Foreign Object Debris and Foreign Object Damage (FOD) Prevention For Aviation Maintenance & Manufacturing

Foreign Object Debris and Foreign Object Damage (FOD) Prevention For Aviation Maintenance & Manufacturing
Your company name here: 1 of 53 Dated: 13 November 2007 Revision No.: Dated: !" November # $
%ooner or &ater' Foreign Object Debris becomes Foreign Object Damage'
This document is an open source document provided by Be !e icopter Te"tron# $nc% for use as a &uide ine for aviation operators and maintainers% The intent of this document is that each individua or&ani'ation (i use this as a customi'ab e basis for estab ishin& their o(n )*D contro + prevention pro&ram that matches their uni,ue operationa re,uirements% This document incorporates a the functiona re,uirements of N-./012% $t is prepared in a 1icrosoft 2ord 2003 )ormat% You may edit and chan&e the names and contents of this document as needed for your or&ani'ation% .u&&estions# ,uestions and comments may be made to dburch3be he icopter%te"tron%com Be !e icopter Te"tron# $nc% assumes no iabi ity for the use and app ication of this document%
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4ara&raph: 1%0 2%0 3%0 4urpose and $ntroduction 5enera 2%1 6eferences 2%2 Definitions and -cronyms )*D 4ro&ram 7ontro s and $mp ementation 3%1 -ssi&nment of 6esponsibi ities and )oca 4oints 3%2 7omp iance 1easurements 3%3 6ecords of 7omp iance 3%0 Trainin& 3%5 !ouse8eepin& 3%9 4arts 4rotection and 1ateria s hand in& 3%7 Too 7ontro 3%: !ard(are 7ontro and accountabi ity 3%; <ost items 3%10 !a'ardous 1ateria s 3%11 )*D 7ritica -reas + -ccess contro -ssemb y and shop operations Test 7e + .pecia .hops =nvironment ) i&ht <ine *perations )ie d and ) i&ht ine faci ity operations 6eportin& and $nvesti&ations 6esources ;%1 )*D contro 4roducts# boo8s# posters and materia s ;%2 .ources of too contro products ;%3 $nternet <in8s to other sources of )*D information
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A++endi,es
4ara&raph: -/1 -/2 -/3 )*D 4revention 4ro&ram *r&ani'ation 7onsiderations )*D 4revention 4ro&ram# )*D -(areness 7ampai&n .u&&estions )*D 4ro&ram comp ete from an e"istin& operator
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Pur+ose and -ntroduction

This document estab ishes the standards for a base ine pro&ram for -viation 1aintenance# 1odification and *perationa or&ani'ations for the contro and prevention of forei&n ob>ect debris ?)*D@ and the resu tin& forei&n ob>ect dama&e ?)*D@ caused by this debris% This app ies to aircraft or components bein& inspected# maintained# modified# repaired# tested and operated any(here in the or&ani'ation% )orei&n *b>ect Debris ?)*D@ often causes )orei&n *b>ect Dama&e ?)*D@% The ma>ority of instances of )*D can be attributed to ac8 of standards in an or&ani'ation# persona comp acency or disre&ard for procedures% These may a so ead to additiona sources of )*D caused by insufficient house8eepin&# trainin& or contro s deterioration of faci ities improper too s and e,uipment improper or care ess maintenance or assemb y fati&ue and schedu in& pressures% )orei&n *b>ect Debris ?)*D@ can come in many different forms and may produce disastrous effects if not identified and corrected% $n severe cases# )*D can direct y threaten safety of f i&ht cre(s and inte&rity of the aircraft% )*D prevention is an essentia e ement in a 7ompany activities and is the responsibi ity of every 7ompany emp oyee . The estab ishment of an effective and comp iant )*D prevention and contro pro&ram (i : 4rovide emp oyee trainin& $dentify potentia prob em areas and actions 4rovide the too s for emp oyees to prevent )*D incidents -ssist mana&ement in proper p annin& 7oordination of corrective actions =stab ish a c imate of A7ontinuous -(arenessB Cse the essons earned by the industry to reduce costs and improve safety%
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References a% Nationa -erospace .tandard N-. 012 Dated *ctober 1;;7 D1;;7 -erospace $ndustries of -merica# $nc% b% -)$ 21/101# -77$ 21/101 c% *4N-E 07;0%2 d% $.*/;000F;001 e% -.;100 f% N-)4$ 5uide ine 6ev% 7# dated 1ay 1;;7 f% Be !e icopter Te"tron# $nc% &% C. !e icopter / Be -erospace .ervices $nc
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Definitions and Acron/ms ?not in a phabetica order@ Foreign Object (FO) or Foreign Object Debris (FOD) G - substance# debris or artic e a ien to an aircraft or system# (hich (ou d potentia y cause dama&e% Foreign Object Damage (FOD) / -ny dama&e or ma function attributed to a forei&n ob>ect that can be e"pressed in physica or economic terms (hich may or may not de&rade the productHs re,uired safety andFor performance characteristics% Potentia& FOD: The 7ondition (here forei&n ob>ect debris may cause dama&eFor fai ure shou d the product be put into use% ="amp es are: 1eta or (ire c ippin&s# so der ba s and debris yin& in the vicinity or e ectrica termina s# circuitry# connectors# components# etc% Too s# hard(are# or debris eft in the vicinity# or in a mi&ratory path or a path of an aircraftHs contro system or en&ine in ets Debris yin& on run(ays# ramps and ta"i(ays 4rope er e"haust# >et e"haust and ti t/rotor do(n(ash b ast $nc ement (eather $ce and sa t Birds and other anima s# items dama&ed by anima s% = ectro/.tatic Dischar&e ?=.D@ 7onstruction debris 7ontaminated or dirty service e,uipment such as funne s# hydrau ic test stand connectors# &rease &un no'' es and etc% $mproper y insta ed or secured operationa or test e,uipment ) uid ea8s% 4rotective covers# ine caps# e ectrica connector protectors and barriers not bein& removed before component insta ation%
4ersona items such as bad&es# hats# pins# pens# penci s# ce phones# pa&ers# poc8et i&hts# 8nives and etc% norma y carried oose on a person or in their poc8ets% (ritica& FO: )orei&n ob>ects inadvertent y eft in areas inside of a component or aircraft from (hich mi&ration is possib e# e%&% throu&h too in& ho es# bend re ief cutouts# drain ho es# inta8es# etc%# (hich are probab e to cause system or component ma function or deterioration shou d the product be put into use% Foreign Object *&imination (FO*): a pro&ram or process used to assure a )*D/free productFsystem% FOD Prevention Program (FODPP): a pro&ram or process used to assure a )*D/free productFsystem% FOD Area (ontro& %/stems: )*D pro&rams typica y use a t(o eve or three eve set of contro s for activities (ith different tit es in (or8 areas and on and around the aircraft% This document uses a three tier system% Csers may adopt either one and name their systems as they (ish% The system described in this document uses: )*D -(areness -rea: )*D .ensitive -rea: )*D 7ritica -rea: FOD A0areness Area: )abrication or maintenance areas (ithin the faci ity (here manufacturin& or maintenance re,uires specific actions% FOD A0areness area contro&s: 7 ean/-s/You/5o )*D barriers on a open ines and tubes (hen not in (or8 )*D barriers on a e ectrica connectors (hen not in (or8
FOD %ensitive Area: -ssemb y areas (here a forei&n ob>ect cou d become entrapped or inaccessib e (ithin components (here maintenance re,uires specific actions% FOD %ensitive Area contro&s: 7 ean/-s/You/5o )*D barriers on a open ines and tubes (hen not in (or8 )*D barriers on a e ectrica connectors (hen not in (or8 No food or drin8s in area% 2ater is acceptab e% )*D barriers on in ets and vents (hen not in (or8 $dentify the area (ith c ear y visib e mar8in&s
FOD (ritica& Area: -reas (hich contain an aircraft ma>or assemb y or in (hich the assemb y Fdisassemb y of en&ines or critica components occur# or a ) i&ht <ine% -ny area (here f i&ht hard(are is in p ace and e"posure to forei&n ob>ects (ou d potentia y cause a system or product fai ure due to deterioration# ma function or dama&e
FOD (ritica& Area contro&s: 7 ean/-s/You/5o )*D barriers on a open ines and tubes (hen not in (or8 )*D barriers on a e ectrica connectors (hen not in (or8 No food or drin8s in area% 2ater is acceptab e% )*D barriers on in ets and vents (hen not in (or8 $dentify the area (ith c ear y visib e mar8in&s and contro ed entryFe"it point 6emove items in poc8ets above the (aist# (ith the e"ception of poc8ets that sea # before contact (ith the aircraft $nventory oose items on be t as a too ?ce phone# pa&er# etc%@ before contact (ith the aircraft FOD 1a&2 or %0ee+: - physica inspection and c eanin& of an area either in the shop or on the tarmac around the han&er# f i&ht ine areas# he ipads# ta"i (ays or run(ays and the areas ad>acent to them% Foca& Point: The desi&nated )orei&n *b>ect Dama&e 4revention )oca 4oint?s@Fdesi&nated )*D *fficerF1ana&er?s@F)*D 4revention 4ro&ram -dministrator?s@ are desi&ners# administrators and responsib e parties of a (e desi&ned )*D 4revention 4ro&ram% Foca& Point of (ontact: 7ontro s the desi&nated (or8 area )*D prevention pro&ram at the shop# fie d and f i&ht ine eve s reportin& to the )oca 4oints% FOD 3arriers: Devices to prevent the entry of forei&n debris or materia enterin& any aircraft# component or assemb y or other dama&e% ="amp es are ed&e protectors# p us# caps# protective covers# and anti/static materia s used to protect openin&s or components in the aircraft# ines# en&ines# e ectronic components# e ectrica connectors and etc% FOD (ans4 rece+tac&es and containers: Desi&nated devices to receive )*D in the shop or operationa areas% FOD 1or2 3ags: - c oseab e container carried by or on an individua for stora&e of )*D deve oped durin& maintenance or manufacturin& ?such as
cotter 8ey ends# oc8 (ire# ta&s and etc%@ unti such time as the individua eaves the area to dispose of it% FOD Persona& e5ui+ment bags: - container for an individua to p ace any persona items such as >e(e ry# pens# penci s# s ide ru es# earrin&s# nec8 aces# rin&s# (atches# bad&es# ce phones# sun & asses# pins or other items (hich mi&ht become )*D (hi e (or8in& in a )*D .ensitive or 7ritica area% (&ean6As67ou6.o: 7 ean the immediate area (hen (or8 cannot continue% 7 ean the immediate area (hen (or8 debris has the potentia to mi&rate to an out of si&ht or inaccessib e area and cause dama&e andFor &ive the appearance of poor (or8manship% 7 ean the immediate area after (or8 is comp eted and prior to inspection% 7 ean at the end of each shift% $f you drop somethin& or hear somethin& drop / pic8 it upI (onsumab&es: .upp ies provided to (or8ers that are e"pendab e% ="amp es are: $ssued appare .afety & asses 5 ue# paint# sea ant 6a&s .andpaper# brushes# app icators .toc8 items such as rivets# (ashers# fasteners and other hard(are% (8it s/stem: - means of contro in& too or parts usin& assi&ned identification numbers to individua s% There are severa methods of usin& the chit system% =ach individua must si&n a chit for each too or part ta8en% This chit is then 8ept at the se ected contro point for inventory% =ach individua must si&n his name or number to a chec8 out sheet ocated on each too hoo8 =ach individua is &iven AJB number of meta or p astic ta&sFdis8s (ith his name or number on them% !e must p ace one of these on the hoo8 or in the cutout for each too he ta8es% $f the technician borro(s a too from another individua then heFshe must a so &ive that person a chit% -t the end of the shift or aircraft movement the technician must account for a of their AJB number of chits% =ach of these 7hits has the potentia to become )*D so the technician must carefu y contro them%
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)oo& -dentification s/stems: - too s# persona and company o(ned must be proper y mar8ed for accountabi ity and inventory% There are numerous permanent methods of mar8in& that must be c ear% Eibro etchin&# aser en&ravin& or e ectric arc mar8in&% 7are must be ta8en so as not to (ea8en the too or to ma8e a raised abrasive surface that cou d dama&e components% Ta&s: These may be bonded or attached by anyards or rin&s% 7aution must be ta8en that these ta&s or attachments do not become oose )*D% .ensors: The use of )6$D ta&s is becomin& easier and more economica and has the advanta&e of bein& used to find the Amisp aced too B in confined areas% This system provides ,uic8 inventory in and out of too s Bar 7odes: - so provides ,uic8 inventory in and out of too s 7o or codes: 4rovides ,uic8 identification but is imited in usabi ity% )oo& (ondition: Too s themse ves can the cause of )*D due to bein& dirty# (orn or dama&ed% - too s shou d be inspected before use for c ean iness# condition and (ear% 7hrome f a8in& off of too s is often a cause of )*D% 2orn too s may dama&e a part (hi e in use% )ote )ra/9)oo& bag: - device for storin&Fcarryin&Ftransportin& too s or e,uipment in a secure manner% )oo& Poc2ets: -n or&ani'ed pouch for carryin& specific too s that is easi y inventoried% *&ectronic )oo& (ontro&9Accountabi&it/ s/stem: - method of too contro s by in8in& each too chec8ed out to an individua Hs uni,ue identifier# typica y a bad&e (ith bar codes or a ma&netic strip% This is a so common y used in manufacturin& areas usin& automated too dispensin& units ?vendin& machines@% (onso&idated )oo& :its: (a&so 2no0n as: ():) A too container or bo" (ith on y the specific too s needed for specified tas8s% .ome 8its are inventoried out and bac8 in to the too cribFstora&e area% $n some 8its each too has a specific ocation provided and either shado( bo"ed or in a foam cutout for ,uic8 inventory% )oo& -nventor/ %8eets9;ogs: 2ritten or computeri'ed inventories of a too s enterin& a )*D .ensitive or 7ritica -rea% - inventories must be reconci ed at the end of each shift or re ease of an aircraft% %+onge (ount9*ver/t8ing gets counted: - items &oin& into or out of a )*D .ensitive or 7ritica area &ets counted% - forma inventory is 8ept%
Your company name here: ; of 53 Dated: 13 November 2007 Revision No.: Dated: !" November # $
.imi ar to the sur&ica operatin& room# nothin& &ets eft (here it shou d not be% %8ado0bo,9%8ado0 board: - too bo" or stora&e board (ith specific# mar8ed ocations for each too so that a missin& too (i be readi y noticeab e% )et8er: - anyard of sufficient stren&th ?(ire# rope# cab e# etc%@ attached to the too Fe,uipment and to the user or fi"ed secure ob>ect% The tether shou d be minimum en&th to prec ude dama&e from tethered too Kfree s(in&%K N*T=: - tether device# if not re&u ar y e"amined may itse f be the )*% )rayin& of the tether materia and the hard(are ?rin&s# snaps# etc%@ can a become )*D% %i, %igma: - comprehensive and proven set of too s and techni,ues app ied in a consistent# systemic fashion to enab e to better so ve prob ems and optimi'e processes in a functiona areas% The main foca points of .i" .i&ma are: 2aste = imination primari y throu&h <ean princip es and too s# Eariation 6eduction throu&h traditiona D1-$7 too s ?Define# 1easure# -na y'e# $mprove# 7ontro @# and 5ro(th and $nnovation usin& the too s and princip es of D).. ?Desi&n for .i" .i&ma@% ;ean Manufacturing: ;ean manufacturing is the production of &oods usin& ess of everythin& compared to mass production: ess human effort# ess manufacturin& space# ess investment in too s# and ess en&ineerin& time to deve op a ne( product% <%: The Lapanese mnemonic based process for house8eepin& and or&ani'in& for efficiency% 5. is a phi osophy and a (ay of or&ani'in& and mana&in& the (or8space by e iminatin& (aste% .ort .trai&hten .hine .tandardi'e .ustain M .ome or&ani'ations use 9. (ith the 9th . bein& .afety%
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FOD Program (ontro&s and -m+&ementation

