Att_2_PPTA_PHSF_SOP_1_Rev_12_FOD_Prevention_and_TCP.pdf

3710/PHSF PAX

5.1.4

13 December 2016

From: Government Flight Test Director

Subj: PRESIDENTIAL HELICOPTER SUPPORT FACILITY PATUXENT RIVER

STANDARD OPERATING PROCEDURE 1 - FOREIGN OBJECT DAMAGE

(FOD) PREVENTION AND TOOL CONTROL PROGRAM (TCP), REVISION

Ref: (a) NAS 412, FOD, 24 th

NATIONAL AEROSPACE FOD PREVENTION

CONFERENCE

(b) NAVAIRINST 3710.1G, CONTRACTOR'S FLIGHT AND GROUND

OPERATIONS

Encl: (1) Missing Tool/Fastener Report

(2) Contractor/Field Maintenance Tool Control Program

(TCP) and Foreign Object Damage (FOD) Brief

(3) QA/Field Team Inventory

(4) Broken/Worn Tool Report

(5) Training and Annual Reviews for Foreign Object Damage

(FOD) Prevention and Tool Control Certification

(6) Shortage Sheet

1. In accordance with References (a) and (b) this Standard

Operating Procedure (SOP) establishes the requirements for the

Presidential Helicopter Support Facility (PHSF) FOD Prevention and TCP and replaces the Revision 11 SOP dated 6 October 2015.

2. This procedure applies to all personnel assigned to, or temporarily working in, controlled access spaces/areas at the

PHSF Patuxent River (PAX).

a. FOD Prevention/Tool Control Procedures. Personnel shall adhere to the guidelines of the above references and this SOP.

(1) Personnel entering or working on an aircraft or in a controlled area shall not carry any potential FOD items in their pockets or attached to their clothing except for access badges attached to lanyards and/or in their pockets. Other items such as pens, Gerber/Leatherman type tools, etc., shall be checked in with the Project Liaison Office (PLO).

(2) Hats or caps shall not be worn on the flight line or taxi ways during aircraft operations.

Subj: PHSF PATUXENT RIVER SOP 1 - FOD AND TCP, REVISION 12

(3) Other jewelry items such as bracelets, earrings or other piercings that may be potential FOD shall not be worn by any personnel on or around aircraft, components, or support/test equipment.

(4) Personnel performing maintenance will be responsible for removing non-aircraft parts and unsecured aircraft parts from the aircraft. In addition, all bolts, nuts, screws, etc.

shall be attached to the part they belong to in a parts bag or

Maintenance Action Form (MAF) bag marked with the Aircraft

Bureau Number (BUNO) and Material Control Number/Job Control

Number (MCN/JCN).

(5) The maintenance department will be responsible for

FOD walk-downs prior to flight operations or anticipated arrival of transient aircraft to the PHSF flight line.

(6) Prior to each engine start inlets, ducting and the immediate area around the aircraft will be thoroughly inspected for objects which could be ingested into the engines.

(7) Air inlet dust covers will be installed when engines are not being operated, except when it is known that:

(a) the engine will be operated again immediately following shutdown;

(b) the aircraft is subject to immediate engine starts and takeoffs;

(c) maintenance is being performed on the engine.

(8) When maintenance is to be performed on or around engines, precautions will be taken to prevent maintenance debris

(nuts, screws, washers, safety wire, etc.) from inadvertently entering engine(s). After completion of necessary maintenance, an inspection will be made to ensure that all accessories and attaching parts are secure and that work areas are cleared of foreign objects prior to engine operation.

(9) Properly marked FOD receptacles will be provided in all work areas in which safety wire, spot ties, etc. may be placed.

(10) Any object lost in or on an aircraft will be treated as a lost tool and will generate a Missing Tool/Fastener Report

[Enclosure (1)], which shall be completed through Section E before releasing the aircraft Safe for Flight. QA will then route the Missing Tool Report to the Tool Control Coordinator for tool replacement. The Tool Control Coordinator will route the Report to QA upon completion of Section F, where it will be retained for one year.

NOTE

A preliminary search of the aircraft and/or suspected areas by the applicable employee/work center (not to exceed .5 hr) should be conducted prior to declaring any tool or item missing.

There will be no disciplinary action for any employee who advises their supervisor immediately of a missing tool or item. Disciplinary action will be taken against any employee who willfully fails to immediately advise their supervisor of a lost tool/fastener or item.

(11) When disconnected, all aircraft and engine lines and hoses will be capped or plugged. A serviceability, cleanliness, and FOD Inspection of both male and female connectors of lines, hoses, and electrical plugs will be performed prior to installation.

