Attachment 24 AFI 21-101 FOD.pdf

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available to coordinate and support stranded MRT tasked by the FGC BW to recovery aircraft similar to the MDS possessed by the unit (T-2).

11.7.2.1. (Added-AFRC) MXG/CC or designated authority will ensure sufficient personnel with appropriate maintenance specialties have official government passports to reduce deployment limitations in support of MRT taskings (T-2).

11.8. Foreign Object Damage (FOD) Prevention Program. All personnel (military, civilian, and contractors) working in, on, around, or traveling through areas near aircraft, flightline munitions, AGE, engines, or components thereof will comply with FOD prevention. (T-1). FOD prevention training requirements are outlined in AFI 36-2650. This section establishes minimum requirements for a FOD Prevention Program.

11.8.1. The WG/CV is responsible for ensuring an effective FOD prevention program is established.

11.8.2. Definition. FOD: Any damage to an aircraft, engine, aircraft system, component, tire, munitions, or SE caused by a foreign object(s) (FO) which may or may not degrade the required safety and/or operational characteristics of the aforementioned items.

11.8.3. FOD Prevention.

11.8.3.1. On aircraft, uninstalled engines, LRUs and AGE. Openings, ports, lines, hoses, electrical connections, and ducts will be properly plugged or capped to prevent FO from entering the systems. (T-1). Note: Do NOT place items (such as, trash bags, rags, cloths) inside open cavities or ducts. When no approved manufactured coverings and/or caps are available for use, securely cover open ducts and/or cavities externally to prevent foreign objects from being introduced. Prior to installation, inspect openings, cavities and ducts for

FO.

11.8.3.1.1. Items that are actively being disconnected, installed, and/or removed will be capped IAW technical data or at completion of the task. (T-1).

11.8.3.1.2. At no time will items, (such as, aircraft forms binders, video tape recorder tapes, checklists, tools.), be placed in or on engine intakes. (T-1). Note: Does not apply to technicians performing inlet maintenance, inspections and blade blending requiring lights, files, or other tools inside aircraft inlets.

11.8.3.1.3. Inventory all items IAW Chapter 8 of this instruction. (T-1).

11.8.3.2. MAJCOMs in coordination with Safety, applicable MDS Lead Commands and Weapon System Teams will review FOD, Incident, and Mishap reports to determine if MAJCOM directed IPI or KTL additions are needed to mitigate identified FOD trends.

11.8.3.2.1. Units will establish MDS specific procedures that ensure pre-launch removal and post-recovery installation of intake/inlet plugs and covers (such as, pitot tubes to include ejection seats as required) remain installed on aircraft as close to crew show as possible to prevent FOD, as determined by MXG/CC guidance. (T-3).

11.8.3.2.2. Units will establish MDS specific FOD prevention guidance that standardizes mitigation procedures when performing high FOD risk maintenance task (use of plugs/barrier paper, tape, inlet/intake/ECS maintenance or equivalent tasks).

(T-2).

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11.8.3.2.3. Technicians will ensure engine inlet run-up screens and anti-personnel guards are used IAW applicable weapon system TOs. (T-1).

11.8.3.3. Covers (such as, engine, pitot tube(s) to include ejection seat) need to remain installed on aircraft as close to crew show as possible to prevent FOD, as determined by MDS/local MXG/CC guidance.

11.8.3.4. Technicians should use a light source of sufficient illumination to inspect the aircraft intakes and exhaust for FO/FOD.

11.8.3.5. Whenever physical entry into an aircraft intake or exhaust is required technicians will wear a pocket-less, zipper-less, button-less, bunny-suit marked "Intakes Only" and cloth over-booties or stocking feet, (Boots may be worn if not restricted for use by TO/MAJCOM and are authorized by the MXG or equivalent), boots if worn must be inspected and FOD removed from boots prior to installing cloth over-booties. (T-2).

11.8.3.5. (AFRC) Personnel will ensure all pockets are emptied and accessories removed prior to donning bunny-suits (T-2).

11.8.3.5.1. When performing intake inspections while wearing a Chemical Warfare Defense Equipment, pockets will be emptied and all accessories removed. (T-1).

