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Foreign Object Foreign Object Elimination (FOE) Elimination (FOE)

ProgramProgram

UNCLASSIFIED

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2) What is FOD ???.... What does the Term FOD mean ???....

3) What is a FOD Sensitive Area ???

4) How many types of FOD Sensitive Areas are there, and how do I identify these areas ???

5) Why does your company need a FOE Program, and to whatlevel of FOD Sensitivity ???

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1) What is FOD ???.... & What does the Term FOD mean ???....* FOD is any item foreign to a product… Something that doesn’t belong where it’s found…

The term FOD has two definition:

* Foreign Object Debris

* Foreign Object Damage (Is caused by the “Debris” !!)

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2) What is a FOD Sensitive Area ???

* A FOD Sensitive Area, is an area set-up around a product, that ensures that the FOD Sensitivity

Level of the product is maintained at all times…

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FOD Awareness Area(Lowest Level of FOD Sensitivity)

FOD Control Area(Medium Level of FOD Sensitivity)

FOD Critical Area(Highest Level of FOD Sensitivity)

3) How many types of FOD Sensitive Areas are there, and how do I identify these areas ??

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FOD “Awareness” Sensitivity Level:Hardware that is at a low risk level for FOD Incidents,

and have minimal potential for FOD migration or

entrapment… Exposure to foreign objects will have

minimal negative effects to form, fit and function of

hardware…

FOD Awareness Area Basic Attributes:• FOD Awareness Area placards are posted at conspicuous locations, at all entrances of the area, and within the area as required…

• Elevated “high standard” of housekeeping… (6-S event should be performed)…

• Periodic FOD Walk Downs may be performed as determined by the local FOD Sensitive Area / Product Manager...

• All personnel who frequent, transit or work in a FOD Awareness Area must have at a minimum, FOE General Awareness Training: LMS Course Code: 008465WPL00… Note: This is a one-time training requirement…

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FOD “Control” Sensitivity Level:Hardware that is at a medium risk level for FOD

Incidents, and have a medium potential for FOD

migration or entrapment… Exposure to foreign objects

may degrade the form, fit or function of components,

systems, and/or assemblies, which could lead to

substandard performance of product / vehicle…

FOD Control Area Basic Attributes:• FOD Control Area placards are posted at conspicuous locations, at all entrances of the area, and within the area as required… Stanchions / Stanchion Placards with boundary tape can be used to localize a FOD Control Area, and can be within a FOD Awareness or Critical Area… (Personnel, miscellaneous small parts, tools and hardware have elevated control…)

• Elevated “high standard” of housekeeping… (6-S event should be performed)…

• Scheduled FOD Walk Downs “must be” performed as determined by the local FOD Sensitive Area / Product Manager with coordination from the local MSP FOE Program Coord / Rep…

• All personnel who frequent, transit or work in a FOD Control Area must have FOE General Awareness Training: LMS Course Code: 008465WPL00, and Area Specific FOE Training: LMS Course Code: 008465WPL01 (this is annual training, 12 month cycle)…

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FOD “Critical” Sensitivity Level:Hardware that is at a high risk level for FOD Incidents,

and have a high potential for exposure, entrapment

and/or migration of foreign objects into hardware, which

could cause serious damage to form, fit or function of

components, systems or assemblies, which could lead to

product / vehicle deterioration, malfunction and/or

complete failure…

FOD Critical Area Basic Attributes:• FOD Critical Area placards are posted at conspicuous locations, at all entrances of the area, and within the area as required… Stanchions / Stanchion Placards with boundary tape can be used to localize a FOD Critical Area, and can be within a FOD Awareness or Control Area. (Personnel, miscellaneous small parts, hardware & tools are strictly controlled; “Sponge Counts” are required) (Single Point Entry & Exit)

• Extreme “high standard” of housekeeping… (6-S event should be performed)…

• Scheduled weekly FOD Walk Downs “must be” performed at a minimum, and are scheduled by the FOD Sensitive Area / Product Manager with coordination from the local FOE Program Coord / Rep…

• All personnel who frequent, transit or work in a FOD Critical Areas must have FOE General Awareness Training: LMS Course Code: 008465WPL00, and Area Specific FOE Training: LMS Course Code: 008465WPL01 (this is annual training, 12 month cycle)…

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4) Why does your company need a FOE Program, and to what level of FOD Sensitivity ??

* The Lockheed Martin contract with your company contains a quality clause (QS5C), which dictates a FOD “Awareness” Level FOE Program.

* Bottom Line: Protect your product from being invaded and/or damaged by foreign objects during manufacturing, assembly, test, packaging and transportation…

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QS5C (FOD Awareness Level)(Lockheed Martin Quality Clause Document: 253-01

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“Basic Rule” for setting up a FOD Sensitive Area:

All physical areas (mfg, assembly & test) must be prepared to receive FOD Sensitive Hardware as to support the FOD Sensitive Classification Level of that specific hardware… (Awareness, Control, Critical), “prior” to the arrival of said hardware !!!...

The local FOD Sensitive Area / Product Manager is responsible for arranging this action, with coordination from the local FOE Program Coordinator / Representative…

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Foreign Object Incident Reporting(FOIR’s)

* Always report all incidents (Internal or External), even if you caused it !!!

* Report all Incidents to your local FOD Sensitive Area Manger (Supv) and to your local FOE Program Coord / Rep…

* Your local FOE Program Coord / Rep is responsible for collecting all pertinent incident information, which includes performing personal interviews…

* The FOE Program Coord / Rep will create and submit the FOIR within the in-house Non-Conformance System…

* If “Cause” or “Corrective Action” is assigned to you, you must respond to the appropriate individual within 10 working days… (excluding weekends, off-Fridays and holidays…)

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Typical Attitudes towards FOE Programs:* This is Stupid, and a waste of time and money !!! * Why can’t people just do their jobs, and not be slobs !!!

* Isn’t this Management’s Responsibility ???

* I’m not going to report anything, it’s a pain in the rear, and besides, there might be restitution against me, especially if I’m the cause !!!

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* FOD Prevention is a Personal Thing !!!

* Must be practiced in our everyday routines !!!

* How important is the FOE stuff anyway ???

Cultural Change

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Prime Examples of Foreign Object Prime Examples of Foreign Object Damage: THAAD Flight 8, May 1998Damage: THAAD Flight 8, May 1998

340V Exposed 340V Exposed conductors (by conductors (by design)design)

Rear view of recovered J4 connector

Self Destruct of Missile (6 seconds)

Initiation of THAAD Energy Management Steering (TEMS) Maneuver

Mission Failure

Nominal Flight (Launch to 2.89 sec)

Pre-flight J4 connector

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Why in the world would you want to prevent FOD ???

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Why ???

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Here’s a good reason !!!(108 people lost their lives !!!)

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FOD comes in all shapes, sizes & types !!!

Be on your Guard !!!