(12) All PHSF personnel shall “Clean-As-You-Go.” This applies to all areas of assembly/manufacturing, work centers, hangar bays, the flight line, and taxi ways.

(a) Clean the immediate area when work cannot continue.

(b) Clean the immediate area when work debris has the potential to migrate to an out-of-sight or inaccessible area and cause damage.

(c) Clean the immediate area after work is completed and prior to inspection.

(d) Clean at the end of each shift.

(13) All aircraft shall be inspected for loose/missing fasteners at a minimum during the following actions (When missing fasteners are discovered Enclosure (1) shall be completed before releasing the aircraft Safe for Flight).

(a) Daily and Turnaround Inspections

(b) Pilot's Pre-Flight and Post-Flight Inspections

(c) Scheduled and unscheduled maintenance

(1) Fastener discrepancies which cannot be immediately corrected, and do not exceed 10% of the total number of panel fasteners, shall be documented on a Maintenance Action

Form (MAF) or Optimized Organizational Maintenance Activity

(OOMA) work order. For panels containing less than 10 fasteners, Maintenance Control shall make a safety of flight determination. Using a black grease pencil draw a circle around the fastener hole. This will indicate the missing fastener is a known discrepancy. The black circle will be removed when the fastener is repaired/replaced. Outstanding fastener discrepancies shall be corrected as soon as practical.

(2) Leading edge fasteners and any other fasteners deemed critical to Safety of Flight by Maintenance

Control must be repaired/replaced prior to flight.

b. Maintenance Officer (MO) Responsibilities.

(1) Review and assess the FOD Prevention and Tool Control Program and make necessary revisions as applicable. In addition, require an annual review of the program.

(2) Assure implementation of corrective actions for FOD prevention and tool control throughout the organization.

(3) Require investigations, audits, and spot checks necessary to define preventive measures which should result in elimination of potential FOD hazards.

(4) Ensure FOD inspections are part of the QA inspection process for all aircraft, aircraft equipment, completed phase maintenance, extensive corrosion control, aircraft engine repair, assembly/manufacturing or modification or after down time in excess of thirty days.

(5) Ensure a wall-to-wall inventory is conducted for Individual Material Readiness List (IMRL), Support Equipment

(SE), and all Tools (to include spares) annually, for a change of command, or whenever deemed necessary. Route completed inventory to the QA Officer (QAO).

c. Group Manager Responsibilities.

(1) The Group Manager will provide liaison between Flight Test and Maintenance Control for all outside contractors performing aircraft maintenance at the PHSF. Visiting contractors will be briefed on PHSF FOD, Safety, and Tool

Control procedures using the Contractor/Field Maintenance Tool

Control Program (TCP) and Foreign Object Damage (FOD) Brief

[Enclosure (2)]. Maintenance Control will contact Quality

Assurance (QA) to conduct a tool inventory of contractor tools, parts, and test equipment as required using the QA/Field Team

Inventory [Enclosure (3)]. Tools will be inventoried before and after each shift, after any work stoppage, and before flight.

At the end of each shift tools will be secured and stored in designated spaces as directed by Maintenance Control.

(2) The Site/Group Manager shall designate in writing, via the Monthly Maintenance Plan, a FOD Prevention Program

Manager and a Tool Control Program Manager.

d. Maintenance Control Responsibilities.

(1) Ensure an aircraft discrepancy is generated for all lost tools and missing fasteners in accordance with Enclosure

(l).

(2) Verify all tools have been accounted for prior to releasing an aircraft Safe for Flight.

(3) Immediately notify the MO any time a missing tool/fastener is reported. During the absence of the MO, the

Assistant MO (AMO)/QAO shall be notified.

e. QA Responsibilities.

(1) Ensure thorough FOD checks are performed on components, assemblies, and completed units.

(2) Ensure FOD inspections are part of the QA inspection process of all aircraft, aircraft equipment, and SE which have completed IMC, phase maintenance, extensive corrosion control, aircraft engine repair or modification by FRC or contract field teams, engine or major component change, or after extended down time in excess of 30 days.

(3) Fully investigate all Missing Tool/Fastener Reports [Enclosure (1)].

(4) Establish and maintain a log to assign a report number to each Missing Tool/Fastener [Enclosure (1)] or

Broken/Worn Tool Report [Enclosure (4)]. A sequential numbering system shall be used and consist of year, type of report, and serial number, for example, 07-M001 (M = missing), 07-B002 (B = broken), or 07-W003 (W = worn). The logbook shall contain, at a minimum, the following information: report number, calendar date, initiated by, work center, tool box/item number, nomenclature, investigator assigned, and final disposition.

f. Maintenance Department Responsibilities.

