Implementing FOE Program Control Processes

FOE Implementation Basic Process 1

FOE IMPLEMENTATION PROCESS FLOWCHART 2

FOE Implementation FOE Implementation Process Flowchart Process Flowchart The FOE Focal Point is selected for every Area to assist in the implementation of the FOE Program and compliance to the requirements. FOE Implementation Process Flowchart Verify External Signage for Correct FOD Control Level Verify FOE Area Control Level Assessment Verify Training Requirements Set Up FOD Metrics Check Applicable Requirements Perform FOD Area Monthly Self- Assessment Checklist (Med/High) Follow Incident Reporting Flowchart if FOD is Found Perform FOD Area Sweep Checklist Daily (Med/High) Perform Material Control (Med/High) Perform Tool Control (High) 3

FOE AREA CONTROL LEVEL ASSESSMENT 4

FO Control Level Assessment Complete General Information about the area Get minimum Control Level from Requirements Identify Potential FOD Risks to the Product Identify any additional FOD controls that will used beyond the Requirements and identify any exceptions Provide any instructions for FOD prevention that are special to the hardware List the Approvals of the Assessment as required. Examples are FOE Focal Point, