Basic Terms and Definitions:

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1 All personnel who work on or around aircraft or aerospace products are responsible for preventing and eliminating foreign object damage! Basic Terms and Definitions: Foreign Object (FO) An alien substance or article that can invade the product during a process or event. Foreign Object Damage (FOD) is any damage attributed to a foreign object that can be expressed in physical or economic terms Foreign Object Debris (FOD) is a substance, debris, or article alien to a vehicle or system that has invaded the product and could cause damage The term FOD has become a general term used in the industry to refer to both foreign objects and foreign object damage. This means the acronym FOD could refer to Foreign Object Damage and its definition, or Foreign Object Debris and its definition. Critical FO is any material that is inadvertently left inside an assembly after closeout or in areas from which migration is possible. A FOD Designated Area is any area where flight hardware is in place and exposure to foreign objects would potentially cause a system or product failure due to deterioration, malfunction or damage. FOE Foreign Object Elimination is a program or process consisting of the best practices used to increase FOD awareness and eliminate damage caused by foreign objects. This is sometimes referred to as a FOD Prevention Program and includes FOD Awareness, training, and specific policies and procedures that significantly reduce the risk of damage due to foreign objects.

2 FOD Prevention Practices Housekeeping Tool Control Hardware Accountability Material Handling & Hazardous Material Physical Entry & Personnel Control Attitude Clean-As-You-Go Sponge Count Kitted Hardware Parts Packaging FOD Designated Areas Right Attitude 5-S Philosophy Shadow Board Hardware Removal & Control Material Inspection FOD Awareness Area FOD Culture FOD Containers Shadow Box Hardware Containers/Tote Trays Material Storage FOD Sensitive Area FOD Bags Consolidated Tool Kits Hardware Storage FOD Barriers FOD Critical Area Permanent Tooling Tool Bags Aircraft Protection Employee Training Aircraft Operation Area Electronic Tool Accountability Chit System Tool Inventory Log Tethers Tool Inspection Disposable Tool Control Personal Tool Control Hazardous Material Handling ESD Restricted Area Access

3 Housekeeping Principles Housekeeping is the responsibility of employees to maintain a clean and orderly work area with necessary tools, materials, and equipment in their places of orderly arrangement Clean-As-you-Go is an ongoing process that removes work debris as it accumulates. The Principles of Clean-As-You-Go are: 1. Clean the immediate area when work cannot continue 2. Clean the immediate area when work debris has the potential to migrate to an out of sight or inaccessible area and cause damage or give the appearance of poor workmanship 3. Inspect and clean all tools after job completion or at the end of each shift 4. Clean the immediate area after work is completed and prior to inspection 5. Clean the work area at the end of each shift 6. If you drop something or hear something drop, pick it up! The 5-S Philosophy is a method adopted from Japanese culture for housekeeping and organization. The 5 S s represent Sort, Straighten, Standardize, Shine, and Sustain. This method is used to increase awareness of workplace organization which directly contributes to eliminating foreign object damage. FOD Cans or FOD Container is a receptacle that is strategically placed in FOD Designated Area or at a location where work debris is normally generated or accumulates. FOD containers feature a spring-loaded lid that helps prevent migration of foreign objects. They are normally brightly colored and highly visible to remind workers about FOD prevention. A FOD Bag is a canvas or non-metallic bag, usually with a Velcro closure, that is used to temporarily store foreign objects and other work debris while performing a task, until the FOD can be disposed of in a FOD Can or FOD Container. FOD Bags are often permanently attached to Consolidated Tool Kits (CTKs), flightline vehicles, or work stands. A FOD bag can also be used to temporarily store personal items such as keys, sunglasses, jewelry, ID badges or any other personal belongings, while working in a FOD Designated Area. FOD Bags should never be used to store or transport tools or hardware. Tools should only be transported in a tool bag and hardware should only be transported in a hardware container/tote tray.

4 Permanent Tooling refers to construction activity of shop areas. After the work activity is completed, a FOD Walk/Sweep must be accomplished to remove any foreign objects prior to the area being put into use. A FOD Walk/Sweep is a physical inspection of an assigned area to detect and remove all foreign object debris (FOD). Tool Control Methods Sponge count is a formal procedure utilizing a written record of all items entering and leaving a work area. A Shadow Board is a method where outlines in the shape of tools are used to designate a tool storage location. This method makes it easy to determine where each tool belongs. Shadowboxing is a method using foam cutouts, typically in tool box drawers, which provides a unique storage location for each tool in the tool box. When shadowboxed, a large tool chest can be inventoried in 60 seconds or less. A Consolidated Tool Kit (CTK) is an inventoried set of company-provided tools that are assigned to a tool box, tool pallet, or portable tool cage. CTKs are normal kept in a tool crib and are signed out and signed in as needed for specific jobs. When CTKs are signed in and signed out, an inventory of all the tools in the CTK is performed. Inventory control of CTKs is the responsibility of either tool crib personnel or an area supervisor. A Tool Bag is a small zippered bag used to transport tools from an inventoried tool box onto an aircraft to perform a task. Tool bags provide a convenient means of carrying small sets of tools away from their primary storage location into a FOD control area such as an aircraft. Tool bags not only keep tools from becoming lost, they also protect the aircraft from damage as a result of contact with the tools. An Electronic Tool Accountability System is a tool control system that uses electronics devices, such as bar codes and laser scanners, to track and account for tools. This is primarily used as a sign-in/sign-out tool control method that links a tool with the technician who is using it. Tool identification is commonly used with Consolidated Tool Kits to assign tools to a particular tool kit or tool box. Tools are typically identified with color coding (color bands on each tool that matches the color identification of the tool box), etching (engraving an identification number on each tool that matches the identification of the tool box), tool tags (a tag that is permanently affixed to each tool with an identification that matches the identification of the tool box), or sensor scanning (using bar codes and laser scanners or some other method of electronically identifying tools that belong in a tool box).