)or an )*D 4revention pro&ram to be effective# it must be p anned# imp emented and continuous y improved%
3asic *&ements:
1% 2% 3% 0% 5% 9% 7% :% ;% )*D 4revention Trainin&% =ar y desi&n consideration for )*D prevention# resistance to dama&e# forei&n ob>ect entrapment# etc% -ssemb y se,uencin& and maintenanceFmanufacturin& techni,ues that inc ude proper care and use of assemb yFmaintenance e,uipment and parts protective devices% !and in& of materia % !ouse8eepin&% 7ontro of too s and persona items% 7ontro of hard(areFconsumab es% 1easurin& techni,ues for ana ysis# trendin&# and feedbac8% $ncident investi&ationFreportin&# K<essons earned%K
10% 7ontro of ha'ardous materia % 11% -ccess contro s% 12% -(arenessF=mp oyee )eedbac8% 13% .e f/Eerification -udits
Preventive Practices:
1% 2% 3% 0% 5% 9% 7% )o o( procedures% 4ractice &ood house8eepin&# K7 ean/-s/You/5o%K -ccount for a too s# hard(are and e,uipment at specific interva s% Cse "/ray# borescope# and other state/of/the/art e,uipment to inspect inaccessib e areas% 4rovide (or8er a(areness to )*D causes% =stab ish desi&nated stora&e areas for adders# hoses# too bo"es and other (or8 aids% $ndustry feedbac8 throu&h essons earned and benchmar8in&% .ome a&encies provide visua inspections upon >ob comp etion by desi&nated Kinspectors%K
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4ersonne shou d be re,uired to have comp eted )*D trainin& before bein& &iven access to desi&nated areas (here )*D may occur%
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Assignment of Res+onsibi&ities and Foca& Points FO(A; PO-N)

The desi&nated )orei&n *b>ect Dama&e 4revention )oca 4oint?s@Fdesi&nated )*D *fficerF1ana&er?s@F)*D 4revention 4ro&ram -dministrator?s@ shou d deve op and imp ement p ans and pro&rams to prevent hard(are dama&e durin& associated desi&n# manufacturin&# assemb y# test# acceptance# pac8a&in&# hand in&# stora&e# transportin&# maintenance# f i&ht ine# and aunch operations% The foca point?s@ or desi&nated )*D *fficerF1ana&er?s@F)*D 4revention 4ro&ram -dministrator?s@ shou d be appointed by the chief operatin& officia and have sufficient authority and or&ani'ationa freedom to identify and imp ement )*D preventive measures (henever and (herever re,uired%
FO(A; PO-N): Designated FOD Officer9Manager(s)9FOD Prevention

Program Administrator(s) Ro&es & Res+onsibi&ities 1% 2% 3% 0% 5% 9% 7% :% ;% Deve op p ans and pro&rams to prevent )*D incidents and forei&n ob>ect dama&e% 6evie( and assess the )*D prevention pro&ram and ma8e necessary revisions% 7onduct schedu ed audits of (or8 areas to assess effectiveness of the )*D prevention pro&ram% 7onduct unschedu ed audits of )*D 7ritica and )*D .ensitive -reas and report findin&s to 1anufacturin&F1aintenance supervisors and their mana&ers% -ssure imp ementation of corrective actions for )*D prevention throu&hout the or&ani'ation% 6e,uire investi&ations and studies by other or&ani'ations necessary to define preventive measures (hich shou d resu t in e imination of potentia )*D ha'ards% -ssure that )*D incidents are thorou&h y investi&ated and that incident reports are comp eted as app icab e% -ssure that causes of )*D incidents are thorou&h y ana y'ed to define essentia corrective measures% $dentify )*D prob em areas by usin& trend ana ysis and provide corrective action to prevent recurrence% Notify affected or&ani'ations and personne of uni,ue )*D prevention re,uirements%
10% Deve op techni,ues and assi&n responsibi ities for pub ication of specia )*D prevention instructions%
11% 6evie( resu ts of the )*D incident investi&ations and eva uate ade,uacy of corrective actions% 12% =va uate the amount and 8ind of forei&n ob>ects found and ho( they (ere found% 13% 6evie( and approve )*D prevention trainin& curricu a# desi&nate trainin& personne # and assure that personne receive re,uired trainin&% 10% -ssure that (ritten procedures provide for ade,uate records attestin& to the current status and ade,uacy of the )*D prevention pro&ram%
FO(A; PO-N) of (ontact: Designated ;oca& FOD

Officer9Manager(s)9FOD Prevention Program Administrator(s) Ro&es & Res+onsibi&ities 1% 6eport a )*D re ated issues to desi&nated )orei&n *b>ect Dama&e 4revention )oca 4oint?s@Fdesi&nated )*D *fficerF1ana&er?s@F)*D 4revention 4ro&ram -dministrator?s@ and 8eep them informed on a re ated )*D issues% 7onduct unschedu ed audits of )*D 7ritica and )*D .ensitive areas and report findin&s to 1anufacturin&F1aintenance supervisors and their mana&ers% )o o( up on )*D incidents and recommend corrective action as re,uired% 6evie( resu ts of the )*D incident investi&ation and eva uate ade,uacy of the corrective actions% 7onduct )*D 4revention trainin& as needed% 4ost metrics on )*D -(areness Boards throu&hout the 1anufacturin&F1aintenance areas%
2% 3% 0% 5% 9%
FO(A; PO-N) of (ontact: Manufacturing9Maintenance Managers9%u+ervisors Ro&es & Res+onsibi&ities

1% 2% 3% 0% 5% =nsure a area )*D and Too 7ontro procedures are fo o(ed as app icab e% $nvesti&ate and document root cause for 1anufacturin&F1aintenance &enerated )*D incidents% $mp ement corrective action to prevent future occurrences for 1anufacturin&F1aintenance &enerated )*D incidents% 7ommunicate area )*D and Too 7ontro needs to proper mana&er or )*D coordinator% =nsure emp oyee )*D 4revention trainin& is current and does not apse%
9%
- 1anufacturin&F1aintenance supervisors in )*D 7ritica -reas (i perform dai y se f/verification audits to inc ude: -% B% 7% D% =% )% 5% !% $% =mp oyees persona attire and items )*D in too ba& Too chits missin& Too ba& inventory ist not ref ectin& contents of too ba& Too s not identified Too s andFor items not o&&ed in at entry contro point )*D found around aircraft )*D found in aircraft Cnacceptab e house8eepin&
FO(A; PO-N) of (ontact: =ua&it/ (ontro& Managers9%u+ervisors

