FRCSWLCP_4790_Ch_10.11_Foreign_Object_Damage_Prevention_Program.pdf

DEPARTMENT OF THE NAVY

FLEET READINESS CENTER SOUTHWEST

P.O. BOX 357058

SAN DIEGO, CALIFORNIA 92135-7058

IN REPLY REFER TO:

FRCSWLCP 4790 (CHP-10.11) CH-1

6.2

AUG 2 4 2015

FRCSW LOCAL COMMAND PROCEDURE (CHP-10 . 11) CHANGE TRANSMITTAL 1

From: Commanding Officer

Subj: LOCAL COMMAND PROCEDURES FOR NAVAL AVIATION MAINTENANCE

PROGRAM STANDARD OPERATING PROCEDURES FOREIGN OBJECT

DAMAGE PREVENTION PROGRAM

Encl: (1) Revised Page 6

(2) Continuation of Revised Page 6

1. Purpose. To trans mi t new page 6, this updates the Foreign Object Damage (FOD) walkdown requirements.

2. Action. Remove the page 6 of t he basic instruction and replace with enclosures (1) and (2) of this change transmittal.

/. 1/. f/~~

T . H. PFANNENSTEIN

Di stribution : Electronic only, via My NAVAIR Web site https : //mynavair . navair . navy . mil/ f rcsw https://mynavair.navair.navy.mil/portal/server.pt/community/mynavair/206

DEPARTMENT OF THE NAVY

FLEET READINESS CENTER SOUTHWEST

P.O. BOX 357058

SAN DIEGO, CALIFORNIA 92135-7058

IN REPLY REFER TO:

FRCSWLCP 4790 (CHP-10.11)

6.2

DEC 0 8 2014

FOREIGN OBJECT DAMAGE (FOD) PREVENTION PROGRAM

From: Commanding Officer

Subj: LOCAL COMMAND PROCEDURES FOR NAVAL AVIATION MAINTENANCE

PROGRAM STANDARD OPERATING PROCEDURES FOREIGN OBJECT

DAMAGE PREVENTION PROGRAM

Ref: (a) COMNAVAIRFORINST 4790.2B

1. Purpose. This Local Command Procedure (LCP) shall be attached to the applicable Naval Aviation Maintenance Program Standard Operating Procedures (NAMPSOP) to clarify geographic area, type, model, series (T/M/S) specific, and command specific details not addressed in the NAMPSOP. This LCP is an integral supplement to the NAMPSOP chapter 10.11 and provides additional local requirements for the Fleet Readiness Center Southwest (FRCSW) Foreign Object Damage (FOD) Prevention Program.

2. Cancellation. FRCSWLCP 4790 (CH 10.11). Due to extensive revisions, changes are not noted.

3. Local Command Procedures for the FOD Prevention Program

a. Clarification of responsibilities

(1) FOD Prevention Committee. The committee shall be co-chaired by the FOD Prevention Program Manager and FRCSW's Aviation Safety Officer. There shall be a primary and alternate member assigned to ensure the respective organization is represented at all meetings. Representatives' terms shall be staggered to prevent all members' terms from expiring at the same time. The committee shall be comprised of a minimum of one representative from the following organizations:

(a) Safety and Occupational Health Division.

(b) Quality Assurance (QA) Program Monitor.

(c) All 900 Department Product Lines.

FRCSWLCP 4790 (CH 10.11)

DEC 0 8 2014

(2) FRCSW FOD Prevention and Investigation Team shall be comprised of the following personnel

(a) FOD Prevention Program Manager.

(b) QA Officer.

(c) Safety Officer.

(d) FOD Prevention Program Monitor.

(e) Additional members with expertise (as required).

(3) FRCSW Integrated Product Team Managers are responsible for the duties outlined for Division Officers in the COMNAVAIRFORINST 4790.2B paragraph 10.11.3.10, in addition to the duties covered in this LCP.

b. Clarification of duties in addition to those outlined in the COMNAVAIRFORINST 4790.2B Chapter 10.11

(1) FOD Prevention Committee Chairperson shall

{a) Convene FOD Prevention Committee meetings at a minimum of once every two months, or as necessary.

(b) Provide for committee personnel FOD Prevention Training.

(c) Schedule quarterly inspections of industrial and flight check areas with committee members, Integrated Product Team Manager/Deputy Integrated Product Team Managers.