5 A Chit System is a means of controlling tools using small tags with an identification number assigned to a specific individual. A chit is located in place of a tool to identify the technician who is currently using the tool or if the tool has been removed from service for calibration or repair. This system is used to prevent tools from being left in an aircraft or other FOD Designated Area. Chits can also be used to designate that a tool has been sent out for repair or calibration. Chits must be accounted for as if they were a tool. A Tool Inventory Log is a form that is used to document all tools and loose items taken into a FOD Designated Area. The form is used as a checklist to document each item a person has in his or her pockets as well as the tools being carried into the FOD Control area. When exiting the area, each item is checked off to verify that the item was removed from the FOD Control area. A Tether is a lanyard of sufficient strength and length, attached to a tool at one end, and attached to the user or a fixed secure object at the other end. Tethers are used in areas where if the tool were to drop or slip out of the technician s hand, the tool may become lost in an inaccessible part of the aircraft or engine. Having the tool tethered to the technician or a fixed object prevents the tool from dropping too far and also allows the tool to be easily retrieved. A Tool Inspection should be accomplished when you complete a job, or at the end of a shift. Tools are inspected to ensure they are clean and free of defects. All tools should also be inventoried or accounted for to ensure they were not left inside and aircraft or aerospace products.

6 Hardware Accountability Practices A Hardware Kit is a pre-assembled kit of consumable hardware which contains the exact amount of hardware needed to perform a specific task. This method is used to ensure that no extra hardware is taken into a FOD Designated Area where it could be lost or left in an aircraft without being detected. Hardware Removal, Control, and Replacement is the method used to maintain control and accountability of hardware that is removed from an aircraft or aircraft component. Drawstring-style cloth bags are often used to store removed hardware until it is either reinstalled or replaced with new hardware. Having a defined method for the control and accountability of removed hardware significantly improves FOD Prevention. A Hardware Container/Tote Tray is a container featuring a spring-loaded lid and is used to safely transport hardware from a storage location to the point of use. Having a spring-loaded or latching lid minimizes the risk of spillage if the tote tray is accidently dropped. Hardware Storage is the method in which hardware is located in a manner where it is accessible to workers while also preventing migration. As hardware storage moves closer to FOD Designated Areas, more stringent prevention and control methods become necessary. Consumables are items that are consumed or used during maintenance operations. This includes glue, paint, sealant, sandpaper, brushes, applicators, and even issued apparel (latex gloves) or safety glasses.

7 Material Handling & Packaging Protection of parts is the responsibility of everyone working on and around aircraft. When unpackaging a part, it should be inspected for damage or contamination. Improper packaging, transportation, and storage of parts often results in foreign object damage. A FOD Barrier is a device used to prevent foreign objects from entering any aircraft, component, or assembly and causing damage or contamination. This includes edge protectors, caps, plugs, or other protective covers that are used to protect hoses, cables, ducts, and even electronic components. FOD Barriers are also used to prevent damage as a result of ESD. FOD Barriers must be controlled and accounted for to prevent them from becoming FOD. Sometimes, FOD Barriers are placed inside lines to prevent contamination. When placed inside lines, flags are often placed on the outside of the line to alert a technician that an internal FOD barrier is present. When FOD barriers are placed inside lines, they must be removed prior to closeout or before the product is put into use. FOD barriers should only be removed by authorized personnel through maintenance or assembly paperwork. Hazardous Materials and ESD can be a source of FOD as they can directly result in damage to aircraft or aircraft component.

8 FOD Incident Reporting A FOD Focal Point should develop and implement plans and programs to prevent hardware damage. The focal point should be appointed by the chief operating official and have sufficient authority and organizational freedom to identify and implement FOD preventive measures whenever and wherever required. A FOD Point-of-Contact (POC) is a person who is in charge of, and in direct control of, a FOD Designated Area. The FOD POC is responsible for personnel entry, tool control logs, FOD audits, posting alerts, and initiating FOD Incident Reports. The FOD POC typically reports directly to the FOD Focal Point. When a FOD incident occurs, work should be stopped and an investigation should be initiated. FOD incidents include near-mishaps so a potential FOD incident should also be reported and investigated. When a tool or item is lost, or when a tool or item is found, an investigation should be conducted. Self-reporting of lost tool incidents typically results in no disciplinary action, but an investigation should still be initiated. FOD costs the aviation industry an estimated 4 billion dollars every year. Although maintenance operations has little control over bird and wildlife in regard to FOD prevention, wildlife is considered to be a major contributor to the FOD problem in the industry.