Ro&es & Res+onsibi&ities 1% 2% 3% 0% 5% 9% 4erform re&u ar inspections of (or8 and ine stoc8 areas as re,uired% 6eturn bac8 o&&ed operations to 1anufacturin&F1aintenance (hen determined operation is not )*D free% 4roper y report a )*D and Too noncomp iance% $nvesti&ate and document root cause for ,ua ity &enerated )*D incidents% $mp ement corrective action to prevent future occurrences for ,ua ity &enerated )*D incidents% 4erform area c ose out inspection and c ose )*D reports prior to transferrin& aircraftFassemb ies to ne"t 1anufacturin&F1aintenance area%
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(om+&iance Measurements
The operationa tar&et in any )*D 4revention 4ro&ram shou d a (ays be K'eroK to enab e visibi ity to prob em areas and trends# provide mana&ement and (or8ers (ith inspection resu ts# incidentFmishap reports# and feedbac8 of pro&ress% 1ethods providin& this information are: 1% 2% 3% 0% 5% Eisibi ity 7harts / statistica &raphics derived from audit or incident data% Csua y provided on an isochronic schedu e# i%e%# (ee8 y or month y% Trend -na ysis / 2here have you beenN 2here are you &oin&N 6eport 7ard / a chec8 ist of areas routine y inspected that sho(s specific prob em areas% 4erformance 6evie( / a revie( of (or8er conformance to standards or e"pectations% 7ustomer comments# concerns# or comp aints%
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2or8ers need specific information about (hat is (ron& before they can be e"pected to improve processes% <et them 8no( (hen theyOre doin& (e or (hen theyOre not% )eedbac8 is vita to process improvement%
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Records of (om+&iance
The desi&nated )orei&n *b>ect Dama&e 4revention )oca 4oint?s@Fdesi&nated )*D *fficerF1ana&er?s@F)*D 4revention 4ro&ram -dministrator?s@ shou d deve op and imp ement p ans and pro&rams to compi e records of trainin&# inspections and any )*D re ated incidents% These sha be maintained for a period as determined by the desi&nated )orei&n *b>ect Dama&e 4revention )oca 4oint?s@Fdesi&nated )*D *fficerF1ana&er?s@F)*D 4revention 4ro&ram -dministrator?s@% The records (i be used as needed for safety and cost ana ysis and for the purposed of prevention and trend ana ysis
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)raining
The primary ob>ective of a )*D prevention trainin& pro&ram is to increase emp oyee a(areness to the causes and effects of )*D# promote active invo vement throu&h specific techni,ues# and stress &ood (or8 habits throu&h (or8 discip ines%
- )*D prevention trainin& pro&ram for emp oyees associated (ith desi&n# deve opment# 1anufacturin&F1aintenance# assemb y# test# operations# repair# modification# refurbishment# and maintenance is re,uired as part of initia >ob orientation and on a continuin& basis%
)raining subjects inc&ude: 1% 2% 3% 0% 5% 9% 7% :% ;% 4roper stora&e# shippin& and hand in& of materia # components# and e,uipment% Techni,ues to contro debris% !ouse8eepin&% 7 eanin& and inspection of components and assemb ies% -ccountabi ityFcontro of too s and hard(are% 7ontro of persona items# e,uipment and consumab es% 7are and protection of end items% Pua ity 2or8manship ?K7 ean/-s/You/5o#K $nspection@% ) i&ht ine# ta"i(ay and ramp contro methods%
10% !o( to report )*D incidents or potentia incidents%

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?ouse2ee+ing
1aintenance# 1anufacturin&F1aintenance and operationa areas must remain c ean% =mp oyees shou d be informed that house8eepin& is a part of their >ob and they (i be &raded on their performance% $ncorporate K7 ean/-s/You/5oK as a re,uired (or8 ethic to prevent debris from mi&ratin& into f i&ht hard(are:
1%
=nsure that a production# maintenance and test areas meet K&ood house8eepin&K standards that enhance forei&n ob>ect e imination% This inc udes s(eepin& and vacuumin& production areas as (e as a re&u ar schedu e for s(eepin& ramp areas% -ssure that ta"i(ays# run(ays# and f i&ht dec8s are free of forei&n ob>ects that may cause dama&e% =nsure that &rounds and surfaces on (hich aerospace vehic es and &round support e,uipment are operated and maintained are free of ob>ects that cou d cause dama&e due to in&estion of forei&n ob>ect or prope er e"haust# >et e"haust# and ti t/rotor do(n(ash b ast effects% =stab ish and maintain safe ta"i distances bet(een aircraft to minimi'e the dan&er of debris bein& moved by the prope er e"haust# >et e"haust and ti t/rotor do(n(ash b ast% =nsure prior to the occupation of ne( y constructed aircraft faci ities that a construction debris ?inc udin& overhead (e din& s a&@ is removed as a forei&n ob>ect e imination measure% $n the refurbishment or maintenance of e"istin& airfie d faci ities or construction of ne( faci ities# assure that a construction debris is removed at the end of each tas8 or at the end of each shift% This re,uirement shou d be entered into contractua a&reements% $nsure that the practice of 7 ean/-s/You/5o is practiced by a emp oyees in a areas and functions of the company% This inc udes: -% The practice of removin& &enerated debris from the aircraft# component or assemb y at fre,uent interva s as (or8 pro&resses to prevent the accumu ation of forei&n ob>ects B% 7 ean the immediate area (hen (or8 cannot continue 7% 7 ean the immediate area (hen (or8 debris has the potentia to mi&rate to an out of si&ht or inaccessib e area and cause dama&e andFor &ive the appearance of poor (or8manship D% =mp oyees (i assure a forei&n ob>ects are removed at comp etion of a tas8# before the ne"t p anned operation or inspection point and prior to (or8 stoppa&e at the end of shift or de ay
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0% 5% 9%
7%
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Parts Protection and Materia&s 8and&ing

- (e /estab ished p an for materia hand in& and parts protection can e iminate many potentia )*D ha'ards% )irst# identify the specifics such as sensitive parts#
assemb ies# surfaces# areas# etc% Then# se,uence events for pac8a&in&# hand in&# shippin& and stora&e# and fina y# eva uate c ean iness and care re,uirements%
(ontro& )ec8ni5ues: 1% - Q emp oyees shou d be trained to assure comp iance (ith pac8a&in&# hand in&#
shippin& and stora&e re,uirements% 2%
1ateria s and accessories used in the pac8a&in&# hand in&# shippin& and stora&e (hich have intimate contact (ith the part or assemb y shou d be c ean
and free of contamination%
3%
4arts and assemb ies sha be pac8a&ed in a manner that (i prec ude any chance of one item ma8in& contact (ith another durin& norma hand in&
operations%
0% 5% 9%
7%
:%
4rotective and pac8a&in& materia s sha be chosen based on their abi ity to ade,uate y resist penetration by tearin&# partin& or piercin& from forces either e"terna or interna durin& norma hand in& operations% .pecific instructions for pac8a&in&Funpac8a&in&Fhand in& sha be estab ished 4rotective devices ?ed&e protectors# cam# p u&s# covers# fi ters# rub strips@ sha be c ean and 1C.T B= secured to prevent accidenta dama&e% *nce insta ed# unauthori'ed remova of protective devices is prohibited% 6emova shou d be authori'ed on y throu&h assemb y or maintenance p annin& paper(or8% 4articu ar care must be ta8en (ith items that are sub>ect to dama&e by = ectrostatic Dischar&e ?=.D@% =.D can be considered )*D dama&e% The use of proper hand in&# &roundin& contro s and devices and proper =.D protective pac8a&in&% 7onsideration shou d be &iven to the visibi ityFdetection of materia used for protection so that the materia in itse f doesnOt become )*D% 7onsideration shou d inc ude: -% 7o or of pac8a&in& or protective devices so they donOt appear to be a part of (hat they are protectin&%
B% .treamers for remova for critica items%
Materia& (8aracteristics:
1% 2%
1ateria s shou d be compatib e (ith the environmenta and physica stresses e"pected to be encountered durin& product service% .tatic sensitive devices sha be proper y protected to avoid dama&e% 1ateria s that are used to protect e ectro/e"p osive devices and sensitive e ectronic components shou d be 8ept c ean# covered# and stored a(ay from ordinary nonstatic safe materia s%
(ondition: Eisua y inspect a pac8a&in&# hand in&# shippin& and stora&e containers for the fo o(in&: 1% Nic8s# dents# ho es# abrasions# scratches# burns# etc%# (hich may be detrimenta to the function and inte&rity of the part or assemb y% 2% 5rease# preservatives# corrosion products# (e d s a&# shop and other dirt# and other materia s forei&n to the item% 3% )*D a so sho(s up as dirt# &rime# debris# meta shavin&s or fi in&s 0% 2hen you come across a container that needs to be c eaned# $dentify it as A Need to be 7 eanedB or c ean it immediate y
Your company name here: 1: of 53 Dated: 13 November 2007 Revision No.: Dated: !" November # $
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)oo& (ontro&
The primary ob>ective of a positive too contro pro&ram is to e iminate accidentsFincidents and oss of ife or e,uipment due to too )*D% There are numerous methods to faci itate accountabi ity of too s ?scre(driver# tor,ue (rench# rivet &un# air hammer# c ecos# etc%@% These inc ude but are not imited to the use of too inventory ists# shado( boards# shado(bo"in&# bar codin&# specia canvas ayouts (ith too poc8ets# too counters# chit system# too ta&s# or conso idated too 8its% Cni,ue contro methods shou d be imp emented for specia too s used in chec8out# test and operationa environments% Too sFe,uipment shou d be tetheredM or suitab y restrained to the user in areas around structura (or8 stands or any other ocations (here a dropped artic e cou d resu t in dama&e to f i&ht hard(are# in>ury to personne # or (here difficu ty in retrieva (ou d resu t if the too (ere dropped% M N*T=: - tether device# if not re&u ar y e"amined# may itse f be the )*% )rayin& of the tether materia and the hard(are ?rin&s# snaps# etc%@ can a become )*D% - oose too s shou d be carried and stored in a tote tray# soft too ba& or other suitab e spi / proof container and not be p aced in a manner that (ou d cause dama&e to f i&ht hard(are or in>ury to personne % $nventory a too s used in the area at the be&innin&Fend of shift - too s used in the area (i be mar8ed to identify source or ori&in Bro8en too s or too s missin& pieces (i be reported in the )*D reportin& system as <ost Too s% Minimum )oo& (ontro&s for Area FOD A0areness area contro&s: None FOD %ensitive area contro&s: $nventory a too s used in the area at the be&innin&Fend of shift - too s used in the area (i be mar8ed to identify source or ori&in FOD (ritica& area contro&s: $nventory a too s used in the area at the be&innin&Fend of shift - too s used in the area (i be mar8ed to identify source or ori&in $nventory too s and consumab es before &oin& onto the aircraft and after eavin& the aircraft $f emp oyee eaves the aircraft for a period on&er than 30 minutes# too s and consumab es must be inventoried and ta8en off the aircraft
Your company name here: 1; of 53 Dated: 13 November 2007 Revision No.: Dated: !" November # $
2hen an emp oyee comp etes (or8 on one aircraft and moves to another aircraft# too s and consumab es (i be inventoried prior to (or8in& on subse,uent aircraft ".A ?ard0are (ontro& and accountabi&it/ The primary ob>ective of hard(are accountabi ity is to assure contro of oose hard(are and parts% There are many effective methods that can be estab ished for contro of hard(are ?nuts# bo ts# scre(s# cotter pins# rivets# c ecos# etc%@: K7 ean/-s/You/5o%K Rit hard(are by tas8% )* containers shou d be p aced in 8ey ocations (ithin the (or8 area and at entry and e"it points% 6emova Finsta ation paper(or8 to trac8 oose parts% )urnish and specify tote trays% 7overed sprin&/ oaded containers Minimum )oo& (ontro&s for Area FOD A0areness area contro&s: None FOD %ensitive area contro&s: !ard(are (i be se&re&ated and identified !ard(are ta8en onto the assemb y (i be stored in a covered container -ny hard(are removed from the assemb y that cannot be retained must be comp ete y removed from the assemb y FOD (ritica& area contro&s: !ard(are (i be se&re&ated and identified !ard(are ta8en onto the aircraft (i be stored in a covered container (ith c ear y mar8ed part number and ,uantity -ny hard(are removed from the aircraft that cannot be retained must be comp ete y removed from the aircraft ".B ;ost items 4roper reportin& of ostFfound too s# hard(are or other items is essentia in a robust )*D 4revention 4ro&ram% -ny time an item is ost durin& an assemb y# manufacturin& or maintenance tas8# cease activity in the affected area and initiate a search for the item% 7ontinue this search unti the item is found or ade,uate assurances are made that the item is not contained in the aerospace vehic e or assemb y% .earchin& for such items may re,uire depane in& or
nondestructive inspections# inc udin& borescope andFor "/ray% $f an item cannot be ocated after a search has been comp eted# annotate app icab e forms (ith a description of the item and search procedure fo o(ed% =mp oyees shou d be a(are that proper reportin& of ost too s# hard(are# or other items (i not resu t in discip inary action% )ai ure to report or concea in& a ost too # ost )*# found too or found )* to the 1anufacturin&F 1aintenance supervisor# is &rounds for discip inary action up to and inc udin& dismissa ".! ?aCardous Materia&s 1ana&ement of ha'ardous (aste materia s is important in the prevention of )*D% Disposition of ha'ardous (aste materia s is dependent upon the commodity discarded% 7onsu t federa # state and oca !a'ardous 1ateria 4rocedures for disposa specifics% ".!! FOD (ritica& Areas & Access contro& 2hen physica entry is re,uired into f i&ht hard(are# such as cre( compartment# en&ine inta8e# e"haust# fue tan8 areas# etc%# personne shou d remove a oose ob>ects# bad&es# >e(e ry# etc%# from c othin&% 4oc8et ess or c osed 'ippered poc8et covera s shou d be (orn to prec ude forei&n ob>ects droppin& from poc8ets onto a )*D critica area% FOD (ritica& Area contro&s: 7 ean/-s/You/5o )*D barriers on a open ines and tubes (hen not in (or8 )*D barriers on a e ectrica connectors (hen not in (or8 No food or drin8s in area% 2ater is acceptab e% )*D barriers on in ets and vents (hen not in (or8 $dentify the area (ith c ear y visib e mar8in&s and contro ed entryFe"it point 6emove items in poc8ets above the (aist# (ith the e"ception of poc8ets that sea # before contact (ith the aircraft $nventory oose items on be t as a too ?ce phone# pa&er# etc%@ before contact (ith the aircraft
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Assemb&/ and s8o+ o+erations

4 an and se,uence maintenanceFmanufacturin& tas8s to prec ude forei&n ob>ect dama&e and entrapment of debris or contamination% Documents shou d contain necessary processes and procedures for contro in& and remova of contamination and debris durin& fabrication and assemb y operations% -s app icab e# the fo o(in& shou d be inc uded in (or8 instructions: 1% 2% 3% 0% 5% 4ractice S7 ean as you &oB% Cpon comp etion of fina machinin& operation# c ean or f ush the machined component to assure that it is free of debris# and immediate y cap or sea e"posed openin&s to deny forei&n ob>ect entry% -de,uate y protect hard(are and e,uipment from sp atter accumu ation durin& bra'in&# so derin&# (e din& and i8e operations% $nspect components and e,uipment for dama&e prior to insta ation and repair as necessary% - (ays ensure part inte&rity before insta ation% Eerify re,uired protective devices ?dust covers# temporary sea s# cushionin&# etc%@ are present and proper y insta ed% $tems (ith protective devices missin& are to be inspected for )*D# c eaned if necessary and protective devices insta ed% -fter f uid and pneumatic system ines and tubin& are cut and deburred# assure thorou&h c eanin& and cap ends of ines% $nspect for and remove e"traneous materia as part of the assemb y step# conduct a forei&n ob>ect inspection and remove debris% $nspect production too in& ?>i&s# fi"tures# hand in& e,uipment# etc%@ to assure it is c ean# undama&ed and free of forei&n materia prior to insta ation and bui d/up of components or assemb ies% ="ercise this same care for (or8 stands# adders# specia test e,uipment# etc%# (hich must be p aced on# in# or around production hard(are to accomp ish specific tas8s% 4rotect products by usin& 4*D barriers# foam pads# covers# etc% )or instance# cover composites on the (in&s and p ace pads bet(een a too and the aircraftFassemb y% - (ays protect sensitive areas and potentia )*D entrapments ?en&ine# open fue ine# harnesses# etc%@
9% 7% :%
;%
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)est (e&& & %+ecia& %8o+s *nvironment

2hen products are in a test ce environment# )*D prevention procedures shou d inc ude# but are not imited to# the fo o(in&:
1% 2% 3% 0% 4ractice S7 ean as you &oB% -ssure that ade,uate preventive maintenance is performed on the test faci ity% $nspect the test ce and faci ity e,uipment for deterioration or dama&e and assure that deficiencies (hich present a )*D ha'ard are corrected prior to test ce operations% $nspect the area before introduction of the test artic e to the test environment to be sure that it is c ean# too s are secured# fi"tures# do ies and specia test e,uipment are proper y prepared and secured# and that re,uired protective devices ?en&ine in et screens# covers for en&ine components and instruments# etc%@ are on hand# c ean and undama&ed% Eisua y inspect the test artic e before it is p aced in the test ce # remova of oose ob>ects and insta ation of the necessary protective devices% =nsure test ce e,uipment# too s and accessories are maintained and used in a manner to protect test artic e from dama&e or contamination throu&h too abuse or in/use fai ure ?chippin&# crac8in&# pee in&# frayin&# etc%@% 4rior to start# visua y inspect en&ine inta8eFe"haust areas for potentia )*D and rotate the en&ine throu&h sufficient revo utions to ascertain if there is unusua noise or bindin& condition% $nstrumentation ines# hoses and (ires shou d be taped or c amped to e iminate vibratory fai ure% Cse of oc8 (ire or cotter pins for this purpose is prohibited% 7% Cpon comp etion of each test artic e run and prior to remova from the test ce # inspect test artic e for presence of )*D and insta protective covers%
5% 9%
7%
:%
@.
F&ig8t ;ine O+erations F&ig8t O+eration Procedures:

1% 2% 3% 0% 5% 9% 7% :% ;% - ) i&ht ine# !e ipads# !e iports and service areas (i be desi&nated )*D 7ritica $nsure that a ) i&ht ine# !e ipads# !e iports and han&ar areas are c ean and order y usin& house8eepin& and c ean as you &o procedures% - too s# test e,uipment and hard(are (i be inventoried and documented each time such too s are ta8en on and off aircraft =mp oyees (i not have pins on hats# >ac8ets or c othin& (hi e (or8in& in f i&ht areas =n&ine inta8e covers (i be insta ed at the end of the f yin& day or (hi e maintenance is bein& performed -ircraft (i have inta8e covers insta ed at a times other than durin& f i&ht operations B ade (ei&hts and other hard(are (i be in se f/contained containers (hen ta8en on aircraft =n&ine in et )*D inspections (i be accomp ished as part of the dai y and pref i&ht inspections 5round cre(Fpi ots (i perform )*D (a 8 prior to startin& en&ines
10% .upport e,uipment par8ed on the f i&ht ine (i be )*D )ree at a times 11% =nsure a too sFe,uipment is accounted for prior to a &round run and aunch activities
$.
Fie&d and F&ig8t &ine faci&it/ o+eration

)ie d and ) i&ht ine faci ity operation may primari y invo ve schedu ed modifications# inspection# care and maintenance of ramps# structures# run(ays# and ta"i(ays% - comprehensive# schedu ed maintenance system usin& s(eepers# ma&nets on vehic es and fre,uent inspections (i provide some confidence# but additiona y# specia considerations may inc ude: 1% 2% Tarmac repair methodsFmateria s and fre,uency of inspections% Eehicu ar traffic patterns and contro sT i%e%# a vehic es shou d be driven on c ean# paved surfaces (hen possib e% $f a vehic e must be driven on an unpaved surface# the operator shou d chec8 the vehic e tires for forei&n ob>ects immediate y after returnin& to the pavement% .upport e,uipment c ean iness / items used in and around aircraft must be )*D free and shou d be inspected prior to movement% - f i&ht ine# ta"i(ays and run(ays (i use s(eepers to ensure )*D free areas .(eeper effectiveness / >ust because a s(eeper is used# does not mean it is effective% 4eriodica y chec8 s(eeper routes and speed to assure c ean iness% 1a&netic bars may be insta ed on the ramp s(eepers to pic8 up meta ob>ects% These bars shou d be chec8ed fre,uent y for proper ad>ustment% .(eeper brushes made (ith meta brist es or spines shou d not be used% -ttendants# f i&ht ine (or8ers and contractors shou d be briefed and continua y reminded of e"pectations re ated to forei&n ob>ect dama&e and contro % - f i&ht ine traffic p an depictin& routes to be used by a approved vehic es re,uirin& access to bui din&s on or around the f i&ht ine shou d be deve oped and posted% 6outine inspection of areas used by contractors# tenants# concessionaires for sta&in& e,uipment# oadFoff/ oad# operations# etc% =stab ish )*D contro procedures for a personne # vehic es# e,uipment and specia events havin& access to the airport operations area%
3% 0% 5%
9%
7%
:% ;%
10% $nc ude )*D prevention considerations in the desi&n# contractin& a(ard# and construction mana&ement for a airfie d pro>ects%
A.
Re+orting and -nvestigations

- incidents of actua or potentia )*D shou d be reported and investi&ated% 2hen a )*D incident occurs# operations shou d immediate y cease and an investi&ation initiated to determine the cause% 7ause and corrective action shou d be attained in a time y manner to prec ude simi ar occurrences from happenin& in the future / "lessons earned%K 7ause may be determined by visua observation# forensic ana ysis# or by ocation of the ob>ect% - Knear mishapK is one (here )*D incidents (ou d have occurred had the event remained undetected% Documentin& near mishap incidents and sharin& them (ith (or8ers is an important part of feedbac8# a(areness and K essons earned - forei&n ob>ect or too found durin& an inspection# audit or abandoned (ithin a )*D .ensitiveF7ritica area (i be documented usin& the )*D 6eportin& .ystem% 2hen in doubt# Pua ity (i ma8e fina determination (hether a found item is considered a forei&n ob>ect or too % A FOD incident re+ort format shou d inc ude the fo o(in&: Date 4art name ?nomenc ature@ Type andFor mode 4art seria number 4art ocation 2hen discovered 2ho discovered !o( discovered Narrative description of )*F)*D (hen ana y'ed (ho ana y'ed ho( ana y'ed 6oot 7ause 7orrective action 6eported by $f )*D incident is discovered after f i&ht operations the report shou d additiona y inc ude: 5roundFf i&ht maneuvers performed Ta"i route -irports invo ved -ircre( contact phone number TimeFse,uence of events 2eatherFenvironment -bnorma operations
These reports shou d be directed to the )*D )oca 4oint (ho shou d perform trac8in& and trendin& ana ysis% The foca point shou d a so assure a affected personne are a(are of a potentia ?near mishap@Factua )*D reports (hich (i faci itate feedbac8 ?K essons earnedK@% 2hen an incident occurs# chec8 contractua re,uirements and notify the appropriate representative as app icab e% 2here a forei&n ob>ect e"ists but cannot be e iminated# found or effective y sea ed# identify# document and record a si&nificant search activity in the appropriate aircraft paper(or8%
B. B.!
Resources: %ome current resources for FOD contro& items and

-nformation /ou can use. FOD (ontro& +roducts4 manua&s4 +osters & materia&s /ou can bu/: )8e F.O.D. (ontro& (or+oration is an outstanding source for FOD +rogram manua&s4 +osters and training su++&ies and FOD contro& +roducts. http:FF(((%fodcontro %comF )8e F.O.D. (ontro& (or+oration :;:7 =ast Tan,ue Eerde 6oad Bui din& 30; / 1ai .top U390 Tucson# -ri'ona C.- :570;/;3;; )o&& Free V A 6?A;)FOD (A or D (<# ) $@ 6$$"# )a" V ?520@ 790/7730 info3fodcontro %com 6>#<6A"@")
*ste, Manufacturing (om+an/ +roduct &ine of FOD contro& +roducts and safet/ e5ui+ment: =ste" 1anufacturin& 7ompany 2here $deas Become .o utions =ste" 1anufacturin& 002 =ast Broad .t 4%*% Bo" 39: )airburn# 5-% 30213 4hone: :00/70;/1220 )a": 770/;90/7530 (((%este"mf&%com Bi !aas 6e&iona Eice/4resident 4hone: 770%;90%3322 )a": 770%;90%7530 bi 3este"mf&%com
B.#
)oo& com+anies t8at +rovide too& contro& items for t8e s8o+ and too& bo,. %na+6on 4hone: 292/959/5200 2eb: (((%snapon%com Matco )oo&s 4hone: 330/;2;/0;0; 2eb: (((%matcotoo %com ;ista -nternationa& 4hone: 50:/02;/1350 1eb: 000.&istaint&.com %tan&e/ Proto 4hone: :00/:00/:995 2eb: (((%stan eyproto%comWhcom )?* <% %)OR*
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SPENRO Kitting Services

