Thursday, September 6, 2012

FOD - Foreign Object Damage or Debries

                 What is "Foreign Object Debris"? "Foreign Object Debris" is anything that potentially impairs the aircraft’s ability to fly. This may include tools, nuts, bolts, caps, paper, vehicles, people, construction material, packaging, plastic bags, dogs, cats, birds, pencils, phones, books, rocks, pavement pieces, aluminium cans, etc. A "Foreign Object Debris" can be all kinds of objects like these:
What can be the consequences of "Foreign Object Debris"?
                    "Foreign Object Debris" in the wrong place can create a potential safety problem.
                          Or, in other words: 
"Foreign Object Debris“ => "Foreign Object Damage"
What might be consequences of "Foreign Object Damage"?
How can we prevent "Foreign Object Damage"? Most FOD can be attributed to poor housekeeping, facilities deterioration, improper maintenance or careless assembly and inadequate operational practices. Therefore a FOD prevention training program as part of initial job orientation and on a continuing basis is to increase employee awareness to the causes and effects of FOD. Following are a few stages and possibilities for FOD prevention to give you an idea of what can be done.

Parts and material handling:  A well-established plan for material handling and parts protection can eliminate many potential FOD hazards. First, identify the specifics such as sensitive parts, assemblies, surfaces, areas, etc. Then, sequence events for packaging, handling, shipping and storage, and finally, evaluate cleanliness and care requirements.

Housekeeping: Maintenance, manufacturing and operational areas must remain clean. Employees should be informed that housekeeping is a part of their job and they will be graded on their performance. Incorporate “Clean-As-You-Go” as a required work ethic to prevent debris from migrating into flight hardware.

Ensure that all production, maintenance and test areas meet “good housekeeping” standards that enhance foreign object elimination. This includes sweeping and vacuuming production areas as well as a regular schedule for sweeping ramp areas.

Ensure that grounds and surfaces on which aerospace vehicles and ground support equipment are operated and maintained are free of objects that could cause damage due to ingestion of foreign object or jet blast effects.

Tool accountability: The primary objective of a positive tool accountability program is to eliminate accidents/incidents and loss of life or equipment due to tool FOD.

There are numerous methods to facilitate accountability: use of shadow boards, shadowboxing, bar coding, special canvas layouts with tool pockets, tool counters, chit system tool tags, or consolidated tool kits.

Unique control methods should be implemented for special tools used in checkout, test and operational environments.

Tools/equipment should be tethered or suitably restrained to the user in areas around structural work stands or any other locations where a dropped article could result in damage to flight hardware, injury to personnel, or where difficulty in retrieval would result if the tool were dropped.

All loose tools should be contained in a tote tray, soft tool bag or other suitable spill-proof container and not placed in a manner that would cause damage to flight hardware or injury to personnel.
Hardware accountability:  The primary objective of hardware accountability is to assure control. There are many methods that can be established for control of hardware (nuts, bolts, screws, cotter pins, rivets, clecoes, etc.), e.g. kit hardware by task; FOD containers should be placed in key locations within the work area and entry and exit points; “Clean-As-You-Go” policy; removal/installation paperwork to track loose parts; furnish and specify tote trays; covered spring- loaded containers; etc.
Lost items: Any time an item is lost during an assembly, manufacturing, or maintenance task, cease activity in the affected area and initiate a search for the item. Continue this search until the item is found or adequate assurances are made that the item is not in the aerospace vehicle or assembly. Searching for such items may require depaneling or non-destructive inspections, including boroscope and/or x-ray. If an item cannot be located after a search has been completed, annotate applicable forms with a description of the item and search procedure followed.
Physical entry into FOD critical area: When physical entry is required into flight hardware, such as crew compartments, engine intake, exhaust, fuel tank areas, etc., personnel should remove all loose objects, badges, jewellery, etc., from clothing. Pocketless coveralls should be worn to preclude foreign objects dropping from pockets onto a FOD critical area.

23M02/ Fliteline Safety/

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