11.8.3.5.1.1. During exercises/inspections, the Chemical Warfare Defense Equipment will be removed and the bunny-suit will be utilized. (T-1).

11.8.3.5.1.2. Chemical Warfare Defense Equipment will only be worn during “real world” situations. (T-1). To minimize the potential for FOD and intake damage where Chemical Warfare Defense Equipment zippers are exposed, cover them with any type of tape and account for the tape upon completion of the inspection. (T-1).

11.8.3.6. Each base will develop a local flightline clothing policy that addresses wearing of hats, badges, and passes aimed at FOD prevention while considering climate and safety.

(T-1). As a minimum, it will include the following requirements:

11.8.3.6.1. Restricted area badges will be secured with a subdued non-metallic cord or plastic armband when worn on the flightline. (T-1).

11.8.3.6.1. (AFRC) When worn around the neck, cords will have breakaway feature (T-2).

11.8.3.6.2. Restricted area badges will be removed when performing intake/inlet/exhaust inspections if personnel physically enter these areas. (T-1).

11.8.3.6.3. Metal insignias/badges will not be worn on the flightline. (T-1).

11.8.3.6.4. Wigs, hairpieces, metal hair fasteners, earrings, or any other jewelry/loose items that may fall off without notice, are not authorized on the aircraft and industrial work areas. (T-1).

11.8.3.6.5. Escorts of visiting personnel will ensure FOD prevention measures are taken. (T-1).

11.8.3.7. All maintenance production areas must have FO containers readily accessible.

(T-1).

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11.8.3.7.1. All vehicles driven primarily on the flightline for direct aircraft maintenance support activities must be equipped with secured and lidded FO containers. (T-1). Note: Permanently affixed FO containers must be approved by Vehicle Management prior to installation IAW AFI 24-302.

11.8.3.7.1. (AFRC) Flight-line vehicle FOD containers will be marked with the word “FOD” in contrasting letters no smaller than two inches and the FOD containers shall be emptied daily (T-2).

11.8.3.8. Control all work order residue used on or around aircraft, uninstalled engines, and AGE. (T-1).

11.8.3.9. Rags will be controlled and accounted for IAW Chapter 8 of this instruction.

(T-1).

11.8.3.9.1. Rag control applies to all organizations and personnel performing aircraft, missile, munitions, and equipment maintenance.

11.8.3.10. FOD walks are mandatory to remove FO from ramps, runways, maintenance areas and access roads.

11.8.3.10.1. In addition, mechanical/vacuum sweepers, magnetic bars or sweeping by hand are highly encouraged to supplement FOD walks.

11.8.3.10.1. (AFRC) Mechanical/vacuum sweeper use (e.g. FOD Boss) is mandatory for F-16 and F-35 units (T-2).

11.8.3.11. When FOD is discovered on a transient aircraft, depot input/output or CRF engine, the host FOD monitor or aircrew must notify the owning organization within 24 hours. (T-1).

11.8.3.11.1. An informational copy of the FOD report must be provided to the owning organization’s safety office/FOD monitor to ensure compliance with AFI 91-204. (T- 1).

11.8.3.11.2. For depot input/output or CRF engine. If the FOD is found during the receiving inspection at one of the aforementioned locations, it will be tracked/charged (if necessary) to the owning MAJCOM unit. (T-1). If discovered any other time at one of the aforementioned locations, it will be tracked/charged to the ALC or CRF. (T-1).

11.8.3.11.3. (Added-AFRC) MXG directive will included deployed FOD prevention procedures (T-2).

11.8.3.12. Ensure local FOD Prevention Program addresses the elimination of FOs to include aircraft cockpits and flight decks before and after flight. (T-1).

11.8.3.12.1. When an item is lost on or in the vicinity of aircraft or equipment, lost item/tool procedures in Chapter 8 of this instruction will be followed. (T-1).

11.8.3.12.2. The MXG/CC will coordinate with the OG/CC to develop procedures to ensure pilots and aircrew members account for all equipment and personal items after each flight and ensure any items that become lost during flight are documented in the aircraft AFTO Form 781A. (T-1).

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11.8.3.12.3. These procedures will be documented in the wing tool/equipment management publication referenced in Paragraph 8.2 of this instruction. (T-1).

