Attachment_07b_4790.11H.pdf

DEPARTMENT OF THE NAVY

FLEET READINESS CENTER EAST

PSC BOX 8021

CHERRY POINT NC 28533-0021

FRC EAST INSTRUCTION 4790.11H

CHANGE TRANSMITTAL 1

FRCEASTINST 4790.11H CH-1

Code 6.4-LEG

AUG 0 4 2014

From: Commanding Officer, Fleet Readiness Center East

Subj: FOREIGN OBJECT DAMAGE PREVENTION PROGRAM

Encl: (1) Revised Pages 16 through 19

1. Purpose. This transmittal provides guidance on foreign object damage requirements for the F-35 aircraft.

2. Action. Remove effected pages from the existing instruction and replace with enclosure (1).

Distribution: II

"UNSURPASSED SERVICE TO THE FLEET AND RELENTLESS FOCUS ON QUALITY, ENVIRONMENT

AND OCCUPATIONAL HEALTH AND SAFETY"

DEPARTMENT OF THE NAVY

FLEET READINESS CENTER EAST

PSC BOX8021

CHERRY POINT NC 28533-0021

FRCEASTINST 4790.11H

Code 6.4-LEG

JUL 0 8 2013

FRC EAST INSTRUCTION 4790.11H

From: Commanding Officer, Fleet Readiness Center East

Subj: FOREIGN OBJECT DAMAGE PREVENTION PROGRAM

Ref:

Encl:

(a) COMNAVAIRFORINST 4790.2B

(b) OPNAVINST 3750.6R

(c) NAVAIR 15-01-500

(d) FRCEASTINST 4460.1H

(e) FRCEASTINST 3710.5L

(f) FRCEASTINST 10290.1N

(g) FRCEASTINST 11200.1D

(h) FRCEASTINST 3140.3B

(i) FRCEASTTINST 4855.8C

(1) Inspection Assignments

(2) Foreign Object Damage (FOD) Prevention and

Housekeeping Program Awards

(3) Investigation of Foreign Object Damage (FOD)

Incidents

(4) General Guidelines of Foreign Object Damage (FOD)

Prevention and Housekeeping for All Employees

(5) Foreign Object Damage (FOD) Prevention/Housekeeping

Guidelines for the Flight Check Office (Code 6.0DB)

(6) Foreign Object Damage (FOD) Prevention/Housekeeping

Guidelines for the Industrial Execution Department (Code 6.2)

(7) Foreign Object Damage (FOD) Prevention/Housekeeping Guidelines for the Industrial Operations Management Department(Code 6.3)

(8) Prevention of Foreign Object Damage (FOD) during Flight Test/Line Maintenance/Launch Operations

(9) Foreign Object Damage (FOD) Walk General Requirements

(10) Foreign Object Damage (FOD) Prevention Checklist for the Test Cells (Code 6.2.1)

1. Purpose. To establish program requirements for the prevention of FOD to aircraft systems. Aircraft systems include aircraft, missiles, power plants, electronic systems, components, and support

"UNSURPASSED SERVICE TO THE FLEET AND RELENTLESS FOCUS ON QUALITY, ENVIRONMENT

AND OCCUPATIONAL HEALTH AND SAFETY"

FRCEASTINST 4790.11H

JUL 0 8 2013

equipment. The presence of foreign objects (FOs) in any area of an aircraft, including its systems, components, or related equipment, is of major concern. The breadth of the boundaries of FOD prevention and housekeeping cannot be overstressed. Foreign object debris left in the vicinity of or in aircraft, system lines, hoses, or component parts left open or uncapped during maintenance or production are potential causes of material failures, aircraft accidents, and loss of life. References (a) through (i) apply.

2. Cancellation. FRCEASTINST 4790.11G.

3. Summary of Changes. Clarified wording in several general and specific procedures, updated references, and competency aligned codes throughout the entire instruction.

4. Program Objectives. The objective of the Fleet Readiness Center East (FRC East) FOD Prevention Program is to provide management with information that identifies problem areas in all departments so action can be taken to:

a. Improve the work environment through proper housekeeping.

b. Improve the quality, uniformity, and reliability of all maintenance practices.

c. Eliminate unnecessary labor-hour and dollar expenditures resulting from carelessness.

5. Acronyms/Definitions. The following are acronyms and their definitions:

FO - Foreign Object. A substance or article that is alien to the aircraft that is allowed to invade the product.

FOD - Foreign Object Damage/Debris. Any damage attributed to a foreign object that can be expressed in physical or economic terms

·which may or may not degrade the product's required safety and/or performance characteristics.

FOE - Foreign Object Elimination. A conscious effort to prevent damage caused by foreign objects.

JUL 0 8 2013

eCAM - electronic Continual Analysis and Metrics (eCAM) System.

A procedure to document potential non-conformances and provide corrective actions.

ER/AR - Evaluation/Action Request. A request to investigate, evaluate, and supply an action plan to prevent reoccurrence.

6. Program Requirements. The FOD Prevention Program will comply with references (a) through (d) . The program will include:

a. A FOD Prevention Committee identification and implementation of FOD prevention measures.

b. Effective FOD prevention training, including refresher training.

c. Measures to protect aircraft, aircraft systems, and engines against FOD.

d. Procedures to ensure that open fittings or open ends of tubes, valves, pumps, air ducts, and fluid carrying items are protected with approved closures.

e. Scheduled inspection of production, maintenance, and material support areas of FRC East to ensure that they are kept clean and free of FOs. Enclosure (1) lists the frequency and responsibility assignments for inspection of these areas.

f. Procedures to protect equipment from exposure to physical, chemical, or environmental damage.

g. Initiation of aircraft/engine FOD incident investigation reports when FRC East custody aircraft/engine exhibit FOD and the repair costs meet the criteria of reference (a).

h. Annual evaluation of the FOD Prevention Program.

i. Awards/recognition program.

j. Cleanup of all production, maintenance, and material support areas twice daily and as necessary to maintain cleanliness.

