FWI 21-015 FOD PREVENT PROGRAM.pdf

BY ORDER OF THE COMMANDER 125TH FIGHTER WING INSTRUCTION 21-015

125TH FIGHTER WING

16 JANUARY 2020

Maintenance

FOREIGN OBJECT DAMAGE (FOD) PREVENTION PROGRAM

COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

ACCESSIBILITY: Publications and forms are available on the 125 Fighter Wing Communications Flight SharePoint page:

https://org2.eis.af.mil/sites/11797/125MSG/125CF/SitePages/Home.aspx

RELEASABILITY: There are no releasability restrictions on this publication.

OPR: 125 MXG/MXQ Certified by: 125 MXG/CC (Colonel Jackson M. Whiting) Supersedes 125 FWI 21-15, 27 July 2011 Pages: 15

This Wing Instruction establishes the 125th Fighter Wing (125 FW) Foreign Object Damage (FOD) Prevention Program and applies to all military, civilian, and contractor personnel while on the 125 FW installation and Detachment-1 Homestead. All personnel working in, on, around, or traveling through areas near aircraft, munitions, Aerospace Ground Equipment (AGE), engines, or components thereof will comply with FOD prevention initiates and this Wing Instruction. Ensure that all records created as a result of processes prescribed in this publication are maintained in accordance with AFMAN 33-363, Management of Records, and disposed of in accordance with the Air Force Records Disposition Schedule (RDS) located at https://www.my.af.mil/gcss-af61a/afrims/afrims. Refer recommended changes and questions about this publication to the Office of Primary Responsibility (OPR) using the AF Form 847, Recommendation for Change of Publication; route AF Form 847s from the field through the appropriate chain of command.

1. FOD Prevention Responsibilities.

1.1. The 125th Fighter Wing Vice Commander (125 FW/CV) is assigned as the FOD Prevention Program Manager.

1.2. The Base FOD Prevention Program Manager:

1.2.1. Ensures the FOD Prevention Monitor is designated, in writing, from the assigned functional area of the 125 FW.

1.2.2. Provides base support and local guidance for the 125 FW FOD Prevention Programs by ensuring unit commanders and maintenance supervision actively support the FOD Prevention Programs.

https://org2.eis.af.mil/sites/11797/125MSG/125CF/SitePages/Home.aspx https://www.my.af.mil/gcss-af61a/afrims/afrims https://www.my.af.mil/gcss-af61a/afrims/afrims

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1.2.3. Ensures each FOD mishap is investigated and ensures that FOD prevention is part of Quality Assurance (QA) inspections.

1.2.4. Reviews submitted unit FOD mishap reports to analyze for trends or underlying problems that may require management action.

1.2.5. Coordinates FOD prevention needs with the airfield manager, civil engineers, and other agencies when construction is in progress on or near the flight line, or other areas where FOD incidents could occur.

1.2.6. Consults with and informs the FOD Prevention Monitor regarding all FOD related issues or concerns.

1.2.7. Coordinates and facilitate the Quarterly Base Safety/FOD Prevention Committee Meeting. The 125th Safety Office (125 FW/SE), will act as the recorder for the Quarterly FOD Meeting and ensure meeting minutes are distributed.

1.3. The 125th Maintenance Quality Assurance (125 MXG/MXQ) is assigned the FOD Prevention Program Monitor duties for the 125 FW and Detachment-1 Homestead. The FOD Prevention Monitor will:

1.3.1. Assist unit in maintaining an effective Wing Instruction for FOD Prevention.

1.3.2. Keep all unit and appropriate agencies informed of FOD hazards, ramp construction, and damage to pavement that creates FOD potential and monitor status with regard to timely repairs.

1.3.3. Monitor and recommend changes to FOD prevention training.

1.3.4. Ensure weekly spot checks are performed and documented throughout the aircraft operations areas and associated work areas with flight line contact, but more frequently if trends in FOD incidents or hazards increase.

1.3.5. Investigate each incident and ensure that the initial report, findings, and recommendations are forwarded to the 125 FW FOD Prevention Manager. Report FOD mishaps according to AFI 91-204, Safety Investigations and Reports.