11.8.3.13. Use extreme care during engine ground runs. Jet blast and helicopter hover power check areas need to be free of debris that could cause FOD.

11.8.3.14. Special emphasis is required for items such as: remove before flight streamer attachment, safing pin condition, hinge pin security, dust and FO prevention cover condition/security, and aircraft forms binder condition. Periodically check these types of items for FO prevention compliance.

11.8.3.14.1. Units will account for -21 equipment and covers IAW AFI 21-103. (T-1).

11.8.3.14.2. Weapons Expediters must ensure all mission specific safing gear is controlled and accounted for to preclude loss and potential FOD. (T-1).

11.8.3.15. Vehicle operators will stop and perform a visual FOD inspection on all vehicles, equipment and tires prior to entering the flightline. (T-1). Refer to AFI 13-213, Airfield Driving, and AFMAN 91-203 for additional requirements, restrictions and exemptions.

11.8.3.16. Grounding wires/points:

11.8.3.16.1. Two allen head screws, or equivalent, will be utilized to secure cable to grounding clip. (T-1).

11.8.3.16.1.1. Screw heads will be coated with sealant or screws will be staked in order to prevent screws from backing out. (T-1).

11.8.3.16.1.2. Unused screws will be removed. (T-1).

11.8.3.16.2. All grounding points will be kept clean of debris at all times and shall be a high interest item for FOD walks. (T-1).

11.8.3.17. Use of magnetic bars on the flightline is optional. If used, the magnetic bars will be towed by, or attached to vehicles primarily used on the flightline and will be inspected and made FOD free daily. (T-2).

11.8.3.18. A locally manufactured tool for removing debris from tire treads is authorized for use and will be identified to the vehicle by using the vehicle ID number. (T-2).

11.8.3.19. Remove metal identification bands from all tubing (except aircraft installed egress system components) and cables on the aircraft.

11.8.3.19.1. With the exception of factory-installed ID tags attached to cargo chains/devices to identify the type being used, remove metal identification bands from cargo tie-down chains/devices prior to use around aircraft.

11.8.3.19.2. Do not remove manufacturer installed metal identification bands from hydraulic hoses.

11.8.3.19.3. Mark hydraulic lines IAW TO 42E1-1-1, Aviation Hose and Tube Manual.

11.8.3.20. Use X-ray, borescope, and other equipment to locate FO in inaccessible areas.

11.8.4. FOD Prevention Responsibilities.

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11.8.4.1. The WG/CV will be assigned as the FOD Prevention Program Manager and will appoint a qualified maintenance AFSC, civilian equivalent or contractor if designated by SOW or PWS, to the position of FOD Monitor. (T-1).

11.8.4.1. (AFRC) A copy of the FOD monitor appointment letter will be sent to HQ AFRC/A4MS (afrc.a4ms@us.af.mil) (T-2).

11.8.4.1.1. The appointed individuals name will be posted in a prominent place within the unit on a locally-developed visual aid which also provides contact information. (T- 1).

11.8.4.2. The WG/CV will:

11.8.4.2.1. Ensure all personnel actively support the FOD Prevention Program. (T-1).

11.8.4.2.2. Provide local guidance to ensure each FOD mishap is investigated and action taken to solve any underlying problems. (T-1).

11.8.4.2.3. Review all unit FOD mishap reports and analyze the reports and other data for trends identifying areas requiring management action. (T-1).

11.8.4.2.4. Coordinate FOD prevention needs with the airfield manager and other agencies when construction is in progress on or near the flightline, or other areas where FOD incidents could occur. (T-1).

11.8.4.2.5. Ensure FOD prevention is part of QA inspections. (T-1).

11.8.4.2.6. Coordinate with the airfield manager to identify and properly mark FOD checkpoints. (T-1).

11.8.4.3. Tenant Unit FOD Prevention Responsibilities. The host base FOD Prevention Program Manager will incorporate tenant units in the host unit program. (T-1).

11.8.4.3.1. Tenant units shall establish their own FOD Prevention Program, but will still participate in the host program and comply with host program requirements. (T- 1).

11.8.4.3.1. (AFRC) Tenant unit FOD Prevention Program monitors will be appointed in writing (T-2). A copy of the letter will be sent to HQ AFRC/A4MS (afrc.a4m@us.af.mil) (T-2).