7. Responsibilities

a. FOD Prevention Committee. A FOD Prevention Committee will be appointed per reference (a), which reads in part, "the FOD prevention committee shall have sufficient authority and organizational freedom to identify and implement FOD prevention measures whenever and wherever required."

(1) Committee Membership

(a) FOD Prevention Program Manager, hereinafter referred to as FOD Manager, Quality Management Division (Code

6. 4 .1).

(b) Aviation Safety Officer or representative (Code 6. OD).

(c) Flight Check Officer representative (Code 6.0DB)

(d) Workload Scope Determination Division (Code 6.2.4)

(e) Production Trades Division representative (Code 6.2.1)

(f) Workload Control and Assignment Division representative (Code 6.3.2)

(g) Industrial Plant Services Division representative (Code 6.3.3)

(h) Metals Processing Branch representative (Code 6.2.1.7)

(i) Production Activity Control Division representative (Code 6.3.2)

(j) Quality Programs Division representative (Code 6.4.2)

(k) Industrial Environmental Division representative (Code 6.3.5)

(2) Committee Responsibilities

(a) Review reports of discrepancies of FOD prevention/housekeeping practices and ensure corrective action is taken to preclude a recurrence.

(b) Develop initiatives in an effort to reduce numbers of discrepancies written.

(c) Discuss during committee meetings the instances where repetitive discrepancies were allowed to accumulate within a shop.

(d) Request the appropriate organization to provide bins, cabinets, containers, covers, chutes, bags, and other associated items necessary to control hardware, reduce clutter, and enhance FOD control.

(e) Review and assess the FOD Prevention Program and initiate necessary revisions.

(f) Inspect shops and areas at random after scheduled cleanups in their respective areas.

(g) Ensure the FOD Monitor Program is active within their areas of responsibility. Refer to enclosure (2).

(h) Assist in investigating FOD incidents as required~

(i) Assist with the FOD Awards Program.

(j) Attend all FOD Committee meetings or provide an alternate attendee.

(k) Attend in-house FOD Prevention training and the National FOD Prevention Conference, as appropriate.

Note: Attendance at the National FOD Prevention Conference will be based on availability of funding and selection by the FRC East FOD Committee membership.

b. All Departments

(1) Provide investigative assistance for FOD related incidents as required.

(2) Protect equipment from exposure to physical, chemical, or environmental damage.

(3) Provide adequate storage space to minimize the necessity of storing parts, wagons, stands, dollies, etc., on hangar decks or within the immediate work areas.

(4) Ensure that required protective devices for material and components are properly installed upon completion of maintenance and prior to movement or storage.

(5) Ensure discrepancies identified during FOD housekeeping surveillances are corrected promptly.

(6) Cease all work operations upon notification of a FOD incident and conduct an investigation in compliance with enclosure ( 3) .

(7) Ensure full support of FOD prevention/housekeeping guidelines established in enclosures (4) through (8).

(8) Practice "Clean As You Go" methodology.

(9) Support the FOE effort.

(10) Report foreign object/housekeeping discrepancies via eCAM (ER/AR) located on the FRC East Web site's main page. For eCam use/guidance, refer to the user manual located in the Local Information section of the FRC East Web site.

(11) At no time is the flight line to be used for through traffic of any kind. Only vehicles engaged in the act of towing, delivering equipment, fuel, and/or personnel to and from aircraft on the flight line are allowed past the concrete barriers. Prior to any vehicle that has treaded tires traveling on the flight line, the driver will stop and check for any rocks, rivets, bolts, or foreign objects in the tire tread, attached to, or sitting on the vehicle prior to entering the flight line.

(12) See enclosure 4, paragraph 5 for indoctrination and follow-on training requirements.

c. Materials Engineering Division (AIR-4.3.4)

JUL 0 B 2013

(1) Provide investigative assistance for FOD-related incidents when requested.

(2) Provide support of reference (d).

d. Aviation Safety Officer (Code 6.0D). Advise the FOD Prevention Committee on all FOD matters relating to aviation safety and flight line operations, as per enclosure (5).

e. Flight Check Officer (Code 6.0DB). Ensure all areas of responsibility are free of FOD hazards and stress the importance of a hardware control effort. Refer to enclosure (6) for guidance.

f. Industrial Execution Department (Code 6.2)

(1) Workload Scope Determination Division (Code 6.2.2). In response to work orders issued by the Strategic Planning Division (Code 6.1.2), conduct a borescope engine FOD inspection of all AV-8 and C-130 aircraft and a visual engine FOD inspection of all other type aircraft inducted into FRC East.

(a) Ensure all protective covers properly fit and are in a good state of repair.

(b) Contact the Planning and Estimation Branch (Code 6.2.2.2) when engine FOD is discovered during aircraft induction inspections. Provide detailed information such as type/model/series, aircraft bureau number, engine type and serial number, engine position, and time/date when FOD was discovered.

(c) Provide Code 6.4.1 a copy of correspondence sent to Code 6.2.2.2 listing any engine FOD noted during aircraft induction inspections.

(2) Planning and Estimation Branch (Code 6.2.2.2)

(a) Coordinate efforts to ensure FOD intake inspections are conducted as outlined in enclosure (5), and that aircraft are provided all protective covers and properly secured per reference

(e) .

(b) Initiate a work order to the Industrial Execution Department (Code 6.2) requiring a FOD inspection of engines of all aircraft be conducted in support of each exercise flight scheduled

FRCEASTINST 4790.11H"

after the aircraft has been "P" sold. In addition, ensure a work document is developed requiring that a FOD inspection be conducted after any and all work has been performed subsequent to the Quality Assurance (QA) "P" Sale FOD Inspection. Work performed subsequent to the subject QA FOD inspection will automatically invalidate the QA "P" Sale FOD Free Validation.