1.4. Group Commanders will ensure their personnel are aware of, involved in, and adhere to this instruction and requirements of the FOD Prevention Program.

1.4.1. All Unit FOD Representatives are encouraged to attend the quarterly FOD Prevention Committee Meeting. They must also notify the Wing FOD Prevention Manager of any concerns or issues that need to be coordinated at a Wing level. Unique individual responsibilities are listed in following sections.

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1.5. Maintenance Group Representative will:

1.5.1. Ensure FOD awareness training is provided and documented for maintenance personnel. Monitor and recommend changes (as required) for FOD prevention training to the Wing FOD Prevention Monitor.

1.5.2. Ensure that when a FOD or lost object condition is suspected or confirmed, the Maintenance Operations Center (MOC) will be immediately notified who will in turn notify QA. All FOD/lost object mishap aircraft (whether suspected or confirmed) will be considered for impoundment and fully investigated.

1.5.3. Assist when FOD is discovered on any transient aircraft, loaner aircraft, or “Queen Bee” engine, the FOD monitor will notify the owning organization immediately. An informational copy of the FOD report will be provided to the owning organization’s safety office to ensure compliance with AFI 91-204. Proper forms documentation will be accomplished in accordance with T.O. 00-20-1, Aerospace Equipment Maintenance Documentation and Procedures.

1.5.4. Report all T.O.00-35D-54, USAF Material Deficiency Reporting and Investigating System, criteria when FOD is discovered during acceptance inspections from either engine or aircraft assets received from the depot or PDM.

1.6. Operations Group Representative will:

1.6.1. Coordinate with the Jacksonville Aviation Authority (JAA) to inspect active runways, taxiways, parking, and servicing areas for potential FOD hazards. Areas identified as hazardous will be reported to proper agencies for clean up or repair.

1.6.2. In accordance with (IAW) 125FWI 13-1, Airfield Operations, the Florida Air National Guard (FANG) Airfield Management and JAA Operations conduct the airfield/runway inspection prior to the first mission departure together. The FANG personnel are responsible for checking taxiways Mike 1, 2, and 3, taxi-lane Mike 4, Kilo ramp, Alert Ramp and active runway prior to first mission departure. The second airfield check is conducted prior to the second mission departure, which consists of Mike 2 and the Kilo Ramp. The 125th Airfield Manager (125 OSF/OSA) personnel will report to JAA Operations at 904-741-2020 if any deficiencies are found on the airfield.

1.6.3. Ensure flight line driver training includes FOD awareness.

1.6.4. Coordinate with JAA when the Airfield Manager or Deputy Airfield Manager is not available.

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1.7. Civil Engineer (CE) Representative will:

1.7.1. Ensure aircraft parking ramps, taxiways, weapons storage areas and on-base convoy routes are swept with the mechanical vacuum sweeper on an as needed bases or when requested by unit personnel.

1.7.2. Ensure sweeper and operators are available for sweeping when requested by maintenance or operations personnel. Alternate methods of FOD removal should be planned for and available when the primary sweeper is not available.

1.7.3. Ensure FOD awareness training is provided/documented for CE personnel. Monitor and recommend changes for FOD prevention training to the Wing FOD Prevention Manager.

1.7.4. Provide FOD awareness brief to all contractors on FOD awareness when they are working on or in the vicinity of flight line operations. CE will, in coordination with Airfield Management and Base Safety, monitor construction sites to prevent possible FOD hazards.

Any FOD hazards, which require attention, will be up channeled to the base safety office, Maintenance Quality Assurance Office (Wing FOD Monitor) and to the 125FW FOD Prevention Manager.

1.8. Vehicle Maintenance Representative will:

1.8.1. Ensure FOD awareness training is provided and documented for vehicle maintenance personnel. Monitor and recommend changes (as required) for FOD prevention training to the Wing FOD Prevention Manager.

1.8.2. Ensure CTK procedures are developed/utilized for flight line access vehicles.

1.9. Security Forces Representative will:

1.9.1. Ensure FOD awareness training is provided and documented for Security Forces personnel. Monitor and recommend changes (as required) for FOD prevention training to the Wing FOD Prevention Manager.

