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

2. 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.

3. FOD Awareness
ACC Non-maintenance FOD Training
USAF

4. 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

5. 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

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

7. 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

8. 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

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

10. Higher-Level Requirements
Authority
Federal Standard 209
ISO , 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

11. 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

12. 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

13. 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.

14. 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.

15. 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

16. 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)

17. 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

18. 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

19. 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

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

21. 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

22. 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

23. 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

24. 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.

25. 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

26. 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

27. 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:

28. 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

29. 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

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

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

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

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

34. 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

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

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

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

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

39. 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

40. 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

41. Questions

42. 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

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

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

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

46. 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

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

48. 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