(1) Fully support and enforce all elements of this procedure.

(2) Account for each tool, part, and material/hardware used in repair of aeronautical equipment.

(3) Keep all SE free from foreign/loose objects.

(4) Protect units, components, and parts during handling, installation, and operation.

(5) Perform thorough pre/post-maintenance FOD inspections of immediate work areas and areas in and around aircraft.

(6) QA and the technician shall do a sight Inventory of all tools at each work stoppage and before operational system check. In addition, the NALCOMIS MAF/OOMA work order job status/worker hour’s section collateral duty inspector (CDI) block shall be initialed at every job status change.

(7) Pick up all loose objects in work centers, hangars, and on flight lines and deposit all objects found into FOD containers.

(8) Perform a diligent FOD walk-down of areas as scheduled.

(9) Conduct a thorough FOD walk-down of aircraft run-up areas and a thorough engine intake inspection prior to engine start.

g. Tool Control Coordinator Responsibilities.

(1) Provide indoctrination training to personnel relating to their responsibilities regarding the Tool Control

Program.

(2) Perform a wall-to-wall inventory of all IMRL/SE and Tools (to include spares) annually, for a change of command, or when directed by the MO. Route findings to the MO/QAO upon completion of the inventory.

(3) Maintain toolbox inventory records per the following:

(a) Inventory: Each toolbox or test set shall have a written inventory record of all its contents, including digital pictures. A master copy of all tool box inventories will be kept in the tool room.

(b) The written inventory will be in the approved PHSF format. The inventory will be a comprehensive breakdown of the toolbox by each drawer. The drawers can be identified with either numbers or letters. The inventory will describe each item in each drawer. The inventory will state the total number of items per drawer. In the case of sockets it will indicate the quantity, type (six or twelve point), drive size (standard or deep well) and the size of each individual socket.

(c) Wrench sizes will be identified individually, whether located in a set or not.

(d) Screwdrivers will be identified by their tips (flat tip or cross tip) and by their length. Screwdrivers will be identified individually whether located in a set or not.

(e) For ease of identification, the tools shall be listed using the organizational Code, work center, drawer, and item number. All tool containers of any configuration, such as pouches, bags, boxes, plastic cases, clips, etc., will be annotated on the inventory.

(4) Maintain work center personal protective equipment (PPE) per the following:

(a) Inventory: Each work center shall have a written inventory of PPE. A master copy of all work center inventories will be kept in the tool room.

(b) PPE shall be defined as: the front and back cranial shell, liner, hearing protection, goggles, and whistle.

(c) For ease of identification, PPE shall be marked using the organizational code, work center, and item number.

(5) Ensure tools, including all consumable items, issued out of the Tool Room are checked out/in utilizing Crib-Master computer-based program.

(a) All personnel requiring tools from the Tool Room will be added into the Crib-Master program and issued a barcode decal that will be retained in the tool room. This barcode will be scanned by the tool room clerk in order to check tools. A sight survey of tools shall be conducted by a Tool Room attendant and a technician during checkout and return.

Consumables that need not be returned are: zip ties, bags, butt connectors, sandpaper, and Scotchbrite. These should be disposed of properly.

(b) QA shall perform a tool container inventory with a technician prior to operational checks, ground turns, and flights.

(c) Personnel checking out tools from another activity shall have a QA or GIO representative with them to ensure an accurate inventory is conducted.

(6) Ensure that only authorized personnel are allowed beyond the issue point of the Tool Room.

(7) Ensure that no more than 10 rags per person are checked out at one time (rags may be exchanged on a one for one basis).

(8) Replacement Tool Accountability.

(a) Issue replacement tools on a one-for-one exchange basis and only for properly marked tools.

(b) Establish replacement tool inventory records detailing National Stock Number/Part Number (NSN/PN), nomenclature, and quantity on hand. Maintain inventory accuracy when tools are replenished/issued.

(c) Ensure an accurate inventory of replacement tools is maintained and that all replacement tools are marked with the WMX organizational code.

(d) When tools are no longer required, maintain them in a locked container until they are disposed of properly.

h. Tool Markings.

(1) All tool markings shall be legible.

(2) Tools can be etched, stamped, vibro-peened, laser engraved, painted, or written on using indelible markers. When marking tools, care should be taken to avoid damaging the tools or creating stress points that could weaken the tool and allow it to fail and cause damage to the aircraft or injure personnel.

