How Important is Tool Control and Accountability in the Aviation Industry?

Prevention is Better than Cure

Modern aviation is one of the safest and most secure forms of transport.

In part, this is down to the rigorous safety and security checks that are carried out pre-flight.

But what most people miss is the extraordinary lengths which airlines go to behind the scenes to ensure that the planes are as safe as possible.

This starts with something as simple as making sure that no foreign objects and debris (FOD)

Including tools, are left in any part of the machinery following routine servicing.

What are the CAA and Faa tool control regulations?

Most UK airlines have a Tool Control and Accountability policy in place, as outlined by The Civil Aviation Authority, under policy 145-2 Equipment, Tools and Materials – OTAR Part 145.109 and in the U.S under The Federal Aviation Administrator. AC No: 150/5380-5B The policies are very similar, but in the U.K the CAA specifies the following:

Tools and Equipment

  “(a) All tools and equipment that are required to be controlled in terms of servicing or calibration under being necessary to measure specified dimensions and torque figures etc should be identified and listed in a control register including any personal tools and equipment that the organization agrees can be used.

Tool Control

  (b) The control of such tools and equipment requires that the organization has a procedure to inspect/service and, where appropriate, calibrate such items regularly and indicate to users that the item is within any inspection or service or calibration time-limit.

Tool Labelling

 (c) A clear system of labeling all tooling, equipment, and test equipment is, therefore, necessary to give information on when the next inspection or service or calibration is due and if the item is unserviceable for any other reason where it may not be obvious. A register should be maintained for all precision tooling and equipment together with a record of calibrations and standards used.

 (d) Inspection, service, or calibration regularly should be following the equipment manufacturers’ instructions except where the organization can show by historical calibration and/or service results that a different period is appropriate in a particular case.”

The Key

Key to this is the fact that organizations such as airlines, need to be able to inspect and monitor the tools and equipment that are being used to service their planes. If a toolbox contains a random jumble of spanners, screwdrivers, and other tools, how can an airline possibly tell if one is missing?


Ensuring that all aviation mechanics adhere to these regulations can be a time-consuming process, both for the mechanic and the airline.

It is, however, a critical process, as the primary objective of most tool control policies is to ensure the elimination of aircraft accidents and incidents that are caused by improper accountability of tools.

The Importance of Tool Control in the Aviation Industry

Leaving a tool in or near an aircraft or its engine is not just an inconvenience, but a safety risk.

In 2015, an Airbus Helicopter crashed in Australia after a tool had been left behind during maintenance.

Tool Control

Tool control is essential to ensure that all aviation tools can be accounted for at the end of the day.

This can only be achieved if each tool as a place where it can be stored – therefore allowing for quick identification if a tool is lost or misplaced.

Tool Control Issues

Issues with tool quality control cost the aviation industry over £500 million every year.

Foam inlays such as Shadow Foam are the preferred choice of most aviation maintenance companies.

CAA Regulation

The CAA regulation states that tools should be identified and listed and labeled and available for inspection regularly.

Shadow Foam provides a simple solution to make this a simple process.

What is Shadow Foam?

Shadow Foam™ is a high-quality foam that can easily be cut and shaped.

The material comes in a variety of grades, meaning it can be customized according to your requirements for a cost-effective solution.

The most popular sort of foam in the aviation industry can be a mix of Shadow Foam easy peel and Shadow Foam Inserts.

The Cut

The beauty of this is that it cuts cleanly with no snags or pulls, leaving behind a clean-cut area, ideal for creating inserts no matter what the shape or size of the tools.

To find out more about Shadow Foam click here.

How is Shadow Foam used in the aviation industry?

Within the aviation industry, many engineers are using Shadow Foam™ to secure their tools and equipment inside their toolkits.

Shadow Foam™ boards are turned into inserts for toolkits for safe and organized storage.

The shapes of the tools are cut into the foam to create secure pockets for the items to sit in.

Take a look at our gallery and you will see how simply Shadow Foam™ brings order to your aviation toolkit.

Roll cab and Chest toolboxes

When applied to the Rollcab or Chest toolboxes it instantly organizes every tool and allows for easy tool accountability.

Customers who use Shadow Foam™ also report that they find it much easier to find specific tools and as it is customizable.

You can, if you wish, organize your tools so the most frequently used are in easy reach.


Shadow Foam™ also makes it easy for engineers to check, at a glance, that all tools have been returned to the toolkit which helps to meet airline regulations and policies and prevent accidents.

What are the benefits of securing tools using Shadow Foam?

As well as making it quick and easy for engineers to check their tool inventory, using Shadow Foam to store tools has several other benefits:

Reduces the risk of foreign objects and debris

FOD, or foreign object debris, is one of the biggest hazards faced by the aviation industry.

Tool FOD

Tool FOD, caused by tools being mistakenly left behind by engineers during construction and maintenance.

Tasks can pose a very serious threat to aircraft and safety.

Keeping tools organized and secure using Shadow Foam reduces the risk of tools accidentally being left behind and causing serious damage and risk to safety.

Improves engineers’ efficiency 

When each tool has its own space in the toolkit it quickly highlights when one is missing.

This makes engineers less likely to lose tools or turn up at a job without a tool they require.

When the toolkit is neat and organized it also helps engineers to complete tasks faster and more efficiently.

Secures tools

Storing tools in a foam board rather than having them loose in a toolkit protects and secures individual tools to avoid them becoming damaged during transportation.

Reduces tool expenses

Specialist tools and equipment can be extremely expensive, and aircraft maintenance requires the highest quality of tools.

Packing tools into Shadow Foam reduces the risk of overlooking a missing tool when packing up after a job.

This saves on expenses for replacing missing tools.

Improves accountability

The need to put safety and efficiency at the heart of aircraft maintenance means accountability and audit trails are essential in the aviation industry.


Engineers in both military and commercial situations are addressing this issue by bringing in enhanced performance.

This gives greater visibility when it comes to tool control.

Shadow Foam™ means that everyday accountability is a simple process.

If you work in the aviation industry and tool control is an issue you need to solve, then call us today on 0808 168 2878 or email [email protected]

    Your Basket
    Your basket is empty
      Apply Coupon
      Did you know ShadowFoam has a new EU site ?
      Select Your Region
      Other Languages Coming Soon