SUMMIT FOD PREVENTION CLASS INSTRUCTION TEXT

Reference Boeing PRO-2396 – prevention of Foreign Object Damage and

Summit Ground Operations Procedure Manual Appendix A

Objective
1. Increase awareness of FOD
2. Understand causes and effects of FOD
3. Techniques to prevent FOD
4. Increase knowledge of good work habits to aid in FOD eliminatio n

Definition of FOD
1. FOD- Foreign Object Debris: substance, debris or article alien
to a component or system which could potentially cause
damage.
2. Foreign Object Damage- Damage attributed to foreign object
debris that can be expressed in physical or economic terms that
may or may not degrade the performance or safety
characteristics immediately or over time.

Examples
- Tools dropped that cause a hole in the skin or something as small
as a chip in the paint.
- Objects ingested into a turbine engine causing a
catastrophic component failure and possibly loss of life…

Foreign Objects or Debris

1. Foreign objects/debris can include tools or parts that are
unaccounted or
2. Contaminants in processing gases or liquids which directly
contact flight hardware. Fuel with water or fungi in it, nitrogen
with oil in it are both examples of this
3. Clippings, plastic tie wraps, lacing cord, lock wire, metal chips,
solder, paint, oil on hands, paper, pens, paper clips, staples,
tacks, cloth, tape, shop towels, Q-tips, food and wrappers,
jewelry, keys, coins…

Why Be Concerned?
Cost of FOD can be upwards of Four Billion Dollars Annually! May also
be fatal!

FOD Can Cause

1
 SUMMIT FOD PREVENTION CLASS INSTRUCTION TEXT

1. Injury or Loss of Life

2. Impact to accomplishing Mission
3. Impact to Schedule
4. Loss of Customer (Boeing) Confidence and Satisfaction
5. Added cost for rework and repair

Most FOD can be attributed to:

1. Housekeeping – Clean as You Go!!
2. Facility Deterioration – Ramps and Taxiways Eroding…
3. Improper Maintenance – Right Tool for the Right Job
4. Careless Assembly – Protective caps, hardware left behind
5. Inadequate operational practices
6. Failure to follow documented procedures
Keeping the Work Area Clean
Cleaning up as you work is an important action you can take to prevent
FOD
As a minimum, clean the work area when:
1. Work stops – Job Completion, scheduled breaks
2. Personnel change
Work area includes parts carts, area on the aircraft where work was
accomplished, and any type of oil/fluid spills on floor.
Clean as You Go is the 1st step in FOD prevention

Material Handling Strategy

These are things that we can do here at Summit to help prevent foreign object
damage

Dropping Parts – Doors off of fuel pods before removal to ease weight and
grip, also prevents breaking of door fittings.

Parts coming into contact with each other during handling – place
something in between them (horsehair, foam, etc…) – This is one of
Boeing’s BIG NO-NO’s!

Use of FOD protective devices (caps, plugs, bags) to prevent entry of FOD
into components.

Packaging materials becoming FOD – Responsibility of Logistics

Personnel to keep FOD in mind when packaging parts for shipment.
Cleaning out shipping cans is also a big part of this.

2
 SUMMIT FOD PREVENTION CLASS INSTRUCTION TEXT

Tool Accountability

Proper tool management is a key ingredient in an effective FOD prevention

program:
1. Account for tools at the start and end of every task
Tool Checklist, tool bags, shadowed tool boxes…
2. Designate storage areas for tools
Tool room, each tool has its own location
Tool boxes- items in boxes must be master inventory. No extra
stuff!!
3. Only take out the tools that are required to complete the job
that you’re doing.

Carrying and storing loose tools:

Tools should be in a proper container. Tool bag and tool box are
acceptable. Container should make it easy to tell if a tool is missing.

FOD Prevention Tips

1. Clean as You Go is the 1st step in FOD prevention
2. Material Handling Strategy to protect parts and hardware
3. Know where your tools are at the start and at the end of every
task
4. Only the tools and parts out in the work area that are needed
for the task at hand