If a tool can be taken apart, each piece of the tool must be marked. If the tool is too small to mark, it will be encased and stenciled that it is too small to be marked. The inventory sheet will also be annotated. Some tools may be too hard to etch; they can be painted or marked with the identification (ID) number. If tool markings are painted or marked with indelible markers, the markings must be maintained to ensure they are readable. It is the tool room lead’s responsibility to ensure every tool is properly marked. In some cases, tools are encased or have holders for ease of accountability or storage. Tool holders and/or cases must also be marked. Tool sets that have their own containers shall have the number of pieces contained in the set clearly written or etched on the exterior of the container. If a tool is broken, it must be listed as such, dated, and removed from the toolbox, and the tool spot shall be marked with broken tool report number using the toolbox shortage sheet [Enclosure (6)].

i. Shadowing.

(1) Each drawer of the toolbox will be set up to accommodate shadowing of the tools. The normal method for shadowing is to use foam and create cutouts to insert each tool.

The purpose of shadowing is to provide instant accountability.

A properly shadowed toolbox is necessary for a visual inventory when a toolbox is checked onto or off of an aircraft. It is very important to ensure that tools are accounted for, shadowing of the tool box should be carefully planned and executed. If a tool is permanently removed from a drawer, the spot will be marked as empty to preclude re-shadowing the entire drawer.

Cases or holders that are not full will have the unused positions identified as empty. The use of contrasting colors in shadowing is a requirement. Methods/techniques of shadowing are to be consistent throughout the PHSF maintenance department.

(2) Miscellaneous Items. There shall be nothing contained in the toolbox that is not declared on the toolbox inventory or that is not marked. This includes nuts, bolts, washers, expendable tools (except safety wire and tie string), aircraft parts, food, or removable personal effects. Any such items are considered FOD.

j. Missing Tool/Fastener Report.

(1) In the event a tool or a part of a tool is missing and not recovered, no aircraft/equipment shall be released safe for flight until an investigation is conducted to confirm the tool/tool part is not in the aircraft/equipment, and the MO has released the aircraft/equipment using Enclosure (1). During the absence of the MO, the AMO/QAO shall perform this function. QA will then route Enclosure (1) to the Tool Control Coordinator for tool replacement. Upon completion of Section f. of

Enclosure (1) it will be routed back to QA, where it will be retained for 1 year.

(2) QA shall establish and maintain a log to assign a tool report number to each Missing/Broken/Worn Tool Report with a sequential numbering system consisting of year, type of report, and serial number.

(3) All missing fasteners will be treated the same as a missing tool. A Missing Tool/Fastener Report [Enclosure (1)] will be completed and retained by QA for 1 year.

NOTE

A preliminary search of the aircraft and/or suspected areas by the applicable employee/work center (not to exceed .5 hours) should be conducted prior to declaring any tool or item missing.

There will be no disciplinary action for any employee who advises their supervisor immediately of a missing tool or item. Disciplinary action will be taken against any employee who willfully fails to immediately advise their supervisor of a lost tool or item.

k. Broken/Worn Tools.

(1) All broken/worn tools will be reported and a Broken/Worn Tool Report [Enclosure (4)] will be initiated.

(2) QA will retain completed Broken/Worn Tool Reports for one year.

(3) Any broken tool that is missing a piece will be considered a missing.tool and treated as such.

1. Un-calibrated tools.

(1) Tools that are inactive will be properly tagged and must be calibrated prior to any use. The IMRL manager is responsible for ensuring that tools are properly calibrated.

m. Camera Use On Aircraft:

(1) All photographic requirements and/or personnel must be approved by the PHSF Security Officer prior to any event taking place. Personnel who have received the appropriate briefing and authorization for camera usage may check out the camera from the tool room after briefing and receiving approval from Maintenance Control to access the aircraft. Photographs shall be processed in accordance with approved local procedures.

The camera shall be appropriately marked in accordance with the requirements set forth in this procedure.

3. Training.

a. Initial Training.

(1) Complete required sections of Training for Foreign Object Damage Prevention and Tool Control Certification [Enclosure ( 5)] .

b. Annual Recurring Training.

(1) Review the NAS 412 PowerPoint presentation and the PHSF FOD and Tool Control Program and initial Enclosure (5).

A.·~~

~- ROBBINS

This page intentionally left blank.

Enclosure (1)

Missing Tool/Fastener Report

Report Number: Date/Time: ________/_____

Note: A MISSING FASTENER REPORT ONLY REQUIRES SECTIONS A-E.

