with no handles to catch on clothing or equipment. In addition, access to them can be controlled by the flight deck.

Imagine how much simpler a flight attendant's job would be, knowing that passengers couldn't just open bins whenever they felt like it. Think how much safer it would be for a pilot to be able to secure the interior bins during turbulence with a single flick of a switch.

That's not all. Intevia-equipped fasteners can not only be controlled electronically, but monitored this way as well. Given the number of accidents that have occurred when screwed/bolted hatches have inadvertently been left open--causing chaos and even disaster in flight--being able to confirm that all hatches are sealed on the flight deck would be a boon for crew/passenger safety.

Back on the shop floor, Intevia fasteners can speed up the removal of access panels and aircraft parts. By doing so, MROs can eliminate a lot of the time spent on non-value-added services such as undoing screws, focusing instead on the activities that make them money. The time saved can be used to do more jobs per day, while the per-job savings can be passed on to customers. It's a win-win situation, as long as the MRO has the OEM codes for accessing the equipment.

Time will tell if OEMs take advantage of Intevia's abilities to lock out unauthorized MRO access to their products. But one thing appears certain: with the advent of intelligent fasteners, the decline of the common machine screw has begun. -- By James Careless

The Big Business of Little Parts

Honeywell's Hardware Products Group is saving OEMs and MROs money and manpower by providing `turn key' ordering and replenishment of fasteners, bearings, and other commodity hardware items.

Think about it for a minute: how much time is spent on making sure your technicians have the hardware items they need to get the job done? Quite a bit. You have to count what you have, keep track of what you've used, and then order how much you're going to need. It's a time-consuming and costly process. What if someone could take all that off of your hands so you, and your staff, could concentrate on doing the jobs that really count?

Well, there is a solution to that problem. Honeywell's Hardware Products Group (HPG) currently offers both large and small shops a variety of specialized stocking and replenishment services. One of the most popular is the Value Added Service (VAS). "VAS is defined as essentially bin management at our customers' locations," explained Mike Harris, vice president and general manager of Honeywell's Hardware Products Group. "The Value Added Service concept is where we support the customer up to the point where they are actually building structure."

"We operate on a two-bin, just-in-time system. As they deplete a bin, we get a signal, and that bin is replenished automatically so they never run out of hardware," he continued. "We do all the forecasting, all the planning, all the material acquisition, all the distribution, and all the logistics so the customer can focus on their core competency, whether that's on the OEM airframe side or the maintenance side."

Harris also said that the advent of the VAS concept changed the way the `parts' distributor now sits in the customer's supply chain. "We are now coordinating for the end-user all of their purchases. It's kind of a change in the model and `value stream' if you will," he added. And it not only streamlines the customer's operation, it also saves them money.

"I've got over 5,100 customers for the business and many of them use the same products and same part numbers," Harris said. "We can actually aggregate that demand electronically and find the supplier that can support the best price at that total demand, then pass that lower cost position on to our customers."

Air Canada Technical Services has been a HPG customer since 2004. "We participate in both an open-binning system and an automated vending machine system with Honeywell Hardware Products Group," said Harry Hall, vice president supply chain management for Air Canada Technical Services. "The major benefit for Air Canada has been huge savings associated with the program. It has allowed us to go to one vendor for all of these hardware products."

Hall also said that ACTS also saves money by not having to buy a warehouse full of hardware just so they have them on hand when they need them. "The only time I get charged is when we consume the products versus the traditional inventory arrangement where I would need to buy the material and keep it in my warehouse for distribution," he explained. "There is a lot of savings in not having to pay for something until you use it."

"Typically a customer's purchasing department will buy six months to two years worth of these commodity parts and put them on a shelf. We eliminate that up-front cost," Harris said. "Now our customers are actually able to generate a positive cash flow with the VAS arrangement. We have warehouses in North America, Europe, and the Pacific Rim and 800 employees dedicated to our distribution centers."

ATCS also uses its Honeywell "vending machines" to increase traceability of parts. "A technician uses a key card and has to enter the aircraft event, along with the particular job workorder number he is working on," Hall added. "Now we can collect exact costs and parts usage right down to the hardware on every job. It's a huge advantage."

And the advantages and savings that ACTS is experiencing are just one example of what is becoming a rapidly growing trend, which could form the future of the parts distribution and supply business. "We now maintain over 650,000 bins around the world and we are probably the most capable VAS provider in the marketplace today," Harris said proudly. "As a matter of fact, last year we shipped over 500 million parts. That's a lot of volume.

"Our customers want these four things," he continued. "Supply chain productivity, efficient asset management, lower transactional costs, and they want immediate availability. The worst thing that can happen with any customer is for a piece of hardware not to be there when a mechanic needs it."

Air Canada Technical Services is one customer that really likes the many advantages Honeywell's HPG brings. "We are expanding our business dramatically," Hall explained. "We have a major contract with Delta in Vancouver. We are using the vending machines on Delta's 767s and will expand it to support the 757 operations as well. We are also looking at it for our new Embraer 175s and 190s when they come on line.

"This type of program takes a lot of the pressure off," he continued. "It's not that there's not an expense associated with it, but when you look at the cost of the parts, the hardware is the least expensive and the fastest moving. We can now spend our time focusing on the more expensive parts and planning a better supply chain for them."

Hardware Products Group, 602-365-7700, www.hpgparts.com.