The Importance of Tool Control in Aircraft Maintenance: A pillar of Safety, Compliance and Efficiency

Tool Control is a Pillar of Safety

In the highly regulated world of aircraft maintenance, tool control is one of the most vital disciplines within a Part 145 Approved Maintenance Organisation (AMO). Every spanner, socket and screwdriver plays a role in ensuring airworthiness, safety, and compliance.

At Jotore Aviation Consultancy, we help aviation maintenance organisations strengthen their safety management systems (SMS), compliance frameworks, and maintenance procedures. Among these, effective tool control is one of the simplest yet most powerful ways to prevent incidents, enhance productivity, and meet regulatory expectations.

Why Tool Control Matters in Aviation Maintenance

Tool control means ensuring that every tool is accounted for, serviceable, and properly stored. A single missing tool can create serious hazards, including Foreign Object Damage (FOD), delayed aircraft release, and potential loss of safety certification.

Strong tool control practices:

• Prevent unaccounted tools from being left in aircraft or engine compartments.

• Reduce rework and maintenance delays.

• Support audit readiness under Part 145 compliance.

• Reinforce a culture of safety and accountability among technicians.

Neglecting tool control doesn’t just risk damage—it can erode trust, cost time, and jeopardise safety.

Part 145 Regulations and Tool Control

Under CASA and EASA Part 145, maintenance organisations must maintain systems ensuring that:

• Tools and equipment are calibrated, traceable, and controlled.

• Technicians only use tools that are fit for purpose and within calibration dates.

• All tools are accounted for at the end of each maintenance task or shift.

• Discrepancies and tool losses are investigated and recorded through approved procedures.

During regulatory audits, tool control deficiencies are among the most common findings—making it a key focus area for compliance managers and quality assurance teams.

Good Housekeeping: The Unsung Hero of Compliance

Tool control and good housekeeping go hand in hand. A clean, organised workspace reduces risk, improves workflow, and strengthens inspection outcomes.

Best practices include:

• Dedicated shadow boards and clearly labelled tool storage areas.

• Regular bench and floor inspections for tool accountability.

• Separation of personal and company-issued tools.

• Routine cleaning, decluttering, and inspection of work zones.

Good housekeeping supports continuous improvement (CI) and demonstrates professionalism to both regulators and clients.

Effective Methods of Tool Control

Different maintenance organisations adopt various tool control systems based on operation size, complexity, and regulatory requirements. Common methods include:

1. Shadow Boards and Foam Inserts

Visual systems where each tool has a dedicated outline and any missing tool is immediately noticeable.

2. Tool Tagging or Sign-In / Sign-Out Systems

Tools are issued and returned using barcodes or manual logs, ensuring traceability to individual technicians.

3. RFID and Electronic Tool Cabinets

High-tech systems using RFID (Radio Frequency Identification) track each tool’s movement and calibration status, providing real-time visibility and alerts for overdue tools.

4. Tool Audits and End-of-Shift Inspections

Routine audits verify full tool reconciliation before aircraft release, embedding accountability into daily operations.

The Cost of Poor Tool Control

The aviation industry has seen costly incidents where forgotten tools caused engine damage or flight cancellations. The financial and reputational damage from a single oversight can far outweigh the investment in effective tool control systems.

Implementing strong procedures prevents:

• Foreign Object Damage (FOD)

• Non-compliance findings during audits

• Maintenance delays and production inefficiencies

• Safety risks to crew and passengers

Building a Culture of Accountability

Tool control is not just a compliance task—it’s a reflection of maintenance culture. It demands discipline, awareness, and ownership from every member of the maintenance team. By integrating modern tool tracking technology, standardised housekeeping practices, and clear accountability systems, organisations can enhance both safety and efficiency.

Conclusion

Tool control remains one of the most critical, yet often underestimated, pillars of aviation maintenance safety. Under Part 145, it’s a regulatory requirement, but more importantly, it’s a commitment to operational excellence.

At Jotore Aviation Consultancy, we support airlines and MROs across the Asia-Pacific region with tailored consulting in maintenance compliance, quality management, and process improvement. Whether you’re refining your Part 145 procedures or seeking to strengthen your tool control systems, we can help you achieve safer, smarter, and more compliant maintenance operations.

Stay Safe,

Craig.