(c) Initiate a work order to the Workload Scope Determination Division (Code 6 .'2. 4) requiring an engine FOD inspection be conducted of all inducted and non-scheduled aircraft.

(d) Initiate a work order to Code 6.4.2 to conduct an engine FOD inspection prior to first flight and immediately after "P" sale on all aircraft reworked in this facility.

(e) Coordinate efforts to ensure engine FOD found during aircraft induction inspections is promptly reported to Code

6. 2.2. 2.

(f) Establish contact with aircraft cognizant activity (squadron, type commander, wing, etc.) communicating FOD issues found during aircraft induction inspection allowing them the opportunity to assess action to be taken.

(g) Initiate a FRC East 4730/10, "FOD Test Cell Incident Report", per reference (b), on engine FOD incidents found during aircraft induction inspections.

(h) Contact the Quality Management Division (Code 6.4.1) on engine FOD incidents and provide copies of the completed FRC East 4730/10.

(3) Support initiatives to reduce housekeeping discrepancies. Refer to enclosures (4) through (10).

(4) Discuss FOD related subjects at stand-up meetings monthly.

(5) Coordinate FOD training.

(6) Ensure division training coordinators schedule all FOD training.

(7) Ensure that all areas of responsibility are free of FOD hazards. Conduct FO ,inspections of all closed areas, entrapment compartments, and migratory routes prior to final sealing. Refer to enclosure (8) for guidance.

(8) Inspect all additional aircraft areas for foreign objects when an eCAM ER/AR is issued by the cognizant Quality Assurance Specialist (QAS) . Provide a written response describing the corrective action taken. Refer to enclosures (5) and (6).

(9) Perform a final FO visual inspection of each aircraft immediately prior to transfer of the aircraft to the Acceptance and Transfer area (Code 6.2.2.2).

(10) Support the FOE efforts. Document accordingly.

(11) In addition, provide an engine FOD inspection in response to a work order generated by Code 6.2.2.2 after each exercise flight conducted after "P" sale.

(a) Engine Air Particle Separators (EAPS) will be removed from all CH-53 and MH-53 aircraft prior to the aircraft undergoing in-hangar rework.

(b) All CH-53 aircraft that have completed rework, and for whatever the reason are required to be brought back into the hangar, will have the EAPS and engines protected.

g. Industrial Operations Management Department (Code 6.3)

(1) Production Activity Control Division (Code 6.3.2)

(a) Inspect items for contamination, damage, and proper identification upon initial receipt.

(b) Ensure full compliance with material handling, storage, and transportation requirements listed in references (c) and (d).

(c) Ensure that support equipment, transportation, and handling equipment are kept clean and free of debris.

(d) Keep all areas of responsibility free of FOD hazards. Refer to enclosures (4), (5), (7), and (8) for guidance.

(e) Ensure production control work spaces and break areas are cleaned at least twice each day.

(f) Ensure wagons are ·not stored in aircraft repair areas.

(g) Provide an overview of production efforts to handle and store parts.

(h) Ensure production supervision is made aware of incidents of malpractice.

(i) Ensure necessary equipment (tool totes/hardware containers, etc.) is available to support the FOD Prevention Program.

(2) Facility Maintenance and Tooling Shop (Code 6.3.3.3)

(a) Conduct two daily clean ups of work, break, and storage areas; one following lunch and one just prior to shift change. Utility rooms should be cleaned as necessary to maintain cleaniness. Refer to enclosures (4) and (7) for guidance.

(b) Respond promptly to work requests and follow-up actions in support of the FOD Prevention Program.

(c) Inspect all carts and vehicles transporting aeronautical material and/or components for cleanliness daily.

(d) Remove all debris, trash, and loose hardware from vehicles (carts, electric trucks, three-wheel bicycles, etc., before traveling through the FRC East).

(e) Brief crews performing construction work on the hazards of FOD. Clean construction areas daily and dispose of all debris properly.

(f) Clean all outside areas (with the exception of those areas used as production storage areas) regularly (for example, roads, fence lines, around buildings, and so on). Refer to enclosures (4) and (6) for guidance.

(g) Ensure test cell equipment and accessories are adequately maintained.

(h) Ensure full support of reference (d) .

(i) Monitor FO/debris cleanup efforts; including those performed by assigned special program employees and contract industrial c~eaning employees, i.e., halls, walls, aisles, office spaces, stairways, outside areas to ensure cleanup schedules compliment the overall appearance of the FRC East.

(j) In an effort to ensure the station sweeper contract is fully supported and scheduling is effective, the Industrial Plant Services Division (Code 6.3.3) will establish and maintain a sweeper log and ensure the sweeper operator initials the log upon their arrival and departure to the FRC East.

(k) Ensure all vehicles assigned to Code 6.2 (i.e., wagons, carts, trucks, forklifts, and tractors) are cleaned daily.

(1) Remove empty soda cans, dirty paper towels, etc.

from vehicles, as they are prohibited.

(m) Contract transportation personnel will conduct a FOD walk daily of the immediate area surrounding the transportation office and the parking areas of all assigned vehicles.

(n) Dispose of trash and food products in the dumpster.

(o) Ensure wagons are not stored in aircraft repair areas.

(p) Place unused pallets in the disposal yard.

(q) Ensure magnets are installed on all tractors and they are cleaned daily.

(3) Industrial Environmental Division (Code 6.3.5)

(a) Establish a scheduled pickup of all FOD container$ located in exterior work areas, i.e., flight line, fence line, hangars.

(b) Ensure all areas utilized for the storage of hazardous material and/or collection and containment equipment are controlled and free of debris.

(c) Replace, as necessary, dumpsters that are raised in the air and dumped into the service trucks with the type that are dumped off premises. All dumpsters located in proximity to aircraft operational areas will be the dumped off premises type.