Inspections shall be informal, and results of the inspection shall be documented.

(d) Maintain copies of the monthly tracking of the weekly FOD walks and prepare presentations showing the trends of the FOD as needed.

(2) The Safety and Occupational Health Division shall

{a) Coordinate with the FOD Prevention Committee on potential FOD problems that may result in injuries.

DEC 0 8 Z014

(b) Assign one representative and an alternate to the FOD Prevention Committee. Forward their names and codes to the FOD Committee Chairperson.

(3) The Industrial Quality Department shall

(a) Continually monitor and audit all phases of the FOD Prevention Program to ensure compliance with applicable directives, standards, and other related requirements.

(b) Establish appropriate certification and verification points during the processing cycle of any weapons system for FOD or potential FOD materials.

(c) Ensure that such verification points and any other FOD related requirements appear on the appropriate processing documents, are certified, and verified as applicable.

(d) Ensure that each of the identified critical compartments and areas is verified to be free of FOD prior to closure, and ensure that closure occurs immediately while that compartment and area is still observed before final closure.

(e) Ensure production and manufacturing areas are spot checked for evidence of program support such as cleanliness, FOD containers, and posters.

(f) Assign one representative and an alternate to the FOD Prevention Committee. Forward names and codes to the FOD Prevention Committee Chairperson.

(g) Provide FOD Incident Reports to the following personnel

1. Director of Quality.

2. Respective Product Line Program Manager.

3. Quality Program Division Representative.

4. FOD Prevention Committee Chairperson.

5. Aviation Safety Officer (ASO).

(4) Integrated Product Team Managers shall

(a) Ensure critical rag control procedures are complied with as outlined in this LCP.

(b) Ensure all in-work aircraft, engines, components, and Support Equipment (SE) are free of FOD.

(c) Maintain a "clean as you go" policy while performing work. NOTE: While it is normal during the course of maintenance to produce metal fragments, rivet components, wire clippings, solder balls, plastic media, and other debris, the intent of "clean as you go" can be summarized by the following:

1. Make every practical effort to capture debris as it becomes waste.

2. For jobs generating multiple pieces of debris (e.g., grinding, riveting, soldering, etc.), a periodic clean-up should be conducted during the maintenance action.

3. At no time should an artisan leave the site of a maintenance action unattended with debris on the surface of the aircraft or on the shop floor.

(d) Any area in which FOD is not retrievable requires a form NAVAIR 5600/2, REI/TEl Request for Engineering Information/Temporary Engineering Instruction, for logbook entry into the Miscellaneous History Section.

(e) Ensure positive control of tools during processing of aircraft, engines, components, and SE.

Supervisors shall be notified, and action taken, per the Command Tool Control Program if lost tools cannot be found.

(f) Ensure all stored aircraft, engines, components, and SE tubing, hoses, and lines are capped and plugged with authorized closures.

(g) Ensure all transported aircraft, engines, components, and SE are correctly preserved and protected from FOD and damage.

(h) Ensure all engine turn operators on the flight line and test cells conduct a FOD inspection prior to, and subsequent to, performing all engine turn-up operations. All incoming aircraft shall be inspected for engine FOD immediately upon arrival.

(i) Maintain and administer required annual FOD training.

(j) Assign one representative and an alternate to the FOD Prevention Committee to represent each product line.

Forward the names and codes to the FOD Prevention Committee Chairperson.

(5) First Level Supervisors shall

(a) Ensure critical rag control procedures are complied with as outlined in this LCP.

(b) Enforce a "clean as you go" policy.

(c) Ensure that any hardware or waste dropped on the deck during maintenance tasks is retrieved promptly in· accordance with the "clean as you go" policy of paragraph 3.b.4.c. If hardware is reusable, return it to its storage container. If the hardware is not reusable, it shall be disposed of in the nearest FOD container.

(d) Ensure all in-work aircraft, engines, components, and SE are free of FOD.

(e) Ensure positive control of tools during the processing of aircraft, engines, components, and SE.

Supervisors shall be notified and action taken per the Command Tool Control Program if lost tools cannot be found.

(f) Ensure all stored aircraft, engines, components, SE tubing, hoses, and lines are capped and plugged with authorized closures.

(g) Ensure all transported aircraft, engines, components, and SE are correctly preserved and protected from FOD and damage.

