"FODHAT" (FOD Or Defect Hazard Analysis Twin) for Digital Process Inspection Verification (DPIV)

There is an urgent need for Digital Process Inspection Verification (DPIV) system in aircraft manufacturing environments as aircraft assembly becomes increasingly complicated with sophisticated work instructions delivered by a variety of digital methods. This process complexity drives corresponding complexity in the requirements of quality assurance processes, including the use of scanning technologies to capture geometric variability and automated workflow management to annotate process completion. Of paramount importance is validation that all parts, tools, and debris (Foreign Objects, FOs) are correct, accounted for, and the product is free of matter which could cause foreign object damage (FOD). FTL's “FODHAT” (FOD Or Defect Hazard Analysis Twin) is a robust and adaptable observation and knowledge capture system for monitoring the construction environment. FODHAT can track location of parts, tools, and debris in the workplace, while addressing technological challenges (impeded line of sight, signal interference, etc.), and to validate completion of assembly tasks while addressing cultural concerns (operator performance monitoring and spoofing) to minimize the overall risk while documenting assembly process progress. FODHAT is capable of recognizing potential FOD situations and providing notification to the operator or quality assurance stakeholder, and store disparate fabrication data elements and be integrated with automated documentation systems.