(d) Periodically inspect dumpsters staged within the FRC East confines. Ensure dumpsters are in a state of good repair.

Dumpsters found discrepant such as having rusted through areas, missing doors, or lids should be replaced.

h. Policy and Quality Department (Code 6.4)

(1) FOD Manager (Code 6.4.1)

(a) Manage the FOD Prevention Program; chair the FOD Prevention Committee.

(b) Establish and manage an awards program to recognize contributions and outstanding achievements in support of FOD prevention. Enclosure (2) provides criteria.

(c) Develop and provide, in accordance with reference (a), the required training (to include refresher training) for all phases of the FOD Prevention Program.

(d) Participate in all zonal inspections, per reference (h), to ensure FOD prevention standards are being accomplished.

Provide assistance to Code 6.4.2 as necessary.

(e) Forward problem discrepancies to Code 6.4 for review and resolution.

(f) Lead and perform follow-up FOD related investigations. Notify the Aviation Safety Officer when flight line or flight related FOD incidents occur. See enclosure (3).

(g) Create an eCAM (ER/AR) on all reportable FOD incidents. Scan and add internal FOD report of the incident (FRC East 4730/10 and/or FRC East 4730/11) and any other pertinent information into eCAM. Utilize the eCAM System to provide program status reports. Ensure FOD committee membership, branch heads, division directors, department heads, the Commanding Officer (CO), and Executive Officer are aware of FOD reports available through eCAM. See enclosure (3).

(h) Furnish the CO information on FOD incidents incurred.

(i) Monitor all FOD-related data to ensure compliance with the program requirements. Identify adverse trends and, if necessary, initiate corrective action.

(j) Maintain documentation on all FOD incidents per enclosure ( 3) .

(k) Develop methods to prevent FOD during assembly, test, packaging, handling, storage, transportation, maintenance, flight line, and launch operations. Refer to enclosures (4) through ( 8 ) .

(1) Monitor Code 6.4 ADR investigations to ensure appropriate replies to customer developed FOD related ADRs.

(m) Monitor support equipment (SE), transportation equipment, and conveyors for FOD prevention compliance.

(n) Serve as the FRC East point of contact during all FOD Prevention Program inspections.

(o) Report FOD prevention and/or housekeeping discrepancies via eCAM System for appropriate action. Management is directed by reference (a) to ensure corrective action is taken in an effort to improve housekeeping and FOD Prevention.

(p) Attend training and meetings of a quality/FOD prevention nature to ensure currency in the field of FOD prevention.

(q) Continually stress the importance of a hardware control effort.

(r) The FOD Manager will ensure he/she wears all personal safety items in the work place while conducting inspections, e.g~, safety shoes, ear plugs, safety glasses.

(2) Quality Program Division Code (6.4.2)

(a) Investigate all occurrences of in-house FOD.

Document test cell incidents on the FRC East 4730/10, flight

JUL 0 8 2013

operations incidents on the FRC East 4730/11, "FOD Flight Operations Incident Report", and any other procedural discrepancies by initiating an eCAM ER/AR. Ensure the FOD Prevention Manager is made aware of all FOD incidents in a timely manner.

(b) Establish quality call points on work documents in areas of aircraft, power plants, and components that are prone to

FOD.

(c) Ensure that all quality characteristic lists, reference (i), contain appropriate measures to eliminate FOD hazards.

(d) Ensure aircraft compartments and hidden areas are verified to be free of FO before closure. Conduct FO inspections of designated critical areas and compartments prior to final sealing. If subsequent access is required, the affected area must be reinspected.

(e) Support FOE efforts.

(f) Prior to releasing an aircraft for first flight and after "P" sale (immediately after paint) perform a FO airframes inspection as follows:

Note: The term "debris" refers to three or more items found in aircraft such as rivets, washers, screws, and similar items that if found by the user activity would be the basis for developing an Aircraft Investigation Discrepancy Report (AIDR) . In the interest of promoting aircraft flight safety and providing our customers with a high quality; lean FO free aircraft, the QA FO-free verification inspection will not be scheduled or conducted while work is being performed on the aircraft or item to be inspected.

Work performed after the QA FO free inspection has been conducted will invalidate the verification.

1. CH-53 Aircraft. A mandatory verification inspection will be conducted of all FOD prone areas in support of panel closure. In addition, prior to first flight and after "P" sale, the cognizant QAS (Code 6.4.2) will randomly select and inspect four structural or paneled areas for FO. A Discrepancy Work Order (DWO) will be initiated to the cognizant CH-53 production branch head if debris is found in any of the four areas inspected. The CH-53 production line will be required to reclean and de-panel the aircraft in preparation for a 100 percent FO inspection. The cognizant QAS will then reinspect the aircraft.

If debris is found during the second QAS inspection, the QAS will terminate the inspection and develop a critical AR for action by the Code 6.2.1 Division Director.

Note: A pre-developed list of CH-53 FO prone areas will be referred to in identifying the scope and extent of the 100 percent reinspection.

2. CH-46 Aircraft. A mandatory verification inspection will be conducted of all FOD prone areas in support of panel closure. In addition, prior to first flight and after "P" sale, the cognizant QAS (Code 6.4.2) will select a minimum of four specific areas and perform a FO inspection. If FOs are found in any of the four areas designated for inspection, the inspection will terminate. A DWO will be developed and furnished to the cognizant aircraft production branch head who will ensure the aircraft is de-paneled and recleaned in preparation for a 100 percent QAS inspection. If debris is found during the second inspection the inspection will terminate and a critical AR will be furnished to Code 6.2.1 for action. After "P" sale (just prior to the painted aircraft going to Code 6.2.2.2, conduct a 100 percent de-fodding inspection of the entire aircraft except for the bilge area.

