Did you know that a single aircraft engine contains around 4,800 precision bolts? Each of these bolts requires regular maintenance to ensure flight safety. KLM Engineering & Maintenance is responsible for this process. In collaboration with DZB Leiden, the bolts are washed, inspected, and resorted. But how do you sort 4,800 bolts quickly, accurately, and efficiently? That’s where Dawn Technology came in.
At DZB Leiden, they help people distanced from the labor market find suitable work. Until recently, the sorting of bolts was done entirely by hand, with only a magnifying glass for assistance.
The work demanded precision but was time-consuming and prone to human error. One misplaced bolt could pose a risk, something unacceptable in the aviation industry. DZB and KLM therefore looked for a solution to increase accuracy without removing the human role.
Dawn Technology developed a visual assistance tool that bridges human expertise and technology. Using a custom-built setup and a tablet with an integrated camera, the app helps employees identify the correct bolt types.
The application uses an object-recognition algorithm that determines which bolt corresponds to which type number with 99.9% accuracy. This enables workers to identify and sort each item in a single motion.
The solution is intuitive, scalable and seamlessly integrates into the existing workflow. A great example of technology that supports rather than replaces people.
The solution was delivered just before the coronavirus crisis. Both KLM and DZB Leiden were highly satisfied with the result: a reliable system that enhances human precision and reduces repetitive work.
The sorting process became faster, the margin of error nearly disappeared and employees experienced greater job satisfaction thanks to the collaboration between human and machine.
At Dawn Technology, we believe the best technology works invisibly, but is tangible in everyday life, even inside the engine of an aircraft.
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