FRCSWLCP 4790 (CHP-10.11) CH-1

AUG 2 4 2·015

(h) Ens ure all engin e turn operator s on t he flight line a nd test cells cond uct a FOD inspection prior to , and subsequent to, perfor ming all e ngine turn-up operations. All incoming a i rcraft shall be inspected for engine FOD i mmediately upo n arriva l .

(i) Ensure that each validation and verification prototype or first time incorporation of a Techni cal Directive (TD) has reporting procedures for un-retrievable FOD.

(j) Ensure compliance for their respective work areas to e liminate potential FOD. Product line policing areas i nclude , b ut are not limited to:

1 . Assembly a nd disassembly areas

2 . Assembly and disassembly benches , rol l aways and work s tands

3 . Test cells

4 . Turn- up pads

5 . Flight line

6 . Aircraft and engine storage a reas , ready service lockers, and o ther work areas

(k) Ens ure a MANDATORY a ll-hands FOD wa lk is conducted as per below r equirements. Results of FOD wal kdowns shall be recorded and submitted by closed of bus iness every Wednesda y for t he wee k to the Quality Assurance Department for analysis . FOD will be posted on FOD Boards. All-hands FOD wa lk down is required as follows :

1 . Externally, at a minimum once a week (or more if required) around the building perimeters in assigned areas.

2. Internally at the start o f each s hi ft dai l y.

If there is no second shift the first s hift will conduct a second walk pri or to the e nd of shift .

FRCSWLCP 4790 (CH 10.11) CH- 1

AUG 2 4 '2015

NOTE: FOD walk-downs in all aircraft and engine turn-up areas shall be performed daily and subsequently throughout the day as required, and the collected FOD posted on assigned FOD boards.

(l) Support and sustain the objectives of the command ' s FOD Prevention Program.

(m) Ensur e al l personnel are- trained in FOD prevention annually. Tr aining shall be documented in the Individual Qualification Record (IQR) .

(n) Ensure that a positive re-examination occurs on all components and sections re-opened or disturbed for any reason after initial certification and verification action .

6a

Void all previous certification and verification stamp imprints of applicable work documents.

(o) Ensure personnel remove loose objects from their person prior to working on aircraft engines.

(p) Ensure personnel remove loose and inappropriate.

clothing (e.g., ball caps, etc.), prior to entering the vicinity of operating jet engines to prevent ingestion.

(q) Ensure personnel perform thorough FOD inspections of ducts, plenum chambers, engine cavities, and other related areas prior to all pre and post-test 6ell runs, maintenance turns, and flights.

(r) Ensure that examination points on work documents for actual or potential FOD are certified and verified as required.

(s) Prohibit the use of compressed air to remove potential FOD materials.

(t) Ensure the use of engine air intake duct covers, exhaust covers, and heat exchangers during all extended periods of engine shutdown.

(u) Ensure the use of appropriate turn up screens and guards for T/M/S during ground check engine turn ups.

(v) Remove all loose objects from the vicinity of engines or aircraft during turning operations.

(w) Ensure only those tools and hardware being used for a specific task is allowed on the stand while the task is in process.

(x) Pick up any loose objects in the work place and deposit it in the appropriate disposal container. Perform periodic FOD walk downs within these areas. NOTE: FOD walk downs in all aircraft and engine turn-up areas shall be performed daily and subsequently throughout the day as required, and FOD posted.

DEC 0 8 Z014

(y) In the Paint Bay Wash Rack area FOD Walkdowns shall be conducted, at a minimum, prior to pre and post-wash of aircraft and aircraft components, and at the beginning and end of each shift if there is equipment in the wash rack area.

(z) Keep aisles, passageways, hangar door tracks, facility grates, and pad eyes free of FOD.

c. FOD Board Requirements. All Product tines shall maintain at least one FOD Board easily visible to all personnel, and preferably placed in a nhigh-traffic" area to promote FOD awareness. At a minimum, the board shall post the local FOD instruction, the results of the recent mandatory FOD walk downs, and when the next walk down is scheduled, unless it is conducted daily.

(1) Due to the fact that some product lines occupy multiple buildings and multiple spaces within one building, it may be necessary for those product lines to maintain more than one FOD board. Product Line Managers should consult the FOD Prevention Program Manager for guidance regarding the number of FOD Boards their product lines should have.