Note: It is imperative that as part of the floor board installation process duct tape be installed on the heater hole and other entry cracks and crevices along the bulkhead. Failure to do so may adversely affect the integrity of the "verification stamp."

The tape on the floorboards should be removed to support painting requirements or as part of the 100 percent final de-fodding inspection.

3. AV-8 Aircraft

~· A mandatory verification inspection will be conducted of all FOD prone areas in support of panel closure. In addition, prior to first flight and after "P" sale, the cognizant QAS (Code 6.4.2) will select doors 60R, 60L, 61, and two randomly selected doors/panels/areas for inspection. If debris is detected in at least one of the randomly selected doors, the QAS will select two additional doors, panels, or areas. If debris is found in any

FRCEASTINST 4790.11H CH-1

AUG 0 4 2014

one of the two additional selected areas, it will require a DWO be furnished to the AV-8 production branch head requiring depaneling of the aircraft.

b. Debris found during the 100 percent panel inspection will result in a critical AR furnished to Code 6.2.1.

c. After first flight, the QAS will inspect the pre-selected panels listed on work order.

4. AH/UH Aircraft. A mandatory verification FOD inspection will be conducted of all areas determined to be flight critical prior to panel closure. In addition, upon the completion of all maintenance and prior to first flight, the cognizant QAS (Code 6.4.2) will inspect all readily accessible (Quick Release) panels and cabin area for FOD. If FOs are found in any panel/area, the inspection will be terminated (at the discretion of the cognizant QAS) . A DWO will be initiated to the cognizant aircraft production branch head requiring a complete recleaning effort prior to reinspection. If debris is found during the reinspection, a critical eCAM ER/AR will be furnished to Code 6.2.1 for action.

Note: Air Force Depot Level Maintenance (DLM) UH-1N Aircraft.

In addition to the above requirements, all Air Force DLM aircraft will receive a FOD inspection of all readily accessible (Quick Release) panels and cabin area prior to delivery to_ Code

6. 2. 2. 2.

5. V-22 Aircraft. A mandatory verification inspection will be conducted of all FOD prone areas in support of panel closure. A DWO will be initiated to the cognizant V-22 production branch head if debris is found in any of the areas inspected. The V-22 production line will be required to reclean and depanel the aircraft in preparation for a 100 percent FO inspection. The cognizant QAS will then reinspect the aircraft.

If debris is found during the second QAS inspection, the QAS will terminate the inspection, develop a critical AR for Code 6.2.1 action.

6. F-35 Aircraft

a. Each aircraft shall be segregated in an individual critical FOD area. A Single Point of Entry (SPOE) concept shall be utilized for each aircraft. All personnel shall enter and exit at a single access point. No personal items (jewelry, phones, pens, wallets, change etc.) shall be permitted beyond the access point into the critical FOD area.

Personal items shall be stored in a locker or plastic bag outside the critical FOD area. The person entering the critical FOD area utilizing Lockheed Martin (LM) forms shall log in all tools, hazmat, and consumable materials. Upon completion of maintenance, all items shall be logged out of the critical FOD area. Any tools or consumables remaining overnight shall be annotated on the appropriate accountability and control LM form.

b. Due to the excessive cure time of sealants, fillers, and coatings associated with the F-35 Low Observation System, installed panels shall not be removed for random FOD inspections. Panels opened during drive-in modification shall receive a FOD inspection prior to close which will require Code 6.4.2 and LM Sustainment Quality Engineer both inspect and clear the compartment prior to panel installation.

~· An inspection of FOD prone areas shall be performed prior to first flight (landing gear compartments, tires, and weapons bays) and will be verified by QA.

d. Debris found in the weapons bays or in the landing gear compartments will result in an Internal Defect Reporting System entry and the appropriate (DWO, AR, etc.)

follow on action as necessary.

(g) Engine Inspections

1. In response to work orders issued by Code 6.2.2.2, conduct an engine FOD inspection prior to the first flight and "P" sale. Conduct an engine FOD inspection after the last scheduled production engine operation/flight is accomplished on all aircraft except C-130s and H-1s. Baroscope inspection is required on all AV8-B aircraft.

2. Ascertain production FOD inspections are being conducted, as applicable, prior to and after each engine operation and flight.

3. Ensure all protective covers properly fit and are in a good state of repair. In addition, prior to and after each engine operation, inspect bell mouth assemblies and FOD screens of all engines (as applicable) for security, damages, proper fit, and structural integrity. Ensure those items in need of repair are immediately removed from service and are not used until properly repaired.

4. Contact the FOD Manager at 464-5033, should FOD prevention problems be encountered.

(h) In response to work orders issued by Code 6.2.2.2, conduct a borescope engine FOD inspection of all DLM T400/T700 engines and AV-8 aircraft prior to the first flight and "P" sale.

Conduct a borescope engine FOD inspection after the last production engine operation/flight is accomplished.

(i) Ensure all protective covers properly fit and are in a good state of repair. In addition, prior to and after each engine operation, inspect bell mouth assemblies and FOD screens of all engines (as applicable) for security, damages, proper fit, and structural integrity. Ensure those items in need of repair are immediately removed from service and are not used until properly repaired.

(j) Contact the FOD Manager at 464-5033, should FOD prevention problems be encountered.

i. Security Department (Code 7.4).

requirements are fully enforced:

Ensure the following I

(1) Vehicles must not exceed 5 mph while traveling in the FRC East compound.

(2) Security vehicles will operate on the flight line per guidelines provided by the Aviation Safety Officer.

J. Defense Logistics Agency Aviation at Cherry Point

(1) Maintain storerooms and hardware bins clean and free of foreign material. Conduct two cleanups on a daily basis.

Supervisors will inspect storerooms and bins daily after each scheduled cleanup.

(2) Ensure the manner in which hardware and kits are supplied and controlled compliments the FRC East FOD prevention effort.

(3) Fully support the applicable requirements listed in references (c) and (d) .