151# -est .. ('rrier P/w0 *)ite 1%0 1r'n Pr'irie, !2 #5050 Phone: "#%$"88$6161 Phone: 800$346$1"5" &'x: "#%$64#$10#% http://www.spenro.com/'3o)t$)s$i$1.html 4m'il: onn',spenro.com
http://5o /ittin6ser+ices.com/
Your company name here: 2; of 53 Dated: 13 November 2007 Revision No.: Dated: !" November # $
B."
;in2s to artic&es on FOD contro& as of: ! October #
http:FF(((%nafpi%comF The Nationa -erospace )*D 4revention# $nc% is the driver for aerospace )*D contro and prevention and a ma>or source of information% http:FF(((%fodne(s%comF http:FF(((%ncatt%or&Ffoe/info%htm http:FF(((%birdstri8e%or&F (((%aviationtoday%comFamFcate&oriesFmi itaryF907%htm http:FF(((%(assco%comF8ise%htm http:FF(((%faa%&ovFairportsXairtrafficFairportsFresourcesFadvisoryXcircu arsFmedia F150/53:0/5BF150X53:0X5b%4D)
A++endi,es: A6! FOD Prevention Program OrganiCation (onsiderations
6ecommend a E4/ eve production or ,ua ity emp oyee serve as the FOD Foca& (ith responsibi ities to &uide )orei&n *b>ect DebrisFDama&e ?)*D@ po icy decisions# ensure effectiveness of corrective actions# and encoura&e positive )*D prevention efforts: Deve op p ans and pro&rams to prevent )*D incidents and forei&n ob>ect dama&e% 6evie( and assess the )*D prevention pro&ram and ma8e necessary revisions as re,uired% 1ana&e re ations (ith customer 8eepin& them informed of )*D issues and so icitin& Eoice of the 7ustomer for opportunities for improvement% 6evie( and approve )*D prevention trainin& curricu um and desi&nate trainin& personne and assure that personne receive re,uired trainin&% Desi&nate )*D areas (ithin the faci ity% 6ecommend a fu /time FOD (oordinator position report to the )*D )oca (ith responsibi ities to dep oy and sustain effective )*D 4revention p ans by partnerin& (ith eadership: 6eport a )*D re ated issues to the )*D )oca and 8eep them informed on a re ated )*D issues% 7onduct unschedu ed audits of )*D desi&nated areas and report findin&s to production supervisors and their mana&ers% -ssure that )*D incidents are thorou&h y investi&ated and that incident reports are comp ete% -ssure that causes of )*D incidents are ana y'ed to define root cause and corrective measures% $dentify )*D prob em areas by use of trend ana ysis and provide corrective action to prevent recurrence% 7 ose )*D + Too reports once ade,uate root cause F corrective action is performed% )aci itate the )*D =mp oyee 7ounci meetin&s and provide feedbac8 to eadership% 4repare )*D + Too 7ontro briefin& materia s and present to the )*D .teerin& 7ommittee% 6epresent the )*D 4revention 4ro&ram in a 7orrective -ction Board ?7-B@ eve meetin&s (here )*D + Too 7ontro issues are addressed% 7onduct )*D 4revention trainin& as needed% 4ost metrics on )*D -(areness Boards throu&hout the faci ity%
- typica day in the ife of the FOD (oordinator: Weekly .pend 1/2 hours in assi&ned areas to observe comp iance to )*D prevention procedures# point out any noncomp iance and correct on the spot# address any ,uestions about the processes or systems and assure that causes of )*D incidents are ana y'ed to define root cause and corrective measures% 6epresent the )*D 4revention 4ro&ram in a 7orrective -ction Board ?7-B@ eve meetin&s (here )*D + Too 7ontro issues are addressed% -ssure that )*D incidents are thorou&h y investi&ated and that incident reports are comp ete% 7 ose )*D + Too reports once ade,uate root cause F corrective action is performed% 6evie( .e f Eerification -udit findin&s and ensure audits are bein& documented in a time y manner% Monthly $dentify )*D prob em areas by use of trend ana ysis and recommend corrective action to prevent recurrence% 7onduct random audits in )*D areas ?est% 30 minutes per audit@% 4repare )*D + Too 7ontro briefin& materia s and present to the )*D .teerin& 7ommittee% 4ost metrics on )*D -(areness Boards throu&hout the faci ity% )aci itate the )*D =mp oyee 7ounci % As Required 7onduct )*D 4revention trainin&% FOD *m+&o/ee (ounci& The )*D =mp oyee 7ounci serves an important ro e in the effectiveness of the )*D + Too 7ontro pro&ram% The purpose of the 7ounci is to &enerate ideas to improve methods in )*D prevention and too contro and ensure comp iance (ith company po icies and procedures G (ho better to provide these ideas than the fo 8s (ho (or8 in the environment day/to/day and have to ive (ith the so utionN The )*D =mp oyee 7ounci is the voice of the f oor and can he p the )*D prevention pro&ram: !i&h i&ht f oor eve concerns (ith )*D + Too 7ontro processes and procedures ?or ac8 of@ $dentify root cause of ostFfound )*D + Too s and potentia so utions $ncrease a(areness of )*D + Too 7ontro at the f oor eve .e ect a representative &roup of emp oyees (ho Ashoot strai&htB# are voca and 8no(n for brin&in& creative so utions to the tab e%
You may (ish to start off (ith bi/(ee8 y sessions and move to month y once you &ain some momentum% .u&&ested topics for the first coup e of sessions: Deve op a Team 7harter 6evie( trainin& curricu um for re evancy and comp eteness Brainstorm )*D prevention techni,ues usin& a 7ause + =ffect matri" 4rovide &uidance on (hetherFho( to imp ement 2or8 -rea 7ontro 4 ans 4rovide feedbac8 on imp ementation of )*D !ouse8eepin& Yones Mont8&/ O+erating Revie0 $nc ude )*D as an a&enda item to revie( the fo o(in& G 4ositiveFNe&ative Trends based on metrics G fo o(/up on corrective actions ?(hoFby (hen@ 7orrective -ctions issued that month and status on corrective actions ?(hoFby (hen@ G and sustainin& 6eco&nition of behaviors (e (ish to reinforce 6andom )*D -udits G summari'e findin&s and report them out each month / as (e as other interna or customer audits are schedu ed# (e (i report the findin&s and corrective actions ?(hoFby (hen@ 6is8 1iti&ation 4 an G (e donHt do this today# but (e need to deve op a 6is8 -ssessment ?.everityF<i8e ihood@ and then report out on the miti&ation strate&ies !e p NeededI
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FOD Prevention Program4 FOD A0areness (am+aign %uggestions
FOD 1a&2s G mana&ement shou d participate as (e as emp oyees (ho are not other(ise assi&ned to the production area% !o d a contest to see (ho co ects the most )*D G >ud&e by physica si'e or (ei&ht% Ba& the )*D and disp ay on your )*D -(areness boards% Caution do not let these walks take on the appearance of a social gathering stand shoulder to shoulder, eyes directed downward and cover the perimeter. Provide FOD containers for the participants. o talking on cells phones and no !unching up of the crowd" #nvite your customer to walk with you. Divide the (or8 area into A?ouse2ee+ing EonesB% *ne or more emp oyees are assi&ned to a 'one and are responsib e for end of shift c ean/up% 6ecommend you rotate the cre( members throu&h a the 'ones on a (ee8 y basis so they eventua y ta8e o(nership of the entire area% This visibi ity ensures the emp oyees are remindin& one another to Ac ean/as/you/&oB durin& the day and provides the individua accountabi ity necessary to sustain &ood house8eepin& practices% Design a c8art for dai&/90ee2&/ FOD 0a&2s9%0ee+s. Post it and insure t8at a&& em+&o/ees in t8e area +artici+ate in its use. The 1or2 Area (ontro& P&an is a mechanism to a o( you to customi'e the implementation of your )*D + Too 7ontro procedure by maintenance and refurbishment area G to account for uni,ue differences in the nature of the (or8# the s8i eve of the cre(# and the e"pectations of the customer% The area foreman (i co aborate (ith the cre( ?,ua ity and the customer shou d be inc uded@ to identify the potentia ris8 for forei&n ob>ect dama&e to the product and document the area# peop e# too and hard(are contro s specific to that area%
FOD 1or2 Area P&an. (ontro&s and Ris2 Mitigation P&an Area:
1% 7 ean as you 5o 2% )*D Barriers on a open ines# tubes# e ectrica connectors and in ets and vents (hen not in (or8% 3% )*D 7ritica -rea (i be desi&nated (ith approved si&ns# stanchions (ith chains and a contro ed entryFe"it point%
0% - visitors ?7ustomers# =n&ineers# 1ar8etin& 4ersonne # out side vendors and etc%@ are re,uired to chec8 in (ith the area supervisor or ead person prior to entry and o& a items brou&ht inFout of the )*D 7ritica -rea in the visitor o&boo8% 5% )*D containers are to be emptied into proper trash receptac es at the end of each shift% Trash cans sha be ocated outside of the )*D 7ritica -rea% 9% 2or8 tab es and computers that reside in the )*D 7ritica -rea (i remain A)*D )reeB at a times%
Peo+&e:
1% .tamp or si&n off your (or8 as you &o and insure a )*D chec8 is comp ete before presentin& the (or8 items to Pua ity contro or your second mechanicFpi ot as the inspector% 2% )*D 4revention 4ro&ram Trainin& (i be an annua trainin& re,uirement% 3% Brea8s and unch periods are to be ta8en in an assi&ned brea8 area or the unch room% 0% =mp oyees are to be A-udit 6eadyB at a times and e"pected to 8no( the )*D 4revention 4ro&ram and specifics app icab e to their >ob duties and to 8no( ho( they use and mana&e a items ta8en into the )*D 7ritica -reas%
)oo&s:
1% Too s used in the )*D 7ritica -reas (i be accounted for by usin& too counts# chits# shado( bo"es# inventory sheets or other accepted system by mana&ement% 2% Too s used in the )*D 7ritica -reas (i be identified by the o(ner (ith permanent mar8in&s% 3% Too Bo"esFtoo traysFtoo ba&s (i be inventoried at the be&innin& and end of each shift% =mp oyees brinin& too s into the area (i use an inventory ist of a too s in and out% 0% =mp oyees (i notify mana&ement immediate y (hen a too or part is missin&% 5% Too s and e,uipment eft on the aircraft overni&ht (i be recorded in a too o&%
?ard0are:
1% =mp oyees assi&ned to the area (i contro hard(are and consumab e items brou&ht into the )*D 7ritica -reas by use of an inventory contro ist% 2% !ard(are ta8e into the )*D 7ritica -rea (i be stored in a covered container (ith the part numbers and ,uantity mar8ed% 3% Ta8e on y the minimum amount of hard(are to comp ete the tas8% 0% =mp oyee (i notify his supervisor immediate y (hen hard(are or a consumab e is missin&% 5% -ny hard(are removed from the assemb y that cannot be retained must be comp ete y removed from the assemb y and accounted for by ba&&in& and ta&&in& it% 9% $dentification ta&s must be insta ed on a items removed from the aircraft%
4osition FOD A0areness bu&&etin boards in Ahi&h trafficB areas throu&hout the faci ity G at a minimum in the brea8 room% Ba& and post )*D found durin& )*D 2a 8s as (e as other found items% $fF(hen you have metrics# post these% 2innin& posters may be disp ayed here as (e as posters you can order on ine from (((%fodcontro %com% !o d a FOD Poster contest for emp oyees and fami y members $%&cerpt from the flyer used to promote a contest' The purpose of the contest is to increase a(areness of the potentia dama&e to aircraft and support e,uipment and the dan&er to personne caused by forei&n ob>ects% )*D can come in many different forms# and produce disastrous effects if not identified and corrected% $n severe cases# )*D can direct y threaten safety of f i&ht cre(s and inte&rity of the aircraft% ="amp es of )*D inc ude a too eft behind on the aircraft# ba bearin&s eft inside a hydrau ic tube# adhesive tape eft on a detai part# a c eanin& ra& eft behind in the cabin# etc% )*D prevention is an essentia e ement in a activities and is the responsibi ity of every emp oyee% The posters shou d address themes around -(areness# 4revention# and 7omp iance% The top 9 posters in the 13V a&e &roup (i be disp ayed at a faci ities on a rotationa basis durin& the ne"t si" months% 4ri'es (i be a(arded to the top 3 entrants in the 12 and under a&e &roup% The )*D =mp oyee 7ounci can serve as the >ud&in& pane % FOD Fig8ter artic&es in a ne0s&etter 4ub ish brief A&ood ne(sB stories hi&h i&htin& outstandin& )*D prevention techni,ues in the faci ity G at a minimum# ,uarter y% Re0ard & Recognition +rogram Deve op a re(ards pro&ram to reinforce the behaviors (e (ish to sustain% $deas / -(ard a month y Atrave in&B trophy to the emp oyee (ith the most si&nificant )*D findin& of that month% 6eco&ni'e the emp oyee?s@ (ho &o 5 business days (ithout any preFpost shift finds in their house8eepin& 'one%
6eco&ni'e emp oyees for comin& for(ard (hen a too is missin&% 6eco&ni'e cre( (ith 'ero finds by Pua ity G the a(ard &ets better the more consecutive inspections (ith 'ero finds G you start a over once Pua ity finds somethin&% 6e,uest test pi ots visit the f oor to than8 the emp oyees for care in preventin& )*D% ?ig8&ig8t continuous im+rovements to /our customer fre5uent&/ F forma&&/ or informa&&/4 just do it'
A6"
FOD Program com+&ete from an e,isting o+erator

