• Consolidated Tool Kits: (also known as: CTK) A tool container or box with only the specific tools needed for specified tasks. Some kits are inventoried out and back in to the tool crib/storage area. In some kits each tool has a specific location provided and either shadow boxed or in a foam cutout for quick inventory.
• Tool Inventory Sheets/Logs: Written or computerized inventories of all tools entering a FOD Sensitive or Critical Area. All inventories must be reconciled at the end of each shift or release of an aircraft.
• Sponge Count/Everything gets counted: All items going into or out of a FOD Sensitive or Critical area gets counted. A formal inventory is kept. Similar to the surgical operating room, nothing gets left where it should not be.
• Shadowbox/Shadow board: A tool box or storage board with specific, marked locations for each tool so that a missing tool will be readily noticeable.
• Tether: A lanyard of sufficient strength (wire, rope, cable, etc.) attached to the tool/equipment and to the user or fixed secure object. The tether should be minimum length to preclude damage from tethered tool "free swing." NOTE: A tether device, if not regularly examined may itself be the FO. Fraying of the tether material and the hardware (rings, snaps, etc.) can all become FOD.
• Six Sigma: A comprehensive and proven set of tools and techniques applied in a consistent, systemic fashion to enable to better solve problems and optimize processes in all functional areas. The main focal points of Six Sigma are:
– Waste Elimination primarily through Lean principles and tools,
– Variation Reduction through traditional DMAIC tools (Define, Measure, Analyze, Improve, Control), and
– Growth and Innovation using the tools and principles of DFSS (Design
for Six Sigma).
• Lean Manufacturing: Lean manufacturing is the production of goods using less of everything compared to mass production: less human effort, less manufacturing space, less investment in tools, and less engineering time to develop a new product.
• 5S: The Japanese mnemonic based process for housekeeping and organizing for efficiency. 5S is a philosophy and a way of organizing and managing the workspace by eliminating waste.
– Sort
– Straighten
– Shine
– Standardize
– Sustain
* Some organizations use 6S with the 6th S being Safety.
3.0 FOD Program Controls and Implementation
For an FOD Prevention program to be effective, it must be planned, implemented and continuously improved.
Basic Elements:
1. FOD Prevention Training.
2. Early design consideration for FOD prevention, resistance to damage, foreign object entrapment, etc.
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