8. Instruction Responsibility. The FOD Manager (Code 6.4.1) will review this instruction annually.

9. Forms Required. The FRC East 4730/10, "FOD Test Cell Incident Report," and the FRC East 4730/11, "FOD Flight Operations Incident Report," are available on Naval Forms Online. See enclosure (3) for document retention of required forms listed above.

/S/

BLAYNE H. SPRATLIN

Distribution: ·II

JUL 08 2013

INSPECTION ASSIGNMENTS

Inspections of produc tion, maintenance, and material support shops and areas will be conducted to ensure compliance with foreign object damage (FOD) prevention requirements.

Responsibility and inspection frequencies are as follows:

1. Division Directors. Inspect cognizant areas monthly to ensure high standards of housekeeping and FOD control are maintained.

2. Branch Heads. Inspect areas of responsibility weekly to ensure shops are compliant with FOD prevention/ housekeeping requirements.

3. Shop Supervisors.

scheduled cleaning.

Inspect shops and areas daily after each

4. FOD Monitors. Inspect assigned areas daily after end of shift cleaning and initial or stamp the applicable FRC Eas t 3162 / 1, "Aircraft / Work Area Surveillance" or FRC East 3162/2 , "Shop/Work Area Surveillance" cards indicating area has been inspected and meets FOD prevention/ housekeeping requirement s.

5. FOD Manager (Code 6.4.1). Inspect Fleet Readiness Cent er East (FRC East) as necessary to identify the potential for FOD and foreign object ingestion. Schedule and inspect all area s within the FRC East confines to provide management with information that identifies · problem areas.

6. Forms Required. The FRC East 3162 / 1, "Aircraft / Work Area Surveillance" and FRC East 3162 /2 , "Shop / Work Area Surveillance" are available on Naval Forms Online. These cards are forwarded weekly to the FOD Manager (Code 6.4.1) via guard mail. There is no requirement to secure the cards in a locked cabinet. Ten percent of the surv eillance cards are drawn monthly by the FOD Manager to disperse awards and the r emaining cards are recycled.

Enclosure (1)

JUL 0 8 20 13

FOREIGN OBJECT DAMAGE (FOD) PREVENTION AND

HOUSEKEEPING PROGRAM AWARDS

1. General. The general characteristics of the FOD awards guidelines are simplified for ease of management. Actual coordination of awards for the "winning" individuals will be the responsibility of the appropriate FOD Committee Member. The awards are, therefore, management tools to assist the Fleet Readiness Center East (FRC East) FOD Committee division representative in promoting the FOD program.

2. Work Area Surveillance. All shops in the FRC East and each aircraft in work will display either the FRC East 3162 / 1, "Aircraft / Work Area Surveillance" card or the FRC East 3162 / 2, "Shop / Work Area Surveillance" card and known herein as the Work Area Surveillance Card. The Work Area Surveillance Card should be representative of a cleaning area responsibility with a minimum of 800 square feet of floor space, as appropriate. Work area surveillance and awards program are outlined as follows:

a. Shop Supervisor

(1) Shop supervisors will assign individual(s) to perform the functions of the shop FOD Monitor. Supervisors must ensure the selected individual is knowledgeable of this instruction , enclosure (2), enclosures . (4) through (9), and reads the reminders / requirements on the back of each work area surveillance card.

(2) Ensure a new and appropriate Work Area Surveillance Card is provided for each work area before the beginning of each succeeding week.

b. Aircraft and Shop Level FOD Monitors

(1) Be knowledgeable of housekeeping and FOD Prevention Program requirements within the FRC East.

(2) Assist a s part of the aircraft / shop cleanup effort and provide a v isual overview of the aircraft and/ or shop to determine if there is a need for a re-cleaning effort. The aircraft overview will require the u s e of a flashlight for internal inspections.

Enclosure (2)

.'IJL 0 8 2013

(3) Inform the supervisor of all discrepancies found and when satisfied that the shop or aircraft has been cleaned.

Initial the appropriate block of the aircraft/shop surveillance card.

c. Division FOD Committee Representatives

(1) Collect all completed Work Area Surveillance Cards weekly and screen to ensure all information required has been provided, i.e., name, shop, or type aircraft .

(2) Deliver completed Work Area Surveillance Cards to the FOD Manager (Code 6 . 4.1) for processing.

(3) When Work Area Surveillance Cards selected during the monthly drawing are returned, each division will write and issue informal awards for "Support of Foreign Object Elimination efforts" to winning FOD monitors within their respective division.

3. FOD Manager (Code 6.4.1). Review completed Work Area Surveillance Cards monthly and compare the master listing of FOD discrepancies written that particular month.

a. Destroy all Work Area Surveillance Cards representing areas and time frames when FOD dis_crepanci_es were written.

b. Place discrepancy free Work Area Surveillance Cards in a box for monthly drawing.

Note: Ten percent of discrepancy free Work Area Surveillance Cards written each month will be drawn during the monthly drawing.

c. Work Area Surveillance Cards drawn during the monthly drawing will be returned to the FOD committee member representing that division for processing.

Note: Individual Awards. Awards will be available on a case-by case basis for individuals who consistently contribute to the success of the FOD Prevention Program within their respective work areas.

4. Required Forms. The FRC East 3162 / 1, "Aircraft / Work Area Surveillance" card and the FRC East 3162/2, "Shop / Work Area Surveillance" card are available on Naval Forms Online.

These cards are forwarded weekly to the FOD Manager (Code 6.4.1) via guard mail. There is no requirement to secure the cards in a locked cabinet. Ten percent of the surveillance cards are drawn monthly by the FOD Manager (Code 6.4.1) to disperse awards and the remaining cards are recycled.