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1.10. Logistic Readiness Support Representative will:

1.10.1. Ensure FOD awareness training is provided and documented for LRS Personnel.

Monitor and recommend changes (as required) for FOD prevention training to the Wing FOD Prevention Manager.

1.11. Aircrew/Flight Crew:

1.11.1. Must account for all equipment and personal items prior to and after each flight and ensure that items not accounted for is immediately reported to the MOC.

1.11.2. Taxiway and runway problems discovered by aircrew or End-of-Runway (EOR) crews will be reported to the SOF or Airfield Manager.

2. FOD Prevention (Elimination): FOD has many causes, but three major contributors are poor housekeeping, poor work habits, and not being cognizant of FO potential. These include not accounting for hardware, safety wire, tools, etc. during maintenance operations. All loose objects, regardless of their origin, can cause catastrophic and costly damage. Pro-active FOD prevention is the responsibility of all maintenance and aircrew personnel. Any FOD hazard, lost tool, or lost object will immediately be reported to maintenance control. We must be vigilant to potential FOD.

The following practices will help eliminate FOD.

2.1. While in storage or during maintenance; engine, aircraft, and AGE equipment openings, lines, hoses, ports, electrical connections, and ducts will be properly plugged or capped to prevent FOD from entering these systems.

2.2. All -21 covers identified in the -6 work cards will be installed at all times when being stored or maintenance is not being performed. Policy for aircraft covers (e.g., Engine intake, secondary heat exchanger intake and exhaust ducts, angle of attack, pitot tube(s), to include ejection seat) is located in Maintenance Operating Instruction (MOI) 21-26, Maintenance Group Commander (MXG/CC) – Commander Options

2.3. Prior to engine start and after engine shutdown for all flight line and test cell maintenance runs, and after any engine intake maintenance, each affected engine intake and exhaust will receive a FOD inspection. The intake/exhaust FOD inspection will be documented in the applicable Air Force Technical Order (AFTO) Form781A, Maintenance Discrepancy and Work Document, on a Red X symbol. Uninstalled engine test cell runs will be annotated on the test cell worksheet. During aircraft intake and exhaust inspections, all pockets will be emptied and loose articles removed including AF Form 1199, USAF Restricted Area Badge, and a white pocket less, zipper less, button less intake bunny suit will be utilized. Boots will be removed for intake and engine exhaust inspections. In addition, all pockets will be emptied prior to entering the cockpit.

2.4. At the beginning of each shift, if in use, all vehicle magnetic FOD bars will be inspected and made free of all debris prior to signing-off the vehicle operator inspection card.

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2.5. All vehicles will stop, turn off vehicle engine and the driver/passenger(s) will perform a tire rollover inspection (Emergency vehicles responding to a real-world incident are exempt from this requirement) and remove all foreign debris with a locally approved and etched debris removal tool prior to entry onto aircraft parking ramps taxiways and runways.

2.6. Use extreme care during engine ground runs. An area FOD check, with particular attention to inlet areas will be performed prior to any maintenance ground run in accordance with AFMAN 91-203, Air Force Occupational Safety, Fire, and Health Standards. Pilot and aircrew awareness during ground operations (i.e. taxing and turning) is required. Jet blast, propellers wash and helicopter rotor wash areas must be free of debris that causes FOD.

2.7. At no time will the engine intake be utilized for holding forms, checklist or any other items.

2.8. Production Superintendents will ensure FOD walks on the aircraft parking ramp and access points are conducted prior to the first flight of each flying day.

2.8.1. The Production Superintendent or Expediter will determine the time of any unscheduled FOD Walks.

2.8.2. FOD Walk announcements will be made over the Line Mobile Radio (LMR) and local intercom system, if available, by Maintenance Operations Control (MOC) personnel.

2.8.3. Coffee Cups, soda cans, etc. are PROHIBITED from the aircraft parking ramp and access points during FOD walks.

2.9. Production Superintendents will ensure utilization of FOD walk Monitors (MSgt or above/TSgt or above at Detachment-1 Homestead) to ensure an orderly and thorough search of the area is performed. The 125 FW Jacksonville will utilize two FOD walk Monitors, Detachment-1 Homestead will utilize a minimum of one monitor. Each FOD walk Monitor will be identified by a safety vest and will have a FOD pouch or disposable bag to collect Foreign Objects (F.O.). All collected F.O. will be placed on display for awareness.