The fo o(in& pa&es are from a current )*D pro&ram from an or&ani'ation active y invo ved (ith &overnment and commercia he icopter 1aintenance% This is formatted so that it is may be easi y copied and modified for your use in your or&ani'ation% This has an intense too and hard(are contro pro&ram that may be too e"tensive for most or&ani'ations but is a &ood basis for you desi&n your o(n% Acron/ms used in t8e Document: -7* -11 7-B 7T$ D** )77 )*D 5)6 1*7 1T) P-6 P7 P7$ P71 -ircraft 7ontract *fficer -viation 1aintenance 1ana&er 7orrective -ction Board% 7ertified Technica $nspector Director of *perations )*D 7ontro 7hec8 )orei&n *b>ect DebrisF )orei&n *b>ect Dama&e 5overnment ) i&ht 6epresentative 1aintenance *perationa 7hec8 1aintenance Test ) i&ht Pua ity -ssurance 6epresentative Pua ity 7ontro Pua ity 7ontro $nspector Pua ity 7ontro 1ana&er
17O8.9 OP47A!:.1 P7O(49874* *4(!:O. 1 ; 14.47A< P7O(49874* O7:1:.A!:O. 9A!4: .O=4MB47 1, %00#
1. GENERAL PROCEDURES 1.1 GROUND OPERATIONS PROCEDURES !he (omp'n0>s 6ro)n oper'tions tr'inin6 pro6r'm ens)res th't 'll personnel to incl) e on$site contr'ctors recei+e initi'l in octrin'tion 'n contin)'tion tr'inin6 'n th't onl0 tr'ine ? @)'li5ie , 'n /or certi5ie personnel per5orm 'ircr'5t 6ro)n oper'tions. Personnel tr'inin6 recor s 're m'int'ine 30 the A)m'n 7eso)rces 9ep'rtment in 'ccor 'nce with tr'inin6 proce )res (document number to be determined). A)m'n 7eso)rces monitors 'll tr'inin6 re@)irements )sin6 ' m'trix which i enti5ies speci5ic tr'inin6 t'ilore to e'ch emplo0ee>s Bo3. !he tr'inin6 m'trix pro+i es 'n )p to 'te st't)s o5 'll emplo0ee @)'li5ic'tion re@)irements 'n when the0 're )e 5or rec)rrin6 or certi5ic'tion tr'inin6. !r'inin6 is con )cte 30 m'inten'nce 5orem'n 'n selecte instr)ctors 'n oc)mente on emplo0ee tr'inin6 recor s which 're m'int'ine in the A)m'n 7eso)rces 9ep'rtment. !he (omp'n0>s 6ro)n oper'tions proce )res incl) e selectin6? tr'inin6, testin6 'n certi5ic'tion o5 personnel ')thoriCe to per5orm 'ircr'5t 6ro)n oper'tions in 'll norm'l 'n emer6enc0 oper'tions 'n 're ' resse in the rem'inin6 sections o5 this m'n)'l. 1.2 SPECIFIC GROUND OPERATIONS PROCEDURES 1.2.1 FOREIGN OBJECT DA AGE PRE!ENTION PROGRA P)rpose !he &O9 Pre+ention Pro6r'm )tiliCin6 .A* 41% 6)i 'nce is pl'nne , inte6r'te , 'n e+elope in conB)nction with o)r s'5et0, @)'lit0, m'inten'nce 'n 5li6ht oper'tions 5)nctions. :t is esi6ne to promote 5li6ht s'5et0 'n pre+ent 'm'6e to 'ircr'5t, components 'n e@)ipment )n er6oin6 m'inten'nce, rep'ir 'n o+erh')l. &O9 c'n 3e pre+ente thro)6h 6oo ho)se/eepin6, pro5ession'l m'inten'nce pr'ctices 'n proce )res, contin)'l personnel tr'inin6, e55ecti+e
Your company name here: 3; of 53 Dated: ; *ctober 2007 Revision No.: > Dated: !@ October # $
in+esti6'tion o5 &O9 inci ents 'n initi'tion o5 correcti+e 'ction to pre+ent rec)rrence. 7esponsi3ilities. !he 'ppointe &O9 o55icer is esi6n'te 's the &O9 pre+ention pro6r'm 5oc'l point. Ae is responsi3le 5or e+elopin6, re+isin6, monitorin6, re+iewin6, 'n 'ssessin6 the &O9 Pre+ention Pro6r'm 'n in+esti6'tin6 &O9 inci ents 'n e+'l)'tin6 pre+enti+e me's)res to pre+ent rec)rrence. !he 9irector o5 Oper'tions is responsi3le 5or implementin6 these proce )res in 'il0 m'inten'nce, rep'ir, o+erh')l, 5li6ht line 'n l')nch oper'tions. !he M'teri'l <o6istics M'n'6er is responsi3le 5or implementin6 &O9 pre+ention proce )res )rin6 stor'6e, shippin6 'n h'n lin6 o5 m'teri'l 'n components. !he &O9 4mplo0ee (o)ncil is m' e )p o5 emplo0ees 5rom 'll ep'rtments. !he co)ncil meets perio ic'll0 'n is responsi3le 5or 6ener'tin6 i e's to impro+e metho s in &O9 pre+ention 'n tool control 'n ens)re compli'nce with comp'n0 policies 'n proce )res
&O9 Pre+ention !r'inin6 !he prim'r0 o3Becti+e o5 the &O9 pre+ention tr'inin6 pro6r'm is to incre'se emplo0ee 'w'reness o5 the c')ses 'n e55ects o5 &O9 'n to promote 'cti+e emplo0ee p'rticip'tion in elimin'tin6 c')ses )rin6 per5orm'nce o5 'il0 wor/ ro)tines thro)6h 6oo wor/ h'3its 'n isciplines. .ew emplo0ees sh'll recei+e &O9 pre+ention in octrin'tion tr'inin6 's p'rt o5 their initi'l Bo3 orient'tion. !his tr'inin6 will 3e con )cte 'n oc)mente in 'ccor 'nce with tr'inin6 proce )res (document number to be determined).
Your company name here: 00 of 53 Dated: ; *ctober 2007 Revision No.: > Dated: !@ October # $
(ontin)'tion tr'inin6 5or 'll emplo0ees in+ol+e in rep'ir, o+erh')l, re5)r3ishment, 'ccept'nce, oper'tion 'n m'inten'nce, 'n @)'lit0 'ss)r'nce o5 'ircr'5t will 3e con )cte 'n oc)mente in 'ccor 'nce with tr'inin6 proce )res cont'ine in (document number to be determined).
&O9 pre+ention tr'inin6 sh'll '
ress the 5ollowin6:
o Proper stor'6e, shippin6, 'n h'n lin6 o5 m'teri'ls components, 'n e@)ipment. o !echni@)es to control e3ris. o (le'nliness in wor/ 're's Dho)se/eepin6E. o (le'nin6 'n inspection o5 components, 'ssem3lies 'n 'ircr'5t. o Proper control, 'cco)nt'3ilit0 'n c're o5 tools 'n h'r w're. o (ontrol o5 person'l items, e@)ipment, 'n cons)m'3les. o Proper c're 'n )se o5 'ircr'5t, component 'n e@)ipment protecti+e e+ices. o F)'lit0 wor/m'nship. o &li6ht line, t'xiw'0, 'n r'mp control metho s. o Aow to report &O9 inci ents or potenti'l inci ents. Pre+ention o5 &O9 9)rin6 *tor'6e 'n A'n lin6.
7ecei+in6, M'teri'l <o6istics personnel 'n F)'lit0 (ontrol :nspectors per5orm recei+in6 inspections on 'll m'teri'l, 'n p'rts or ere in s)pport o5 'ircr'5t m'inten'nce 'n re5)r3ishment oper'tions. :niti'l recei+in6 inspections 're per5orme to ens)re items were not 'm'6e )rin6 shippin6, th't items 're properl0 p'c/'6e 'n preser+e to pre+ent 'm'6e or cont'min'tion )rin6 stor'6e 'n h'n lin6, 'n th't the0 're properl0 i enti5ie . *tor'6e 'n h'n lin6. *peci5ic proce )res 5or stor'6e o5 'll m'teri'l 'n p'rts )se in s)pport o5 pro )ction oper'tions 're cont'ine in oper'tion'l proce )res (document number to be determined). !hese proce )res pro+i e 5or proper stor'6e, i enti5ic'tion, 'n preser+'tion o5 'll m'teri'l 'w'itin6 iss)e to pro )ction 'ircr'5t.
(ontrol o5 9e3ris )rin6 M'inten'nce/7e5)r3ishment Oper'tions. All items, 'ssem3lies, 'n /or components s)3Bect to 5orei6n o3Bect intr)sion '5ter remo+'l 5rom 'ircr'5t )n er6oin6 m'inten'nce 'n re5)r3ishment sh'll h'+e 'll lines, 5ittin6s, ports or openin6s properl0 c'ppe or co+ere . -here re@)ire , these items will 3e preser+e to pre+ent corrosion or eterior'tion. All remo+e items, 'ssem3lies, 'n /or components sh'll 3e properl0 t'66e Dm'nil' t'6E 'n store on component st'n s or p'rts 3ins esi6ne 5or e'ch 'ircr'5t. :tems will 3e store in s)ch ' m'nner 's to pre+ent 'm'6e 30 ph0sic'l cont'ct or cont'min'tion. =is)'ll0 inspect 3ins 5or &O9 pre+ention or cont'min'tion 'n ser+ice'3ilit0. All remo+e , o+erh')le or new items, 'ssem3lies 'n /or components sh'll 3e inspecte )pon receipt 'n /or prior to inst'll'tion 5or &O9 'n cont'min'tion.
9)rin6 re'ssem3l0 'n 5ollowin6 m'inten'nce 'ctions, 'll 're's to 3e enclose sh'll 3e inspecte 5or 5orei6n o3Bects prior to clos)re. !hese inspections 're impose on the m'inten'nce process thro)6h wor/ instr)ctions which re@)ire the emplo0ee, s)per+isor, 'n ' @)'lit0 control inspector to per5orm ' &O9, tool 'n corrosion inspection chec/ 't the completion o5 e'ch wor/ t's/. (ompli'nce is oc)mente 30 si6n't)re/st'mp on e'ch wor/ instr)ction.
Pre+ention o5 &O9 )rin6 &li6ht <ine M'inten'nce/<')nch Oper'tions. M'inten'nce personnel wor/in6 in s)pport o5 'ircr'5t 'n en6ine oper'tions sh'll: o Geep the 're' cle'n 'n 5ree o5 e3ris. o *ec)re 'll loose o3Bects 3oth on the r'mp 'n on 'll m'inten'nce st'n s 'n s)pport e@)ipment. o 7eport 'll potenti'l &O9 con itions to 0o)r imme i'te s)per+isor 5or 5)rther m'n'6ement 'ction when s)ch con itions c'nnot 3e correcte on the spot. o 4ns)re p'nels, oors, etcH o5 ' B'cent 'ircr'5t 're sec)re. o :nspect 'll 'ircr'5t/e@)ipment p'nels 5or loose 'n )nser+ice'3le 5'steners. <oose 5'steners sh'll 3e repl'ce imme i'tel0. o :nspect 'll open p'nel 're's 5or 5orei6n o3Bects 'n remo+e 'll e3ris prior to p'nel reinst'll'tion. o 7emo+e 'n sec)re 'll non$essenti'l test e@)ipment, m'inten'nce st'n s, 'n +ehicles 5rom the 're's 'ro)n oper'tin6 'ircr'5t.
o 4ns)re en6ine inlet protecti+e screens 're inst'lle 'n 5ree o5 e3ris prior to en6ine r)n$ )p>s. o 7emo+e 'll loose items, i.e., pens, 3' 6es, etc. 5rom clothin6 prior to m'inten'nce or inspection o5 en6ine int'/e 'n exh')st 're's. o 4ns)re 'll tools 're 'cco)nte 5or 3e5ore en6ine r)n )p or 5li6ht. o (e'se 'll 'cti+it0 'n0 time 'n itemDsE is lost )rin6 per5orm'nce o5 ' m'inten'nce t's/ 'n initi'te ' se'rch 5or the item. :5 the items 're not loc'te , initi'te lost tool/item proce )res. &li6ht crew personnel sh'll inspect 5or e3ris 'n &O9 while per5ormin6 pre5li6ht 'n post 5li6ht inspections in 'ccor 'nce with the oper'tor>s m'n)'l prior to en6ine r)n$)p 'n 5li6ht. 7)n$)p 'n ho+er 're's sh'll 3e closel0 monitore 30 5li6ht crews 5or loose 'n 5l0in6 e3ris th't co)l potenti'll0 c')se &O9.
A'r w're (ontrol 'n Acco)nt'3ilit0 7e)s'3le h'r w're s)ch 's n)ts, 3olts, screws, w'shers, cl'mps, etc. will 3e collecte 'n pl'ce in pl'stic 3'6s )pon remo+'l 5rom 'ircr'5t or components. 4'ch 3'6 will 3e 'tt'che to the component or will cont'in ' t'6 th't i enti5ies the 'ircr'5t t'il n)m3er 'n component th't the h'r w're w's remo+e 5rom 'n will 3e sorte in esi6n'te 'ircr'5t p'rts 3ins. 8nser+ice'3le h'r w're will 3e isc'r e in &O cont'iners imme i'tel0 )pon remo+'l. 9)rin6 component inst'll'tion or m'inten'nce rep'ir 'ctions, emplo0ees will onl0 tr'nsport
'3o'r the 'ircr'5t the 'mo)nt o5 h'r w're necess'r0 to 'ccomplish the Bo3/t's/. Bench stoc/ h'r w're m'int'ine in m'inten'nce 're's will 3e controlle 'n stoc/e in 'ppro+e c'3inets 'n cont'iners Di.e., sprin6 lo' co+ers, etc.E. 4xpen '3le tools 'n cons)m'3le s)pplies Di.e., s'n in6 isc, 3r)shes, etc.E 're iss)e 30 Pro )ction (ontrol A)3 to -or/ 're' &orem'n 'n store 30 &orem'n in 'ppropri'te c'3inets in m'inten'nce 're'. Are' 5orem'n 're iss)e cons)m'3les to s)pport 'il0 oper'tion'l re@)irements 5or their section. 4xpen '3le tools 'n cons)m'3le s)pplies will 3e isc'r e in &O cont'iners when no lon6er )se'3le. 4mplo0ees will )se Icle'n$'s$0o)$6oJ techni@)es. i.e., cle'n the imme i'te 're' )rin6 wor/ in pro6ress, '5ter wor/ is complete 'n prior to inspection. !'s/ remo+'l 'n inst'll'tion wor/ instr)ctions will 3e )se to 'ssist in tr'c/in6 p'rts 'n h'r w're. An0time 'n item Di.e., h'r w'reE is lost )rin6 'ssem3l0 or ' m'inten'nce t's/, ce'se 'cti+it0 in the '55ecte 're' 'n initi'te ' se'rch 5or the item. (ontin)e the se'rch )ntil the item is 5o)n . :5 the item c'nnot 3e loc'te 5ollow the proce )res in lost tool proce )res.
!ool (ontrol 'n Acco)nt'3ilit0 !he prim'r0 o3Becti+e o5 the tool control pro6r'm is to elimin'te 'cci ents/inci ents 'n loss o5 li5e or e@)ipment )e to tool &O9. &or this pro6r'm to 3e e55ecti+e, the cooper'tion, in octrin'tion 'n e )c'tion o5 'll personnel who wor/ irectl0 with tools 're essenti'l. O)r tool control pro6r'm:
Pro+i es tool room stor'6e, iss)e 'n 'cco)nt'3ilit0 proce )res 5or comp'n0$owne tools : enti5ies the owner o5 person'l tools 30 ' )ni@)e m'r/in6 s0stem 7e@)ires tool 3oxes to 3e Ish' ow 3oxe J to e'sil0 i enti50 missin6 tools 7e@)ires e'ch emplo0ee tool 3ox to h'+e ' c)rrent in+entor0 sheet 7e@)ires tool 3ox in+entories to 3e con )cte 30 the emplo0ee 't the 3e6innin6 'n en o5 e'ch shi5t 'n re@)ires emplo0ees to 'cco)nt 5or 'll tools 't the completion o5 the Bo3 t's/ 7e@)ires ' m'n 'tor0 si6n$o55 30 ' s)per+isor or @)'lit0 control inspector on e'ch complete wor/ instr)ction )se in s)pport o5 ' pro )ction process th't tool 'cco)nt'3ilit0 h's 3een complete . Pro+i es 5or imme i'te noti5ic'tion )pon isco+er0 o5 ' lost tool 'n se'rch reportin6 proce )res.