(2) For product lines that lack adequate space in a nhigh-traffic" area for a FOD board, they should consider utilizing a nroaming" FOD board that can be relocated to various spaces within their building. Product Lines Managers should consult their FOD committee representative for guidance on building a nroaming" FOD board.

d. Personnel FOD prevention awareness and procedures

(1) Each product line, within their spaces where maintenance is conducted, should clearly distinguish between nmaintenance spaces" and ntransit spaces" (i.e., walkways) by the most appropriate means necessary.

(2) Prior to entering a nmaintenance space" and before leaving the space, ALL personnel shall account for all potential FOD on his or her person to include: Loose change in pockets, jewelry, glasses, pens or pencils, notebooks, and consumables for the maintenance being completed, etc.

FRCSWLCP 4190 (CH 10.11)

(3) Personnel not completing maintenance and just transiting from point A to point B shall utilize "transit spaces" and shall NOT transit through "maintenance spaces".

e. FOD Can requirements for all work areas

(1) Ensure that RED FOD containers with lids are readily available and uniquely identifiable with black lettering.

(a) A sufficient number of FOD cans shall be present within work areas to prevent unnecessary transit time for artisans to dispose of FOD. Readily accessible FOD cans shall promote the "clean as you go" policy.

(bY Garbage (i.e., garbage generated from anything other than maintenance, to include packing material) shall not be disposed of in FOD containers. NOTE: Eating in work areas is strictly prohibited, and therefore, trash from food containers should not be found in work areas or in FOD containers within work areas.

(2) All product lines that conduct maintenance on aircraf.t components and aircraft that produce waste (e.g., nuts, bolts, washers, liquid or any other material that may be considered FOD) ~~hall utilize easily portable point of use FOD containers.

(a) Each product line shall provide artisans that are conducting maintenance, which produces waste, a point of use FOD container that is secure but accessible at their work location to prevent waste items from being placed on the aircraft or deck.

(b) All FOD cans shall be emptied daily and as required at the completion of maintenance, and at the completion of each work shift.

f. Critical Process Rag Control Procedures. Historically, the use of uncontrolled rags has allowed entry of foreign objects into critical systems. Procedures that identify the control of rags in critical areas are outlined below.

(1) Controlled color coded rags will be checked out from the respective Hazardous Material (HAZMAT) Center or from the authorized program issue center controlled source.

(2) Rags will be issued for each critical task to the artisan only. Critical tasks and artisans will be identified by program. This information must be provided to the applicable HAZMAT Center or authorized product line issue center controlled source. NOTE: Critical tasks are identified by product line as those that impact flight or personal safety, and that can cause possible damage to aircraft, engines, components or Support Equipment (SE) . The controlled rag process is outlined below but is not limited to:

(a) Aircraft fuel systems.

(b) Aircraft bleed air systems.

(c) Aircraft flight controls.

(d) Aircraft hydraulic and pneumatic systems.

(e) Critical compartments as defined by the aircraft and component program.

(3) Critical task artisans will record the following information in a logbook or by electronic entry at the HAZMAT Center or authorized program issue center controlled source:

(a) Quantity of rags.

(b) Aircraft sequence number and critical task.

(c) Applicable component critical task.

(d) Certification stamp and date (legible signature and pay number authorized only if not in possession of a certification stamp) .

(4) Upon completion of the task, artisans will turn in used rags to the HAZMAT Center or to the authorized program issue center controlled source, and comply with the following:

(a) Both issuing personnel and artisans will be responsible for the initial issue of rags, and will account for the number of rags signed out.

(b) Upon return, both artisans and issuing personnel will sign the logbook or make an electronic entry to acknowledge that the correct number of rags has been turned in.

(c) Rags will be properly disposed of in accordance with established HAZMAT procedures.

(d) Any lost critical process rag will be treated and documented as a lost tool in accordance with the Tool Control Program.

g. Responsibilities. ·All personnel shall strictly comply with these requirements, which shall'be used to develop specific requirements for each product line and system.

4. Forms. REI/TEI Request for Engineering Information/ Temporary Engineering Instruction, form NAVAIR 5600/2, is available online via the Naval Forms Online website at https://navalforms.documentservices.dla.mil/web/public/forms o2. l.f. fJ.{ ~

T. H. PFANNENSTEIN

Distribution:

Electronic only, via https://mynavair.navair.navy.mil/frcsw