FOD Prevention Training Program

FOD Prevention Training Program
Foreign Object Debris/Foreign
Object Damage (FOD) Prevention
Training Program
May 2010
Company Confidential
1
FOD Training Program Objective
•The primary objectives of a FOD prevention
training program is to increase employee
awareness to the causes and effects of FOD,
promote active involvement through specific
processes & prevention techniques, and
stress good work habits through work
disciplines.
2
What is FOD?
Foreign Object Debris (FOD)
A substance, debris, or article alien to the
component, assembly, system or vehicle that could
cause damage.
Foreign Object Damage (FOD)
Any damage or incident attributed to a foreign
object that can be expressed in physical or
economic terms that may or may not degrade the
product’s required safety and/or performance
characteristics.
3
FOD Training Program Topics
•
Proper storage, shipping and handling of material,
components, and equipment
• Techniques to control debris
• Housekeeping
• Cleaning and inspection of components and assemblies
• Accountability/control of tools and hardware
• Control of personal items, equipment and consumables
• Care and protection of end items
• Quality workmanship (“Clean-As-You-Go,” Inspection)
• How to report FOD incidents or potential incidents
4
Examples of FOD
• One should always be aware of and on the look out for
FOD or Potential FOD, here are some examples of
recognized FOD
a.Unorganized workplace
b.Unaccounted for tools or tool details
c. Scattered components on work bench
d.Metal chips not cleaned up in the work place
e.Food at workspace
f. Protective covers not installed or improperly installed
5
Outcomes of FOD
• FOD can cause delays in manufacturing and
assembly
• FOD can cause product failure
• FOD can cause loss of business
• FOD can cause injury and death
FOD comes in all shapes & sizes……..
6
Failures Caused by FOD
• FOD may cause many failures and damages, but worst of
all – it might cause injuries and even loss of human life!
• FOD can also cause damage to the company’s finances
and reputation.
• It is a fact that foreign objects and/or debris have
contributed to jammed flight controls, engine damage,
electrical shorts, fluid contamination, control valve
failures, fires and other major failure incidents that have
resulted in costly material damage, loss of vehicle and of
life.
• Foreign material comes in many shapes and forms. It
may present itself as a hand tool, dust, grime, oil, metal
shavings, loose nuts, bolts, cotter pins, lock wire
remnants, pencil, pen, packing material, etc.
7
Examples
Typical FOD
8
Examples
Small, seemingly insignificant items
can lead to Big Problems
9
Examples
Manufacturing Process Debris:
Polishing Material-FOD
This pump was
returned by a
customer because
of a foreign object.
Scotch bright
10
Examples
Assembly Process Debris:
Fabric In Sealed Assembly-FOD



Product leaked during acceptance testing
Leak was caused by a nylon fiber contaminant preventing
seal integrity at a manifold interface
The nylon fiber came from clothing or a lab coat
11
Examples
Assembly Process Debris:
Fasteners-FOD
This pump blew after
ingesting several screws
at the customer. Small
FOD can cause big
problems.
12
Examples
Food In The Workplace:
Food-FOD
Oatmeal on a
Turbine Blade!!
13
Examples
Food In The Workplace:
General Housekeeping (6 S)-FOD
14
What is 6-S?
Every Thing has a Place and Every Place has a Thing!






Sort – Discard everything that you don’t use
Shine – Clean!
Straighten – Label & organize in a way to promote work flow
Standardize – Assign rolls and responsibilities, standardize
processes
Sustain – Audit on a set frequency to make sure the 6S
program is being maintained
Safety – Keep the work area safe and walk ways clear
We can layout our areas so they flow better and are
easier to clean and maintain.
15
Examples
Tool Control:
Tool Details-FOD
Lever
After repeated use, the screw
backs out of flex socket
16
Proper storage, shipping and handling of
material, components, and equipment.
• Handle and store parts, assemblies, fixtures, and
equipment in a manner that prevents damage,
deterioration, or contamination.
• Be aware of any special handling considerations, this
may include hazardous material requirements as
applicable.
• Properly store equipment and tooling in designated
areas
• Use protective caps and material as specified.
• Be aware of any ESD requirements the product may be
effected by.
17
Examples
PART PROTECTION & MATERIAL HANDLING
• Packaging & Shipping our product creates an opportunity
for objects to invade them.
• By adding a FOD check along with a quality inspection, we
can push FOD problems back to their sources. This will
eventually make our jobs easier.
• Upon Receiving and Prior to Shipping Material Inspect for:
» Proper part number
» Proper packaging
» Damage
» Cleanliness
» Foreign Object Debris/Damage
• Report any Non-Compliance per Procedure.
18
Examples
Manufacturing Process Debris:
Machining Chips-FOD
Machining
Chips
19
Examples
Manufacturing Process Debris:
Tumbling Media-FOD
Tumbling Media
20
Methods For Preventing FOD
Key Attributes of Robust FOD Prevention