1ener'l !ool Acco)nt'3ilit0 Proce )res !he s)ccess o5 the tool control pro6r'm lies with the -or/ Are' &oremen 's well 's 'll emplo0ees. &oremen 're responsi3le 5or the implement'tion 'n m'inten'nce o5 the tool control pro6r'm. 4mplo0ees will in+entor0 their tool 3oxes 't the 3e6innin6 o5 e'ch shi5t 'n '6'in 't the en o5 the shi5t, 'n will complete ' 9'il0 !ool (ontrol =eri5ic'tion (document number to be determined). (omplete +eri5ic'tion sheets will 3e t)rne into the 're' 5orem'n 't the en o5 e'ch wee/ 5or re+iew. !he 5orem'n will con )ct r'n om tool 3ox +eri5ic'tion ') its on 't le'st two tool 3oxes 'il0. !hese +eri5ic'tion ') its will 3e oc)mente on (document number to be determined). (omplete +eri5ic'tion ') it 5orms will 3e
t)rne into the respecti+e m'inten'nce m'n'6er 5or re+iew 't the en o5 e'ch wee/. Prior to commencin6 ' wor//pro )ction 'ction, emplo0ees will m'/e ' +is)'l or si6ht in+entor0 o5 the tool cont'iners. *hort'6es or missin6 tools i enti5ie 't this point will re@)ire completion o5 <ost !ool/A'r w're/:tem 7eport (document number to be determined). Person'l !ool (ontrol :n+entor0 'n 9'il0 !ool (ontrol =eri5ic'tion 5orms will 3e ret'ine in the emplo0ee>s tool3ox. -or/ :nstr)ctions )se 't this 5'cilit0 sh'll cont'in ' m'n 'tor0 si6n$o55 3loc/ which st'tes K!AA! A !OO< A((O8.!AB:<:!L A.9 &O9 :.*P4(!:O. AA* B44. (OMP<4!49K. !his 3loc/ will 3e complete 30 the emplo0ee, s)per+isor 'n F(:/(!: in ic'tin6 th't 'll tools )se in s)pport o5 the m'inten'nce t's/ h'+e 3een 'cco)nte 5or. !ools )tiliCe )rin6 5li6ht line m'inten'nce oc)mente on 'ircr'5t 5orms sh'll re@)ire 'n &O9 control chec/ D&((E )pon completion o5 wor/ t's/ 'n the 5ollowin6 ' e to the correction 'ction entr0 on Ddocument number to be determined) which sh'll i enti50 &O9 'n tool 'cco)nt'3ilit0 chec/ complete . -or/ instr)ctions )se )rin6 6ro)n oper'tions o not re@)ire the I&((J entr0 on the Ddocument number to be determined). O-.47*A:P P7O(49874* Person'l !ools All emplo0ees en6'6e in m'inten'nce 'n rep'ir t's/s 're re@)ire to pro+i e person'l h'n tools 'n tool3oxes 's ' con ition o5 emplo0ment. !ool3oxes m)st 3e c'p'3le o5 3ein6 loc/e . !ool cont'iners will 3e intern'll0 sh' owe so th't 'll tools will h'+e speci5ic loc'tions 5or @)ic/ tool 'cco)nt'3ilit0. All person'l tools sh'll 3e le6i3l0 'n perm'nentl0 m'r/e with the ownerMs i enti5ic'tion m'r/ Dm'r/s sho)l 3e somethin6 )ni@)e to the in i+i )'l, s)ch 's color co in6, initi'ls, 3' 6e n)m3er, etc. which is not li/el0 to 3e )se 30 'nother in i+i )'l 't this 5'cilit0E. 4mplo0ees sh'll +eri50 tools 're ser+ice'3le 'n le6i3l0 m'r/e 's p'rt o5 their 'il0 in+entor0.
8nser+ice'3le/3ro/en tools will 3e imme i'tel0 remo+e 5rom the emplo0ee>s tool 3ox 'n the sh' ow loc'tion will 3e t'pe o+er )ntil the tool is repl'ce . !he emplo0ee>s m'ster in+entor0 sheet will 3e )p 'te 30 Ceroin6 the item, 'nnot'tin6 I3ro/enJ 'n then noti50in6 5orem'n imme i'tel0 to )p 'te the in+entor0 sheet. A compile list o5 'll emplo0ees> tool m'r/in6s will 3e m'int'ine 30 the Pro )ction (ontrol. :tems which 're too sm'll to 3e in i+i )'ll0 m'r/e sh'll 3e /ept in ' cont'iner with the contents liste on the cont'iner. Person'l tools sh'll 3e store in the ownerMs tool3oxDesE, when not in )se. 4'ch emplo0ee sh'll esi6n'te r'wer/ r'wers in their tool cont'iner 's ' IPerson'l :temsJ loc'tion. !ools, speci'l tools, expen '3le tools 'n s)pplies Di.e. h'r w're, s'5et0 wire, cotter /e0s etc.E sh'll not 3e store in the IPerson'l :temsJ loc'tion. Personnel per5ormin6 6ro)n oper'tions 're ')thoriCe to c'rr0 'n )tiliCe person'l items. Personnel in or 'ro)n 'ircr'5t 6ro)n oper'tions "i## ens$re th't person'l items 're sec)re prior to 'ircr'5t oper'tions. Prior to 3e6innin6 wor/, e'ch new emplo0ee sh'll set$)p his/her person'l tool3oxDesE 's in ic'te '3o+e 'n sh'll prep're ' Person'l !ool (ontrol :n+entor0, D oc)ment n)m3er to 3e etermine E. !he emplo0eeMs 5orem'n sh'll 3e responsi3le 5or +eri50in6 the 'cc)r'c0 o5 the initi'l in+entor0 'n 'n0 ch'n6es, 'n 5orw'r in6 copies o5 the in+entor0 recor s to the F)'lit0 (ontrol M'n'6er. One cop0 o5 the in+entor0 will 3e ret'ine in the emplo0eeMs tool3ox 'n one cop0 will 3e m'int'ine 30 F(. !hese in+entories sh'll 3e )p 'te 't 'n0 time when ' tool is ' e to or elete 5rom the tool3oxDesE. -or/ Are' &oremen sh'll sche )le 'n con )ct perio ic in+entories Dnot less th'n semi$'nn)'ll0E o5 emplo0ee tool3oxes to ens)re 'cc)r'c0 o5 m'ster tool list. !hese in+entories sh'll 3e recor e on Person'l !ool (ontrol :n+entor0 (document number to be determined). NOTE% UN ARKED TOOLS& TOOLS NOT ON T'E IN!ENTOR( RECORD T'AT ARE FOUND
Your company name here: 0: of 53 Dated: ; *ctober 2007 Revision No.: > Dated: !@ October # $
DURING IN!ENTORIES )ILL BE CAUSE FOR DISCIPLINAR( ACTION. F( 9ep'rtment represent'ti+es sh'll con )ct D't le'st one per 3i$wee/l0 perio E, s)r+eill'nce inspections o5 in+entories to 'ssess the ' ministr'tion o5 the pro6r'm. !hese inspections will 3e oc)mente on (document number to be determined) 'n 5orw'r e to the 'pplic'3le Aircr'5t M'inten'nce M'n'6er 5or correcti+e 'ction. C*+,-n. T**#s (omp'n0 tools 're controlle thro)6h the m'in tool room loc'te in the M'teri'l <o6istics ep'rtment 'n s'tellite tool rooms in +'rio)s m'inten'nce sections. !ool rooms/s'tellite tool rooms will )se sh' ow3ox 'n sh' ow 3o'r techni@)es to speci5ic'll0 m'r/ loc'tions o5 'll tools so th't ' missin6 tool will 3e re' il0 notice'3le. A ition'll0 'll G:!* will h'+e ' l'3el '55ixe to the cont'iner i enti50in6 the n)m3er o5 items in the /it. *i6n o)t or chit s0stem proce )res will 3e )tiliCe 5or proper tool 'cco)nt'3ilit0 on D oc)ment n)m3er to 3e etermine E. 4mplo0ees sh'll ret)rn 'll common tools to the tool room/'re' tool c'3inets no less th'n 15 min)tes 3e5ore close o5 3)siness on the s'me '0 the tools 're si6ne o)t. !he tool room speci'list/'re' 5orem'n will con )ct ' closin6 tool in+entor0 5or proper 'cco)nt'3ilit0 'n 'cco)nte 5or on D oc)ment n)m3er to 3e etermine E. <ost !ool Proce )res :5 tools 're missin6 'n e5ine 's lost 't the en $o5$t's/ or en $o5$shi5t in+entor0, the mech'nic/ technici'n sh'll imme i'tel0 report the isco+er0 to their 5orem'n, who will noti50 their respecti+e m'n'6er. !he wor/ site will imme i'tel0 3e impo)n e 'n ' se'rch sh'll 3e initi'te . !ool/A'r w're/:tem :nci ent 7eport D oc)ment n)m3er to 3e etermine E sh'll 3e initi'te 'n s)3mitte to the F(M who will con )ct 'n ' ition'l se'rch. :5 the missin6 item is still not 5o)n , the inci ent sh'll 3e reporte to the 1o+ernment FA7/AMM 5or
Your company name here: 0; of 53 Dated: ; *ctober 2007 Revision No.: > Dated: !@ October # $
5)rther re+iew 'n 'ction. !he F(M sh'll ret'in 'll <ost !ool/A'r w're/:tem :nci ent 7eports 5or tren 'n'l0sis. !he F(M rele'se 'ircr'5t 3'c/ to m'inten'nce. Aircr'5t )n er MO( or M!& st't)s sh'll h'+e 'n entr0 in the 'ircr'5t lo63oo/. I*t't)s 7e 2, s)specte lost tool the F( sh'll si6n o55 to rele'se 'ircr'5t 5or MO(, M!& )pon completion o5 inspection.J !he F(M will 3rie5 the &O9 o55icer 'n 9OO concernin6 'll lost h'r w're 'n tools inci ents. NOTE% NO E PLO(EE )ILL BE SUBJECT TO DISCIPLINAR( ACTION FOR I EDIATEL( REPORTING A LOST TOOL OR 'ARD)ARE ITE / 'O)E!ER& E PLO(EES )ILL BE SUBJECT TO DISCIPLINAR( ACTION FOR FAILURE TO REPORT LOST ITE S OR IF UNREPORTED LOST ITE S ARE FOUND IN AN AIRCRAFT OR CO PONENT UPON )'IC' T'E E PLO(EE )AS )ORKING. -or/ Are' (le'nliness 'n Ao)se/eepin6 Pre+ent'ti+e Me's)res. (le'nliness 'n 6oo ho)se/eepin6 pro+i e 'n e55ecti+e me'ns o5 pre+entin6 &O9. 4mplo0ees will m'int'in their wor/ 're's in ' ne't 'n or6'niCe m'nner )sin6 Icle'n$'s$0o)$6oJ techni@)es to 'ssist in pre+entin6 &O9 h'C'r s. -or/ e3ris 'cc)m)l'te insi e or on 'ircr'5t, components or 5li6ht line +ehicles 'n e@)ipment will 3e remo+e 's 6ener'te 'n )rin6 the 'il0 cle'n)p con )cte 't the en o5 e'ch shi5t. (onspic)o)sl0 m'r/e tr'sh 'n &O9 cont'iners will 3e re' il0 'ccessi3le in 'll h'n6'r 'n shop wor/ 're's to properl0 ispose o5 e3ris. !hese cont'iners
will 3e emptie &O9.
'il0 so 's not to 3ecome so)rces o5
A 'il0 cle'n)p o5 'll m'inten'nce 'n shop wor/ 're's will 3e con )cte 't the en o5 e'ch wor/ shi5t to incl) e 'ircr'5t. 9)rin6 this time, h'n6'r 'n shop 5loors will 3e swept, wor/ 3enches, m'chiner0, 'n e@)ipment will 3e cle'ne , 'n &O9 cont'iners 'n tr'sh c'ns will 3e emptie . M'inten'nce 'n shop 5orem'n will inspect their 'ssi6ne wor/ 're's 't the en o5 e'ch wor/ '0 to ens)re 'ccomplishment o5 'il0 cle'n)p. All emplo0ees sh'll 'ssist in contin)'ll0 pre+entin6 potenti'l &O9 h'C'r s 30 pic/in6 )p 'n isposin6 o5 e3ris 's the0 tr'nsition thro)6h h'n6'r, shop 'n 5li6ht line 're's. !he 5li6ht line 5orem'n will con )ct ' 'il0 &O9 w'l/ o5 'll o)tsi e r'mp 're's 'n 'ircr'5t r)n$)p 're's to ens)re remo+'l o5 e3ris 'n potenti'l &O9.
:n+esti6'tin6 'n 7eportin6 &O9 :nci ents. One o5 the most import'nt 5'ctors in &O9 pre+ention is the imme i'te 'n thoro)6h in+esti6'tion o5 &O9 inci ents to pre+ent rec)rrence 30 i enti50in6 'n elimin'tin6 the root c')ses. !he in+esti6'tion will 'ttempt to etermine the o3Bect which c')se the 'm'6e 'n hi6hli6ht m'inten'nce pr'ctices or proce )res which m'0 h'+e contri3)te to the inci ent. -hen ' &O9 inci ent is s)specte , the 5ollowin6 'ctions will 3e 'ccomplishe . M'inten'nce noti5ies the F(M 'n stops 'll wor/ on the 'ircr'5t, en6ine or components )ntil ' &O9 in+esti6'tion is complete 'n F)'lit0 (ontrol rele'ses the 'ircr'5t or item 5or rep'ir.
F)'lit0 (ontrol will con )ct ' thoro)6h in+esti6'tion o5 the inci ent to i enti50 the 5orei6n o3Bect 'n its so)rce thro)6h close inspection o5 the 're'. At the concl)sion o5 the in+esti6'tion, ' &O9 :nci ent 7eport Ddocument number to be determined) will 3e complete 30 the F)'lit0 (ontrol M'n'6er 'n s)3mitte to the &O9 o55icer. !he &O9 o55icer will coor in'te with the 9OO to etermine i5 5ollow$on 'ction D(AB, ') it, 1&7, 'n A(O noti5ic'tionE is re@)ire . !he 1&7 will 3e noti5ie o5 'n0 &O inci ent res)ltin6 in 'm'6e to 6o+ernment propert0. !he &O9 O55icer will implement ch'n6es to the &O9 pre+ention pro6r'm i5 'ppropri'te 'n ens)re correcti+e 'ctions 're implemente to pre+ent rec)rrence. &O9 Pre+ention Pro6r'm 7e+iew D&O9PPE !he &O9 O55icer will re+iew the &O9PP semi$ 'nn)'ll0 to ens)re the pro6r'm is 'chie+in6 speci5ie 6o'ls. !his re+iew will e+'l)'te c)rrent proce )res, &O9 inci ents i enti5ie )rin6 the pre+io)s 1% months 'n st'tistic'l 't' collecte 30 F( )rin6 @)'lit0 inspection c'lls. &ollowin6 the re+iew, the &O9 O55icer will, i5 re@)ire , re+ise the &O9 pre+ention proce )res 'n 3rie5 the 9OO 'n 'pplic'3le ep'rtment m'n'6ers o5 note tren s 'n re+ise proce )res. !he &O9PP will 'lso 3e ') ite perio ic'll0 's p'rt o5 the @)'lit0 'ss)r'nce ') it pro6r'm in 'ccor 'nce with D oc)ment n)m3er to 3e etermine E, :ntern'l F)'lit0 A) its. !he &O9 O55icer will pro+i e &O9 tren 'n'l0sis 't @)'rterl0 m'n'6ement re+iews. !ren 'n'l0sis will 3e 3'se on lost tool reports, c)stomer inspections, 'n F(: inspections.
$$$4n o5 &O9 (ontrol Pro6r'm$$$