JUL 0 8 2Q 13

INVESTIGATION OF FOREIGN OBJECT DAMAGE (FOD) INCIDENTS

1. General Requirements. When a reportable FOD incident occurs, all operations on the engine, aircraft, or component will cease and a team consisting of the personnel listed in paragraph 2 wil l participate in an investigation of the incident. The investigation will begin promptly after the FOD incident. In all cases, the Commanding Officer will be informed of the inc i dent and of the findings of the investigation team by the Director of Operations (Code 6.0DB) and / or the FOD Manager (Code 6.4.1) .

Note. A reportable FOD incident is defined as one which requires aircraft engine / module removal; occurs on an engine test cell; or in the case of an engine that requires fan blade or turbine replacement without engine removal. Non-reportable FOD is defined as repair without engine, fan blade, or module removal.

Internal engine component failure and the damage result i ng from such failure shall not be interpreted or reported as FOD.

2. FOD Investigation Team and Responsibilities . The Team membership shall consist of the following:

a . Artisan, test cell operator, or pilot that identif ied the

FOD.

b. Shop supervisor that has cognizance of the fodded en gine, aircraft, or component.

c. Cognizant Quality Assurance Specialist (QAS)

d. Cognizant Fleet Support Team Engineer

e. Cognizant Quality Assurance Branch Head

f. FOD Manager (Team Leader)

g. Production Shop Supervisor

(1) Notify the Quality Programs Division Director (Code 6.4.2), cognizant QAS, and the FOD Manager immediately when a FOD incident occurs.

(2) Cease all operations and maintenance on the damaged item and await further instructions from the Fleet Support Team member of the FOD investigation team.

Enclosure (3)

(3) Coordinate any movement, necessary maintenance, or operational requirements of the item in a manner conducive to good investigative practices.

(4) Have the test cell, component, or aircraft operator provide a description of the sequence of events leading up to the FOD incident by completing Section 1 of the FRC East 4730/10, "FOD Test Cell Incident Report" or the FRC East 4730 / 11, "FOD Flight Operations Incident Report" as applicable.

h. Quality Programs Division (Code 6.4.2)

(1} When a FOD incident occurs ensure that all operations and maintenance on the damaged item ceases. Immediately contact the FOD Manager (Code 6.4.1) and start a preliminary investigation.

(2) Provide written preliminary findings of the FOD incident to the FOD Manager (Code 6.4.1) within two working days of the incident.

(3) The QAS will identify and provide a description of circumstances and the extent of damage that could be used to determine the cause of the incident. Complete Section 2 of the FRC East 4730 / 10 or the FRC East 4730 / 11 as applicable.

(a) Use the FRC East 4730 / 10 to describe incidents and report investigation findings that occurred during te&t ce-ll operations ·.

(b) Use the FRC East 4730 / 11 to describe incidents and report investigation findings that occurred during flight line operations or during a flight.

(4) Create an electronic Continual Analysis and Metric (eCAM) Evaluation Request / Action Request (ER/AR) as directed by the investigation team lead and/ or the FOD Manager (Code 6.4 . 1).

i. Materials Engineering Division (AIR-4.3.4)

(1) Assign, upon request, an engineer to the investigation team to provide investigative, scheduling, and technical support in identifying the cause and extent of the damage.

FRCEASTINST 4790 . 11H

(2) Require photographs, microscopic studies, and chemical analyses, as necessary to determine the type item that caused the damage.

(3) Coordinate investigative scheduling with the FOD investigation team leader to ensure the investigation is completed within the five-day window allowed.

Note: The cognizant Quality Assurance Specialist Branch Head will serve as team lead only when the FOD Manager (Code 6.4.1) is unavailable to lead investigation.

j. Investigation Team Lead and/ or FOD Manager (Code 6 . 4 . 1) .

The FOD Manager (code 6.4.1) shall serve as the· team lead of the FOD Investigation Team. He/she shall:

(1) Schedule and coordinate the efforts of all team members to ensure a thorough investigation of the FOD incident.

Utilize Section 5 of the applicable report form (FRC East 4730 /1 0 or FRC East 4730 / 11) to coordinate and ensure participation of all team members. Team members will complete the part of the form that applies to their respective areas, and will attach copies of supporting documents.

(2) Collect and review all pertinent information from the investigation team members.

(3) Submit an Engine FOD Incident Report within five working days of discovery of each reportable FOD incident via Naval message. Utilize the FOD Incident Report format in Chapter 10, Figure 10-11-1 of reference (a).

(a) Submit the preliminary Engine FOD Incident Report in Naval message format to the Policy and Quality Department Head (Code 6.4) for concurrence.

(b) Upon concurrence from the Policy and Quality Department Head (Code 6.4) make dissemination of the FOD Incident Report.

(c) A follow-up message will be released if unknowns in the initial FOD Incident Report are quantified such as cost data and action to prevent recurrence.

(4) Create an eCAM ER / AR on all reportable FOD incidents.

Input investigation data of findings, objective evidence, ~onclusions, and recommendations in appropriate ER/AR fields as required. Facilitate corrective and preventative actions, following the established requirements in reference (i), with cognizant area of concern.

(5) Scan pertinent information into the AR such as FOD incident message traffic, MRP II work orders, e-mail correspondences, FOD Test Cell or Flight Operations Incident reports, Quality Characteristics Lists, borescope inspections / photos, Material Engineering Laboratory Analysis Report, photos, and any other document that supports investigation findings.

(a) An e-mail will be created detailing the eCAM AR serial number upon completion of the preliminary internal FOD Incident investigation requesting review and comments. Subject line of email shall state "FOD Incident Case of" then include engine type, engine serial number, and operation being performed when FOD occurred such as ground check, test flight (include type/model/series and bureau number), or test cell operations.

