LESSON 5 Control of Manufacturing Environment and Foreign Object Debris 15November2013 Lesson 4: Safety Stock

Lesson Introduction Given a contract with Foreign Object Debris (FOD) standards, you will be able to perform surveillance on the supplier’s FOD prevention/elimination program.

FOD Awareness ACC Non-maintenance FOD Training USAF

Lesson Objectives Upon completion of this lesson, you should be able to: Identify contractual FOD prevention/elimination surveillance requirements. Identify FOD and potential FOD in a supplier’s facility. Differentiate between FOD Controlled Areas and FOD Awareness Areas. Relate the Clean-as-You-Go process to FOD prevention/elimination surveillance activities. Select Quality Assurance Specialist (QAS) FOD prevention/elimination surveillance methods. Lesson 4: Safety Stock

Lesson Topics This lesson covers the following topics: References, Authority, and Definitions FOD Control and Awareness Areas FOD in Supplier’s Facility Supplier FOD Surveillance Requirements QAS FOD Prevention/Elimination Surveillance

WIIFM? This lesson provides an explanation of policy, terminology, and concepts relevant to performing surveillance on the supplier’s FOD prevention and elimination program.

References, Authority, and Definitions Lesson Topics: References, Authority, and Definitions FOD Control and Awareness Areas FOD in Supplier’s Facility Supplier FOD Surveillance Requirements QAS FOD Prevention/Elimination Surveillance

Topic 1: References, Authority, and Definitions Definitions include: Foreign Object/Debris (FO/FOD) Foreign Object Damage (FOD) Foreign Object Elimination (FOE) Program 5Ss Consumables Clean-as-you-go

References Military Standard (MIL-STD-980) (30 July 1982), Foreign Object Damage Prevention in Aerospace Products Federal Aviation Agency (FAA) Advisory Circular (9-30-09) DCMA Instruction 8210.1

Higher-Level Requirements Authority Federal Standard 209 ISO 146644-1, Cleanrooms and Associated Controlled Environments ISO 9001:2008 AS9100 Institute of Environmental Sciences and Technology Standard (IEST-STD)-CC1246, Product Cleanliness Levels and Contamination Control Program 46 Code of Federal Regulation (CFR) Part 57, Welding and Brazing NAS 412, Foreign Object Debris and Foreign Object Damage Prevention

DCMA Policy All DCMA personnel follow the supplier’s FOD prevention program Foreign objects can cause damage to any commodity Foreign object damage (FOD) includes systems degradation

Definitions (1 of 6) Foreign Object/Debris (FO/FOD) – Substance, debris, or article alien to an assembly or system that could potentially cause damage Tools: flashlights, screwdrivers, wrenches, sockets Excess hardware: washers, nuts, screws, tie straps, cables Other: dirt, dust, ash, sand, oils, pens, name tags, rings, watches, rags, eye glasses, paper clips

Definitions (2 of 6) Foreign Object Damage (FOD) – Damage attributed to a foreign object that can be expressed in physical or monetary terms and that may or may not degrade the product’s required safety or performance.

Definitions (3 of 6) Foreign Object Elimination (FOE) Program – A program or process that uses regimented procedures and controls to ensure an FOD free product/system.

Definitions (4 of 6) 5s A systematic process or method for creating and maintaining an organized, clean, high-performance workplace suited for high quality and efficient operations. SORT SIMPLIFY SWEEP STANDARDIZE SUSTAIN DISCIPLINE

Definitions (5 of 6) Consumables – Expendable supplies provided to workers. Issued apparel Safety glasses Glue, paint, sealant Rags, sandpaper, brushes Stock items (washers, fasteners, hardware)

Definitions (6 of 6) Clean-as-You-Go A process for eliminating FOD that could: Become entrapped in closed spaces Shift to damage or impede electronics or mechanical systems Block access Cleaning the workspace periodically and after work is completed

Question and Answer Which process specifically entails cleaning the workspace periodically and after work is completed. Foreign Object Cleaning Consumables 5Ss Clean-As-You-Go

FOD Control and Awareness Areas Lesson Topics: References, Authority, and Definitions FOD Control and Awareness Areas FOD in Supplier’s Facility Supplier FOD Surveillance Requirements QAS FOD Prevention/Elimination Surveillance

Topic 2: FOD Control and Awareness Areas FOD Controlled Areas FOD Awareness Areas

Examples: Examples: FOD Controlled Areas Flight Line Flight Deck Require an increased level of control to ensure that exposed flight hardware or mission critical equipment is protected from FOD at all times. Examples: Flight Line Flight Deck Hangar Deck Examples: Flight Line Flight Deck Hangar Deck

Examples: FOD Awareness Areas Examples: Squadron Work Center Require a heightened level of awareness of cause and effects of FOD Any area where non-mission critical equipment is present Examples: Squadron Work Center Maintenance Work Center Air Rework Center Examples: Squadron Work Center Maintenance Work Center Air Rework Facility Power Plant Rework Center Q-Tip