A. Report Originator

Name/Rank BUNO/EQUIP

Work Center Container Number

Tool Nomenclature Panel/Drawer/Item

Circumstances:

Originator's Signature

B. Maintenance Control

Immediately notify:

____ QA, ____ Contractor Lead, ____ GIO or GQAO, ____ MO

____ Flag ADB: _____ Initiate MAF (provide MCN):

Remarks:

Maintenance Control Signature Date/Time

C. Quality Assurance

Investigator Assigned: Date/Time: /

Investigator report and recommendation:

Investigator Signature Date/Time

2 Enclosure (1)

Missing Tool/Fastener Report

D. GIO or GQAO Recommendation:

GIO or GQAO Signature Date/Time

E. Maintenance Officer

Aircraft released for flight/Equipment released for use? Yes / No (circle one)

Comments:

Released for Flight/Use Signature/Date ___________________________/___________

F. Tool Control Program Coordinator

Copy received by: Date/Time: /

Tool replaced from spare? Yes / No (circle one)

Document Number:

Supply status:

Tool issued:

Tool Control Program Coordinator Date

Enclosure (2)

From:

To: Contractor/Field Maintenance Team

Subj: CONTRACTOR/FIELD MAINTENANCE TOOL CONTROL PROGRAM (TCP)

AND FOREIGN OBJECT DAMAGE (FOD) BRIEF

1. Quality Assurance (QA) shall brief contractor/field maintenance teams on the command

TCP and FOD requirements prior to maintenance actions.

2. A Quality Assurance Representative (QAR) and the contractor/field maintenance team leader shall jointly conduct a tool inventory prior to and upon completion of each maintenance assignment. The team leader shall notify QA of any additional tools introduced after the initial tool inventory. If the volume of tools precludes a practical inventory, the team leader will list each tool used to certify accountability following work accomplishment.

3. The team leader shall immediately notify QA upon discovery of a missing or broken tool.

Tools broken during a maintenance action will be sighted by a QAR and all pieces accounted for.

4. I have been briefed by the activity QAR on the responsibilities of all personnel working in, on, and around aircraft/systems/components/support equipment with respect to proper TCP and

FOD procedures. A copy of the tool inventory is attached.

Team Leader Signature Date:

5. Aircraft/system/component under repair; remarks:

6. a. Prior to maintenance, tool containers were inventoried by:

QAR Signature Date:

b. Upon completion of maintenance, tool containers were inventoried by:

QAR Signature Date:

2 Enclosure (2)

Enclosure (3)

QA/FIELD TEAM INVENTORY

Date: Aircraft Buno: Tool ID Mark:

Name: Task: Phone #:

QTY TOOL/ITEM DESCRIPTION IN OUT IN OUT IN OUT REMARKS INSTL

D

PAGE OF

Enter Date & Sign

(PLO/QA)

2 Enclosure (3)

Enclosure (4)

Broken/Worn Tool Report

Report Number: Date/Time: /

A. Report Originator

Name/Rank BUNO/EQUIP

Work Center Container Number

Tool Nomenclature Panel/Drawer/Item

Circumstances:

Originator's Signature

B. Maintenance Control

Remarks:

Maintenance Control Signature Date/Time

C. Quality Assurance

Investigator Assigned: Date/Time: /

Investigator report and recommendation:

Investigator Signature Date/Time

D. Tool Control Program Coordinator

Broken/worn tool received by: Date/Time: /

Tool replaced from spare? Yes / No (circle one)

Document Number:

Supply status:

Tool issued:

Tool Control Program Coordinator Date

2 Enclosure (4)

Enclosure (5)

Training and Annual Reviews for

Foreign Object Damage (FOD) Prevention and Tool Control Certification

PRINT: LNAME, FNAME, MI

Signature Date

1. Required Reading:

a. NAS 412 PowerPoint Presentation.

2. Required Training and Review:

a. New/Temporary Personnel Indoctrination

b. Maintenance personnel shall review the FOD Procedures and the NAS 412 Power

Point annually. After each review, the individual shall initial and date the appropriate box below indicating the review is complete.

Year NAS412 Tool & FOD

2 Enclosure (5)

Enclosure (6)

CONTAINER SHORTAGES

Tool Container No:

NOMENCLATURE

DRAWER/PANEL/ITEM

TOOL

REPORT NO

DOCUMENT

NO.

TOOL CONTROL

REPRESENTATIVE

INITIALS

DATE

REPLACED

WC

SUPERVISOR

INITIALS

TOOL INDUCTED FOR CALIBRATION

NOMENCLATURE

DRAWER/PANEL/ITEM

DATE INDUCTED FOR

CALIBRATION

TOOL CONTROL

REPRESENTATIVE

INITIALS

DATE

REPLACED

WC

SUPERVISOR

INITIALS

2 Enclosure (6)