2.10. FOD Walk Areas of Responsibility: The following shops are responsible for FOD Walks in the following FOD Free areas assigned.

2.10.1. Main Parking Ramp: At 0730 or as directed by the Production Superintendent, all available maintenance personnel not assigned to a specific area, unless otherwise stated, are responsible for FOD walking the aircraft parking ramp to include the apron area.

2.10.1.1. The FOD Boss will be utilized each day at the direction of the Production Superintendent or equivalent daily.

2.10.1.2. The FOD Boss will be disconnected prior to aircraft launch and during inclement weather. The Expediter will avoid towing the FOD Boss in front of and at

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the rear of any operating aircraft engines.

2.10.1.3. All debris collected by the FOD Boss will be emptied at least daily.

2.10.2. Maintenance Hangar: Inspection Element, upon completion of the main parking ramp FOD walk, will perform a FOD walk inspection of the maintenance side of the hangar. The Inspection Element will also conduct a 1600hr, or as directed, daily FOD walk of the maintenance side of the hangar.

2.10.3. Avionics Hangar: Avionics Element, upon completion of the main parking ramp FOD walk, will perform a FOD walk inspection of the radar side of the hangar.

2.10.4. AGE Area: AGE Element, upon completion of the main parking ramp FOD walk, will perform a FOD walk inspection of the AGE area.

2.10.5. KILO: Weapon Element, each morning at 0645 or as directed will conduct a FOD walk of the KILO area. EOR/DEARM crew will conduct a FOD walk prior to each mission departure each day.

2.10.6. MIKE 2: Propulsion Element will conduct a FOD walk of this area each morning at 0730, or as directed. (Except during night fly operations)

2.10.7. MIKE 3: AIS Element will conduct a FOD walk of this area each morning at 0730, or as directed. (Except during night fly operations)

2.10.8. Fuel Barn Area: Fuels Element will conduct a FOD walk of the entire Corrosion Facility and concrete apron area each morning at 0730, or as directed. (Except during night fly operations)

2.10.9. Corrosion Facility Area: Sheet Metal Element will conduct a FOD walk of this area each morning at 0730, or as directed. (Except during night fly operations)

2.10.10. Hush House: Tow Team is responsible for FOD walking the Hush House and apron area prior to parking an aircraft inside the Hush House.

2.10.11. Trim Pad: Tow Team is responsible for FOD walking the Hush House and apron area prior to parking an aircraft inside the Hush House.

2.10.12. Home Station Alert Facility: The Alert Area and MIKE 1 will be FOD walked daily and augmented daily with the FOD Boss whenever the Alert Facility is in use, and when contractors have completed work in the area. When not in use, the area will be inspected once a month for FOD. When an aircraft is towed into the area the tow team is responsible for FOD walking the area.

2.10.13. Detachment 1 Homestead: The Production Superintendent will designate a time

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for a daily FOD walk of the Alert Facility. All available maintenance personnel are responsible for FOD walking the Alert Facility inside the fenced perimeter; to include the apron areas.

2.10.13.1. The Production Superintendent or equivalent will utilize the FOD Boss/Base Sweeper truck to augment daily FOD walks.

2.10.13.2. The FOD Boss will be disconnected prior to aircraft launch and during inclement weather. Personnel will avoid towing the FOD Boss in front of and to the rear of any operating aircraft engines.

2.10.13.3. All debris collected by the FOD Boss will be emptied at least daily.

2.11. All maintenance areas will have foreign object containers readily accessible to workers. Vehicles normally driven on the flight line will be equipped with lidded FOD containers with the word “FOD” stenciled in contrasting letters no smaller than two inches and secured to the vehicle. All containers will be emptied when full or once a day, whichever comes first.

2.12. Due to the nature of the hazard, AFI 21-101, Aircraft and Equipment Maintenance Management dictates that loose clothing or other articles, which could be drawn into intakes, are prohibited at all times, to include daily FOD Walks. This includes wigs, hairpieces, metal hair fasteners, earrings, finger rings (of any material, including medal, rubber ect.), watches, bracelets or other jewelry, which may fall off without notice. Metal insignias/badges will not be worn on the flightline. Optional cloth insignias are authorized and encouraged. MXG/CC may authorize hats within the flightline area.