Question and Answer In the Q-Tip, Rotary Aircraft Drive Train Gearboxes, what was the primary FOD? Oil Plug Safety Wire Protective Plugs Attaching Fasteners

Question and Answer What is the primary difference between a FOD Controlled Area and a FOD Awareness Area? FOD Controlled Areas are accessible to the QAS, while FOD Awareness Areas are not. FOD Awareness Areas are accessible to the QAS, while FOD Controlled Areas are not. FOD Controlled Areas exceed the requirements of FOD Awareness Areas. FOD Awareness Areas exceed the requirements of FOD Controlled Areas.

FOD in Supplier’s Facility Lesson Topics: References, Authority, and Definitions FOD Control and Awareness Areas FOD in Supplier’s Facility Supplier FOD Surveillance Requirements QAS FOD Prevention/Elimination Surveillance

Topic 3: FOD in Supplier’s Facility Tools: Flashlights, screwdrivers, wrenches, sockets Excess hardware: washers, nuts, screws, tie straps, and cables Other: Dirt, dust, ash, sand, oils, pens, name tags, paper clips, rings, watches, eye glasses, rags

Expendable supplies provided to workers: Consumables as FOD Cleaning products Issued apparel Safety glasses Glue, paint, sealant Rags, cheese cloth Sandpaper, brushes, applicators Stock items Expendable supplies provided to workers:

Question and Answer Which of the items is an example of either a potential or actual FOD in a supplier’s facility? CAC Wrench Safety glasses I II I and III I, II, and III

Supplier FOD Surveillance Requirements Lesson Topics: References, Authority, and Definitions FOD Control and Awareness Areas FOD in Supplier’s Facility Supplier FOD Surveillance Requirements QAS FOD Prevention/Elimination Surveillance

Topic 4: Supplier FOD Surveillance Requirements Prevention Early Detection Correction FOD Source Supplier FOD Review Process

Supplier FOD Review Process Audits Areas Audited Daily Periodic Verify compliance with FOE process Production Test Stock Receiving

Supplier FOD Review Process (cont.) Team Personnel FOD Focals FOD Program Manager Product Line Managers AUDITORS

Question and Answer Which item does NOT relate to the FOD review process for potential FOD sources? Correction Prevention Early detection Product examination results

QAS FOD Prevention/Elimination Surveillance Lesson Topics: References, Authority, and Definitions FOD Control and Awareness Areas FOD in Supplier’s Facility Supplier FOD Surveillance Requirements QAS FOD Prevention/Elimination Surveillance

Topic 5: QAS FOD Prevention/ Elimination Surveillance QAS ENSURES… Good Housekeeping Practices FOD PREVENTION

QAS Determines Method QAS Determines Method FOD Surveillance Product Examinations QAS Determines Method Process Reviews System Audits QAS Determines Method

Supplier Work Area Walk-Throughs Random Toolbox Inventory Regular Checks Perform in Operational Processing Areas Check Work Areas TRAITS

Noncompliance Identified Verify Root Cause Correction Walk-Throughs - CARs CAR Issued Noncompliance Identified Verify Root Cause Correction WHY?

Question and Answer What should the QAS ensure in a supplier’s facility to facilitate FOD prevention? Supplier’s product examination results Good housekeeping practices Personnel are certified for their work task A cleaning company visits regularly

Summary Having completed this lesson, you should be able to: Identify contractual FOD prevention/elimination surveillance requirements. Identify FOD and potential FOD in a supplier’s facility. Differentiate between FOD Controlled Areas and FOD Awareness Areas. Relate the Clean-as-You-Go process to FOD prevention/elimination surveillance activities. Select QAS FOD prevention/elimination surveillance methods. Lesson 4: Safety Stock

Questions

Review Question 1 Which FOD prevention process requires periodic checks of the work space and a check after work is completed? 5S QMS Audit Walk-Through Clean-As-You-Go

Review Question 2 Which item is NOT part of the 5S process? Sorting Simplifying Sequencing Standardizing

Review Question 3 Which is NOT an example of an FOD Controlled Area? Air Rework Facility Flight Line Flight Deck Hangar Deck

Review Question 4 What is an example of FOD in a supplier’s facility? Washers Safety glasses Broken gear teeth All of these

Review Question 5 Which activity is performed by the QAS during a walk-through of a supplier’s facility? Root cause analysis Product examination Random toolbox inventory Product verification

Review Question 6 The supplier’s review process to control FOD is centered around which areas? Correction Prevention Early detection All of these

Exercise: FOD Surveillance Strategy Students work in pairs to identify FOD and discuss potential surveillance strategies. Open CMQ101_M7_L5_E1_FODIdentification.pdf. Time: 10 minutes