FOD Awareness and Training – Promote participation in
FOD elimination and provide frequent training.

Material and Part Handling – Move and store all parts and
production tooling in a way that prevents all damage and
corrosion.

General Housekeeping and 6-S – Implement good
cleaning practices as well as organization of parts, tools, and
supplies.

FOD Reporting – Know who to contact and what to do in an
actual, or suspected, FOD event
21
Methods For Preventing FOD
Key Attributes of Robust FOD Prevention

FOD Management – Assign a person or people to be the
FOD focal point

Processes – Use prevention, detection, and cleaning to
eliminate process media and debris

Tool Accountability – Know where your tools are and the
condition they are in.

Measuring Performance/Metrics – Track FOD incidents
and finding, use Root Cause and Corrective Actions to make
improvements
22
Methods For Preventing FOD
Key Attributes of Robust FOD Prevention

Communication and Feedback – Put up Posters or FOD
Alerts in common areas so that all personnel are aware of
FOD Risks

Consumable Control – Keep Consumables out of FOD
critical area and use on a “take as needed” basis

Hardware Accountability – Know what you have used
and how much you should have left

Personnel Control – Identify FOD Control Areas, allowing
only the required personnel and tools access
23
Simple Rules To Help Prevent FOD
•
Establish processes to prevent, detect, and
clean debris at proper intervals.
•
House keeping (Clean as you go) Keep your
work area clean and organized.
•
Maintain tool awareness, organize tools so
they are easily accounted for, do so before and
after your work assignment.
•
Secure loose tools with appropriate equipment
or methods.
•
Account for all material and equipment used in
the process, (e.g. shadow boxes, cut-outs, and
designated storage locations for tooling and
equipment).
24
Simple Rules To Help Prevent FOD

Verify that your clothing and accessories (e.g.
pens, staples, strings) do not contaminate or
provide an avenue for contamination.
•
Handle and store parts, assemblies, fixtures,
and equipment in a manner that prevents
damage, deterioration, or contamination.
•
Inform your Supervisor or Team Leader of any
condition that may lead to a potential FOD
induced failure or incident.
•
Ensure that all assembly layouts are free from
foreign objects prior to layout inspection.
25
Simple Rules To Help Prevent FOD
•
Ensure that each component or pre-assembly is
thoroughly clean.
•
Ensure that all sub-assemblies ready for final
build-up are properly protected to prevent FOD.
•
Ensure workbenches are faced with a hard
wearing material.
•
Prevent visible particles from entering the
immediate work bench area of assembly.
26
Simple Rules To Help Prevent FOD
•
Utilize cleaning cloths that are non-shedding
fiber in nature.
•
Post FOD alert prevention signs in designated
areas.
27
Lost Item Program
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 program results are achieved and
properly documented according to the lost
item procedure.
28
PEOPLE IN THE PROCESS
FOD elimination should be a focus at ALL steps
From initial design
to shipment, there
are many
opportunities for
foreign objects to
invade the
product.
Preventing FOD
at only one step
is not sufficient.
Design
Machining
Overhaul
& Repair
Assembly
Shipping &
Receiving
Packaging
Testing &
Inspecting
29
Responsibility for FOD
• It is EVERYONE’S responsibility to
recognize and prevent FOD
• Don’t rely on the person who looked
before you…
...or the person who will look after you
30
RESOURCES
There are a lot of publically accessible
organizations who focus on FOD
elimination, for more information:
• The F.O.D Control Corporation
• National Aerospace FOD Prevention, Inc. NAFPI
• Insight SRI –FOD Papers
• National Center for Aerospace & Transportation
Technologies
31
Questions?
32
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