11.8.5. FOD Monitor. The Wing FOD Monitor’s office shall be located within QA or at the discretion of the WG/CV. (T-3). The Wing FOD Monitor, at a minimum, will:

11.8.5.1. Inform all wing agencies of FOD hazards. (T-1).

11.8.5.2. Develop wing procedures to document and perform spot checks of selected areas weekly. (T-1).

11.8.5.3. Be involved in each FOD investigation and help ensure corrective actions are sound. (T-1).

11.8.5.4. Monitor and recommend changes to FOD prevention training. (T-1).

11.8.5.4.1. Those units having several types of aircraft assigned will have their FOD prevention training incorporated into one wing/center training program. (T-1).

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11.8.5.4.2. Units will ensure an initial FOD awareness and responsibilities briefing is given to all newly assigned personnel. (T-1).

11.8.5.5. Periodically inspect and report damaged pavement, flightline construction, or other hazards in or near aircraft parking ramps or taxiways to the airfield manager and monitor status to ensure timely repairs. (T-1).

11.8.6. FOD Investigation and Reporting.

11.8.6.1. When suspected or confirmed FOD is discovered, the MOC will be notified immediately. (T-1).

11.8.6.1.1. Upon notification, the MOC will immediately notify the Wing FOD Monitor, and Wing Safety as required, IAW AFMAN 91-223. (T-1).

11.8.6.2. Units must make every attempt to determine the root cause of FOD-related mishaps before returning engines and modules to the depot for investigation. (T-1).

11.8.6.2.1. If engines/modules are returned to the depot, an information DR will be completed and forwarded IAW procedures outlined in AFI 91-204 and TO 00-35D-54.

(T-1).

11.8.6.2.2. All FOD-mishap engines and modules returned to the depot must be properly marked on the outside of the packaging as a FOD-mishap asset. (T-1).

11.8.6.2.3. Mark container or package in red with the following statement, “FOD mishap investigation required.” (T-1).

11.8.6.3. FOD incidents are classified as preventable and non-preventable. Only preventable FOD over $50K (parts and labor) are to be chargeable to the FOD rate. FOD is considered preventable except when the damaged can be attributed to the following:

11.8.6.3.1. Caused by natural environment or wildlife. This includes hail, ice, animals, insects, sand, and birds. Report this type of damage IAW AFI 91-204. Do not include these in the FOD rates.

11.8.6.3.2. From internal engine materiel failure, as long as damage is confined to the engine.

11.8.6.3.3. Caused by materiel failure of an aircraft component if the component failure is reported as a DR using the combined mishap DR reporting procedures of AFI 91-204 and TO 00-35D-54.

11.8.6.3.4. Found during depot overhaul for maximum operating time.

11.8.6.4. Additionally, the following apply:

11.8.6.4.1. Engine damage caused by improper anti-ice/de-ice procedures by either flight or ground crews are considered preventable.

11.8.6.4.2. Engine or airframe damage caused by gunnery or rocket mission ricochets are considered non-preventable provided mission parameters were not exceeded and range cleaning was sufficient.

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11.8.6.4.3. Engine and propeller damage caused by rocks, stones, wood, or other objects ingested during low hover operations or unimproved runway landings are considered non-preventable, provided mission parameters were not exceeded.

11.8.6.4.4. MAJCOMs will determine reporting criteria for FOD incidents that result in a blade blending requirement IAW applicable tech-data.

11.8.6.4.4. (AFRC) See paragraph 11.8.6.9 for reporting requirements.

11.8.6.5. Preventable FOD over $50K incurred at ETS or on trim pad will be chargeable.

(T-1).

11.8.6.6. Appropriate MAJCOM offices will assist in resolving any questionable FOD issues, preventable or non-preventable.

11.8.6.6. (AFRC) Contact HQ AFRC/A4MS (afrc.a4ms@us.af.mil) for AFRC assistance (T-2).

11.8.6.7. The Wing FOD Monitor will provide an initial report of all FOD incidents to the MAJCOM FOD monitor within 24 hours of occurrence. (T-1).

11.8.6.7.1. A follow-up report will be required every 45 days until closeout. (T-2). Use the FOD report format as listed in Attachment 6 of this instruction.