Foreign Object Debris and Foreign Object Damage (FOD) Prevention For Aviation Maintenance & Manufacturing

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Foreign Object Debris and Foreign Object Damage (FOD) Prevention For Aviation Maintenance & Manufacturing

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Copyright:

Formati disponibili

Foreign Object Debris and Foreign Object Damage (FOD) Prevention For Aviation Maintenance & Manufacturing

%ooner or &ater' Foreign Object Debris becomes Foreign Object Damage'

0%0 5%0 9%0 7%0 :%0 ;%0

Pur+ose and -ntroduction

FOD Program (ontro&s and -m+&ementation

Assignment of Res+onsibi&ities and Foca& Points FO(A; PO-N)

FO(A; PO-N): Designated FOD Officer9Manager(s)9FOD Prevention

FO(A; PO-N) of (ontact: Designated ;oca& FOD

FO(A; PO-N) of (ontact: Manufacturing9Maintenance Managers9%u+ervisors Ro&es & Res+onsibi&ities

FO(A; PO-N) of (ontact: =ua&it/ (ontro& Managers9%u+ervisors

Your company name here: 10 of 53 Dated: 13 November 2007 Revision No.:

10% !o( to report )*D incidents or potentia incidents%

Parts Protection and Materia&s 8and&ing

Assemb&/ and s8o+ o+erations

)est (e&& & %+ecia& %8o+s *nvironment

F&ig8t ;ine O+erations F&ig8t O+eration Procedures:

Fie&d and F&ig8t &ine faci&it/ o+eration

Re+orting and -nvestigations

Resources: %ome current resources for FOD contro& items and

SPENRO Kitting Services

;in2s to artic&es on FOD contro& as of: ! October #

A++endi,es: A6! FOD Prevention Program OrganiCation (onsiderations

FOD Prevention Program4 FOD A0areness (am+aign %uggestions

FOD Program com+&ete from an e,isting o+erator

&O9 pre+ention tr'inin6 sh'll '

ress the 5ollowin6:

will 3e emptie &O9.

'il0 so 's not to 3ecome so)rces o5

$$$4n o5 &O9 (ontrol Pro6r'm$$$

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