2.12.1. MXG/CC authorizes Hats and Protective head gear (Weather, Safety and Medical) may be worn within the flight-line area but must be secured to the individual by means of a lanyard that does not create a FOD hazard. Berets are not authorized on the flight-line. All protective head covering must be removed from all individuals within the flight-line area prior to first aircraft engine start, or first aircraft taxing into the flight-line area. Authorized items may be placed back into use upon last engine shutdown, or last aircraft taxing beyond the flight-line area.

2.13. Restricted area badges and passes will be secured with a subdued nylon/cotton cord, plastic armband or break-away neck-strap with or without holder. These items will be removed and secured when around operating aircraft. Removable metal clips are not authorized.

2.14. Remove all readily removable (slide or pressure fit) pocket clips from tools (e.g., flashlights, continuity testers, small screwdrivers) prior to placement in tool kits. Do not disassemble/ damage tools for sole purpose of removing clips, rubber switch guards, etc.

2.15. All work order residue (nuts, bolts, fasteners, safety wire, etc.) used on or around aircraft must be controlled and accounted for. Unused items will be returned to the

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benchstock, place back to the items designated location or disposed of properly.

2.16. Escorts of visiting personnel will ensure a FOD prevention briefing is given prior to entering a maintenance area. A copy of this brief can be obtained by contacting the Quality Assurance Office at extension 7215.

2.17. Government tools/equipment permanently assigned to individuals or duty positions will be marked and controlled. Personal tools are not authorized on the flightline or any maintenance area.

2.18. Aircraft cockpits will be inspected before and after flight to ensure the elimination of FO. Inspections will be augmented through the QA Maintenance Standardization and Evaluation Program (MSEP).

2.19. When FOD is discovered in inaccessible areas X-ray, borescope, and other equipment will be used to the fullest extent possible to locate the item.

3. FOD Prevention Committee Meeting. FOD prevention committee meetings will be conducted quarterly if needed and chaired by the 125 FW/CV. The 125 MXG/CC will chair the meeting in the absence of the 125 FW/CV. This meeting will normally be a part of the 125FW Safety council meeting (Minutes are recorded and distributed to all committee members).

The purpose of the meeting is to identify negative trends and develop action plans to resolve them. The following functional units or their designated representatives should be present if available:

3.1. 125 FW/CV, Vice Commander

3.2. 125 OG/CC, Operations Group Commander or designated representative

3.3. 125 MXG/CC, Maintenance Group Commander

3.4. 125 MSG/CC, Mission Support Group

3.5. 125 SFS/CC, Security Forces Commander or designated representative

3.6. 125 CE, Base Civil Engineer or designated representative

3.7. 125 AMXS/CC, Aircraft Maintenance Squadron

3.8. 125 MXS/CC, Maintenance Squadron

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3.9. 125 FW/SE, Wing Safety Office

3.10. 125 OSF/OSA, Airfield Manager

3.11. 125 MXG/MXQ, Wing FOD Monitor

MATTHEW J. FRENCH, Colonel, FLANG Commander 125 Fighter Wing

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ATTACHMENT 1

GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION

References:

AFI 21-101, Aircraft and Equipment Maintenance Management, 21 May 2015

AFI 91-204, Safety Investigations and Reports, 27 April 2018

AFMAN 91-203, Air Force Occupational Safety, Fire and Health Standards, 11 December 2018

AFMAN 33-363, Management of Records, 1 March 2008

125FWI 13-1, Airfield Operations

MOI 21-26, Maintenance Group Commander (MXG/CC) – Commander Options

T.O. 00-35D-54, USAF Material Deficiency Reporting and Investigating System

T.O. 00-20-1, Aerospace Equipment Maintenance Documentation and Procedures

Forms:

AF From 1199, USAF Restricted Area Badge, 1 November 1986

AFTO Form 781A, Maintenance Discrepancy and Work Document, 8 January 2008

AF Form 847, Recommendation for Change of Publication 22 September 2009

Abbreviations and Acronyms:

OPR – Office of Primary Responsibility

FW – Fighter Wing

RDS – Records Disposition Schedule

AFTO – Air Force Technical Order

AGE - Aerospace Ground Equipment

PDM - Programmed Depot Maintenance

EOR – End of Runway

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FANG - Florida Air National Guard

FO – Foreign Object

FOD - Foreign Object Damage

IAW – In Accordance With

JAA – Jacksonville Aviation Authority

MOI – Maintenance Operating Instruction

MSEP - Maintenance Standardization and Evaluation Program

POC – Point of Contact

CTK – Composite Tool Kit

POC – Point of Contact

MOC – Maintenance Operations Center

QA – Quality Assurance

VTR – Video Tape Recorder

Office Symbols

125 FW/CC – Wing Commander 125 OG – Operations Group 125 FW/CV – Vice Commander 125 OG/CC – Operations Group Commander 125 FW/CCA – Commanders Support Staff 125 OSF/OSA – Airfield Manager 125 FW/SE – Safety 125 LRS – Logistics Readiness Squadron 125 MXG – Maintenance Group 125 LRS/LGRV Vehicle Maintenance 125 MXG/CC - Maintenance Group Commander 125 CE – Civil Engineering 125 MXG/MXQ – Quality Assurance 125 SFS – Security Forces Squadron

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ATTACHMENT 2

FOD MISHAP INVESTIGATION WORKSHEET

A1.1. FILL OUT ALL APPLICABLE ITEMS. IF AN ITEM DOES NOT APPLY, PUT

N/A. LEAVE NO ITEMS BLANK.

NOTE: DO NOT DISCARD ANY REMAINS FROM BIRD STRIKES. ALL REMAINS

MUST BE BAGGED AND GIVEN TO 125FW/SE FOR INVESTIGATION

PROCESSING

1. Date of FOD Mishap: ______________________

2. Mishap Title: ____________________________ (i.e. FOD in cockpit, bird strike, #1 Eng FOD)

3. Aircraft Equipment Engine Tire (circle one)

4. If Equipment or Tire, state type ____________________________

5. Complete Engine Serial Number: ___________________________

6. Engine Position: 1 2 3 4

7. Aircraft MDS/Model and Serial Number: _______________

8. Specific Mishap Location _______________________________________________ (Flt line/Test Cell/In Flight etc.)

9. AIRCRAFT IMPOUNDED: Yes No Date & Time: __________________________

10. 125 FW/CV Notified: Yes No Date & time: ______________ Name: ____________

11. Wing Safety Notified: Yes No Date & Time: ______________ Name: ____________

12. Type of damage: ____________________________________________________________

13. Discovered by individual(s): _______________________________________

14. Probable Cause: ____________________________________________________

15. Type Of Aircraft Mission: __________________

16. Pilot: ___________________________________

(Check one) Initial: ______ Final: ______ Date C/W:

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17. Crew Chief(s): ________________/__________________

18. Pilot aware FOD occurred (indications): Yes No _______________________________

19. Other aircraft involved in mission: (Tail # and Pilot) ______________________________

20. Air to Air Refueling: Yes ____ No ____ If so, contact refueling unit to see if anything missing from the tanker. Unit: _____________ Individual contacted: _____________________

21. Disposition of damaged equipment (i.e. condemned/shipped/repaired locally)

22. Estimated cost of repair.____________________________________

23. Action Taken to Prevent Recurrence.____________________________________________

24. Recommendations to prevent further incidents of this sort:

25. NARRATIVE OF FOD MISHAP FROM “DISCOVERED BY” INDIVIDUAL. USE

SEPARATE SHEET

QA/SAFETY INVESTIGATION USE

Check the following and document findings (as applicable):

♦ Condition of ramp/taxi way used, etc.

♦ CTK (Impound and inventory any CTK used prior to mishap) ♦ Date and type of last scheduled inspection ♦ Maintenance last performed on aircraft (particularly maintenance performed in area of FOD) ♦ Missing hardware, etc. in area of FOD (or in front of) ♦ Panels removed in FOD area recently ♦ Cockpit area ♦ Vari-ramps ♦ Previous X-rays on file ♦ Trends

Document in QA Program FOD database. (125 MXG/MXQ only): ________________________

Analysis and Recommendations.___________________________________________________