11.8.6.7.2. MAJCOMs will determine FOD standards, MDS specific flying hour source data, period of time for calculation, reporting procedures, and meeting frequency for units that exceed standards in their supplement to this AFI.

11.8.6.7.2.1. (Added-AFRC) Standard is 3.0 for C-5, C-17, C-130H/J, WC-130J, C-40, and KC-135 (T-2). Standard is 1.0 for A-10, B-52, F-16, HH-60, and HC- 130 (T-2).

11.8.6.7.2.2. (Added-AFRC) MDS specific flying hour source data is defined as the flying hours flown. Period of time for calculation will be the previous month (T-2).

11.8.6.8. FOD rates are computed by MDS as follows: Number of Preventable FODs (damage exceeding $50K) ÷ Aircraft Flying Hours X 10,000 = FOD Rate. Note: ALCs compute FOD rates as follows: Number of Preventable FODs (damage exceeding $50K) ÷ Aircraft Flying Hours X 1,000 = FOD Rate. ALCs compute aircraft flying hours by using acceptance flights, functional check flights, ground runs, and the number of un-installed ETS starts.

11.8.6.9. (Added-AFRC) Reporting requirements. All FOD incidents (except for engine blade minor sand nicks and scratches) will be reported (T-2).

11.8.6.9.1. (Added-AFRC) Engine Management (EM) section must be notified immediately upon engine FOD, and receive a Blade Blending/FOD Damage Work Sheet or applicable form for EM to file (T-2). The EM section will transcribe information provided in the Blade Blending/FOD Damage Work Sheet into the applicable engine/module records (i.e. AFTO Form 95) MIS, and CEMS, IAW TO 00- 20-1 (T-2).

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11.8.6.9.2. (Added-AFRC) The wing FOD Monitor will report all FOD incidents to the wing safety office and AFRC FOD Manager (afrc.a4ms@us.af.mil) immediately upon discovery of FOD (T-2). Send a courtesy copy to the appropriate NAF/A4M. The AFRC FOD Manager will assign the unit a FOD Control Number (FCN).

11.8.6.9.3. (Added-AFRC) The wing FOD Monitor, engine technician, and wing safety office will jointly investigate FOD mishaps which meet the reportable criteria requirements of AFI 91-204, Safety Investigation Reports (T-2).

11.8.6.9.4. (Added-AFRC) The wing FOD Monitor will ensure all AFRC Form 42s are completed and forwarded to the AFRC FOD Manager within 30 days of the incident (T-2).

11.8.7. FOD Prevention Committee Meeting. This meeting is mandatory for units that exceed the MAJCOM-established standard. (T-1).

11.8.7. (AFRC) Meetings will continue until the unit goes three consecutive months without exceeding the standard (T-2).

11.8.7.1. The WG/CV will chair the meeting, if required, and will determine minimum required attendees. (T-1). The purpose of this meeting is to identify negative trends and develop and execute action plans to resolve them.

11.8.7.1.1. The MXG/CC (or equivalent) will chair the meeting in the absence of the

WG/CV. (T-2).

11.8.7.2. Meeting agenda items should include issues that resulted in the wing exceeding the FOD standard, such as:

11.8.7.2.1. Total number of airframe, engine, and tire FOD incidents during the reporting period. Indicate quantity and cause. Current status of all other pending incidents will be discussed.

11.8.7.2.2. Mechanical/vacuum sweeper status.

11.8.7.2.3. Review and refinement of the existing FOD prevention program.

11.8.7.2.4. New directives/actions established to minimize FOD.

11.8.7.2.5. Status and condition of engine run-up screens as applicable.

11.8.7.2.6. Results of X-rays for FOs during engine bay inspections, acceptance inspections, and PH inspections. Maintenance trends should be discussed when an increase in FO is discovered during these X-rays.

11.8.7.2.7. Identification of potential FOD sources.

11.8.7.2.8. Lost tools/items.

11.8.7.2.9. Increased potential for FOD within the next 30-60 days.

11.8.7.2.10. Dropped objects. Pay particular attention to those that result in downstream FOD.

11.8.7.2.11. Breakdown of FOD inspections/assessments.

11.8.7.2.12. Cockpit FO incidents.