(b) The e-mail shall be sent to the Commanding Officer (Code 6.0D), Executive Officer (Code 6.0DB), Director of Operations (Code 6.0DB), Aviation Safety Officer (Code 6.0D), Industrial Execution Department Head (Code 6.2), cognizant Industrial Execution Department Division Directors (Code 6.2), Policy and Quality Department Head (Code 6.4), and Quality Programs Divi-sion Directo-r- (Code 6.4.2)··.

(6) Perform physical follow up on all corrective and preventative actions related to FOD incident (i . e., AR) in accordance with reference (i). Perform follow up to ensure root cause analysis precluding repeat non-conformances. Time line of follow up investigation will be dependent on the risk assessment code and degree of corrective action involved, Chapter 11 of this instruction applies . Timeline of follow up investigation will be dependent on the Quality Characteristic Indicator and degree of corrective action involved in accordance with reference (i) and will generally be completed in three months or upon notification that all corrective actions (ARs) have been completed.

3. Reporting. The Director of Operations (Code 6.0DB) will report the incident to higher authority, as required.

4. Document Retention

a. As per Chapter 10 of reference (a), FOD shall be retained for two years, then recycled.

shall be filed in a secured file cabinet within Management Division (Code 6.4.1).

Incident Reports These reports the Quality

b. Pertinent supporting documents will be scanned into the eCAM system. Retention of these reports shall meet FRCEASTI NST 5215.1U for audit investigations. Corrective and preventative actions resulting from a FOD Incident Investigation will be controlled and maintained by the eCAM system.

c . In the event that eCAM is down, utilize the FRC East 4855/5 7 , "Evaluation Request / Action Request", per reference (i).

5. Required Forms. The FRC East 4730 / 10, "FOD Test Cell Incident Report", FRC East 4730/11, "FOD Flight Operations Incident Report", and FRC East 4855/57, "Evaluation Request/Action Request" are available on Naval Forms Online.

GENERAL GUIDELINES OF FOREIGN OBJECT DAMAGE (FOD) PREVENTION

AND HOUSEKEEPING FOR ALL EMPLOYEES

1. General Housekeeping a . Empty trash cans when full and at the end of each shift.

Do not leave trash or debris for the oncoming shift.

b. Keep desks, tables, and work areas free of debris, pools of oil, etc.

c. Do not use unauthorized areas for storage of covers, brackets, loose hardware, excessive parts, etc.

d. Keep storage areas, cabinets well organized and free of debris.

e . Keep office areas clean, neat, and orderly.

f. Protect inaccess i ble areas during work in process to prevent the introduction of foreign objects.

g. Clean work areas after lunch, just prior to shift change, and as necessary to maintain cleanliness. Remove debris (absorbent towels, coffee cups, food wrappers, etc.) from the floor. immediately. Shop supervisors will check work areas after each cleanup or assign a FOD monitor as applicable.

h. Personal items (except radios) i.e., food, drinks , spittoons are prohibited from the hangar floors and flight l i ne area; however, a covered drink will be allowed on hangar floors.

Ensure that all personal items (including radios) i.e . , food, drinks, spittoons are restricted from inside or on any aircraft.

l. Clean hangar door rails as necessary.

j. Keep floors / decks clean. Sweep and mop as required .

k. Store brooms and mops in racks.

l . Remove foreign matter from components and aircraft following shot peening, grit blasting, or plating operations.

The Production Trades Division (Code 6.2.1) will be

Enclosure (4) required to clean plastic media from aircraft located on the hangar floor and flight line when notified of this discrepancy.

m. Police outside areas daily, i.e., around aircraft. Shop personnel working in the area are responsible for this cleaning.

n. Clean aisle storage areas daily.

o. Clean drip pans as part of the shop cleanup. Remove oil and debris.

p. Maintain the FRC East 3162 / 1, "Aircraft / Work Area Surveillance" cards and the FRC East 3162/2, "Work Area Surveillance" cards in a current status.

q. Inspect work areas for foreign objects upon completion of each task. Remove . all chips, shavings, lockwire, tie wraps, rivet bucktails, loose hardware, paper towels, etc., and dispose of them in an approved manner. Do not use high or regulated air pressure to remove debris.

r. Apply absorbent material (such as "oil dry") to pools of oil. Remove and dispose of the absorbent or "oil dry" as soon as possible after application. Cloth rags are prohibited from inside aircraft or on any hangar floor or in any flight/test environment.

s. Remove all debris from vehicles, i.e., electric trucks, three-wheel bicycles, etc., before traveling within the Fleet Readiness Center East (FRC East) . Shop supervisors will inspect vehicles as required to ensure drivers are complying with this requirement.

t. Do not use any aircraft as a break area. Identified designated areas on the hangar floor(s) will be used as a break area.

u. Ensure protective caps are cleaned after use. If they are in serviceable condition, sort by size / type and store in a covered container.

v. Conduct FOD walks on all flight areas, engine test facilities, and adjacent aprons at the beginning of each shift.

FRCEASTINST 4790.11H . ,. J UL 0 8 4V ,J _, { . "

Conduct FOD walks i n remaining areas such as roadways, aprons, and production areas as necessary to support foreign object elimination efforts .

w. Identify and properly dispose of potential foreign objects.

x. Establish requirement for the thorough cleaning and inspection of all components, assemblies, and completed product.

y. Protect the end product and its components during handling, installation, and operation.

2. Storage and Handling a.

times.

b.

debris.

Keep parts carts and conveyors free of debris at all Store parts carts in an orderly manner.

Keep containers used for storage clean and free of Use only approved types of containers.

c. Ensure material and parts remain properly tagged/identified during handling and storage. Handle carefully and store neatly.

d. Place personal lockers in the locker spaces provided .

Stencil lockers with the assigned employees name and shop number.

The general rule of one locker per employee applies due to space limitations.

e. Segregate Material Review Board items in the shop. Keep the area neat and clean.

f. Do not use work stands to store hardware, parts, tools, etc. Keep work stands free of debris.

g. Return fi x tures and tooling to…