AMET226 Wk2 FOD

Page 1: Centennial College School of Engineering Technology & Applied Science (SETAS) Advanced Manufacturing and Automation Technology (AMAT) COURSE: AEROSPACE ASSEMBLY COURSE CODE: AMET226 WEEK 2: LECTURE – FOREIGN OBJECT DAMAGE FOD Date: Winter 2024

  • Course: Aerospace Assembly

  • Course code: AMET226

  • Week 2 lecture: Foreign Object Damage (FOD)

  • Date: Winter 2024

Page 2: WEEK 1 REVIEW

  • Introduction to the course

  • Course outline

  • Safety and ergonomics

  • Lab safety

  • Identify risk factors in workstations

  • Apply concepts learned at workstations

  • Change work habits

Page 3: AMET226 - FOD FOD CENTENNIAL COLLEGE

Page 4: OBJECTIVES: AMET226 – WEEK 2 OBJECTIVES

  • Identify hazards related to foreign objects in aircraft

  • Define FOD (Foreign Object Damage)

  • Explain human factors influencing FOD in aircraft

  • Recognize responsibilities in eliminating foreign objects

  • Propose solutions to eliminate FOD at the source

  • Describe precautions when working near aircraft

Page 5: Did you know…

  • In the aviation industry, the percentage of errors related to missing steps, components, tools, FOD, etc. in the plane is:

    • A-25%

    • B-32%

    • C-47%

    • D-56%

    • E-61%

Page 6: Percentage of common errors in the aerospace industry

  • Forget a step, part, tool, etc.: 56%

  • Wrong installation: 30%

  • Wrong part: 8%

  • Others: 6%

Page 7: What is FOD? - Foreign Object Damage

  • Anything that should not be on the aircraft when the task is accomplished

  • Includes parts, tools, refuse (debris)

Page 8: What is FOD? Common Foreign Objects left on the airplane include:

  • Tools: Wrenches, pliers, snaps, sockets, punches, drills, etc.

  • Hardware: Rivets, hi-lites, bolts, nuts, washers, DNR, parts (uninstalled)

  • Personal belongings: Flashlights, keys, phones, hats, PPE

  • Garbage: Rags, masking tape, tywrap tails, drill swarf, pencil marks, pipe caps

Page 9: Why is there presence of FOD?

  • Operations of assembly manual (movement, etc.) are not always respected

  • Statements in notebooks include:

    • Clean and remove all foreign objects

    • Make a cleanup

    • Remove all FOD

    • Verify cleanliness

Page 10: Environmental Protection Precautions to be Taken

  • Protect adjacent components against intrusion of FOD

  • Inventory of tools checked at the beginning and end of each shift

  • Take only necessary hardware and tools inside the aircraft

  • Make a list of tools, equipment, hardware, etc. taken in the aircraft

  • Use barcode identification on new serialized components to reduce FOD presence

Page 11: Manage your inventory to leave nothing behind

  • Protect tubes and pipes (end cap)

  • Install access doors if needed

  • Protect all electric connectors

  • Reduce presence of foreign objects

Page 12: FOD and Human Factors

  • Lack of communication

  • Individual work instead of teamwork

  • Lack of attention, comprehension

  • Lack of knowledge (consequences)

Page 13: Communication

  • Verbal communication complements written communication

  • Read and follow assembly manuals and instructions

  • Respect cleaning instructions

  • Perform aircraft cleaning with precision

Page 14: Team Work

  • FOD problems are everybody's business

  • Eliminate FOD at workstations

  • Discuss with colleagues and suggest ideas

  • Have a common purpose in work team

Page 15: The lack of attention

  • Lack of attention contributes to the presence of FOD

  • Double-check and ensure adequate lighting

  • Check all corners and use a mirror if necessary

  • Stay concentrated and check inventory list

Page 16: The lack of knowledge

  • Consequences of hardware, metal chips, forgotten rags, and unauthorized matter

  • Do not use stringer, cables, or flight control mechanisms as tool support

Page 17: The lack of knowledge

  • Consequences of loss of personal belongings and use of non-authorized matter

  • Contamination or corrosion with certain products

  • FOD is dangerous

Page 18: FOD can lead to catastrophic loss of ship and loss of life

  • FOD is dangerous

Page 19: The results of FOD

  • Short circuit and fire in the avionic bay

  • Unexpected damages and depressurization

  • Flight control surfaces problems and fire in the engines and cabin

  • Loss of electrical/electronic systems and loss of hydraulic pressure

Page 20: Real Cases: Events linked to the presence of FOD

  • Pliers left on a flight control pulley

  • Forgotten mirror in an engine, damaged turbine blades

  • Forgotten mirror and flashlight under a flap, damage to flap

  • Forgotten fasteners, flight control mechanism blocked by a rivet head

Page 21: Be professional when performing your work

  • Clean work area after completion

  • Discard gloves, leftover hardware, rags, and foreign objects

  • Manage tools, hardware, and components brought into the aircraft

  • Use available means of protection

  • Do not use cables or flight control mechanisms as tool support

  • Close out operations are not used to clean

Page 22: FOD Prevention

  • Communication campaign: AMET226 - FOD

  • Tools fitted with RFID chip/tag

    • If tool not returned, red light registers

    • Aircraft electronically scanned for missing tool

  • Wrist and waist bands issued with FOD bags attached

  • FOD stations at each entrance to the aircraft

  • Banners and posters presented company-wide

  • Morning meetings held everyday

  • New ideas solicited from employees

Page 23: My FOD Project

  • FOD (hardware and garbage) entering APU intake door during assembly

  • APU turbine blades being destroyed in 60% of aircraft

  • FOD sucked into APU upon start-up, destroying impeller blades

  • Door left vulnerable during final assembly work

  • APU door opened and closed multiple times during installation

Page 24: My FOD Project Solution

  • Solution from previous FOD prevention project: 3M product called Dirt Trap

  • Dirt Trap used to line walls of paint booths to mitigate overspray

  • Dirt Trap cut into strips and laid over sidewall intercostals

  • Prevents swarf and contaminants from falling into wire harnesses

  • FOD gets trapped and collected on the surface

  • Same process used to cover APU intake door when not in use

Page 25: FOD is Serious Business!

  • FOD prevention is a multi-million dollar industry

  • FOD prevention integrated into every quality tool and process

  • FOD is a concern in various industries (aerospace, automotive, electrical, food, construction, etc.)

Page 26: Solutions Areas to Consider in FOD Control Plan

Page 27: Additional Reading Material

  • FOD Prevention Guideline National Aerospace FOD Prevention, Inc

  • Contact: 1-800-FOD-1121

  • Object FOD Object Centennial College

Page 28: End of Week 2

  • AMET226 - FOD

  • Centennial College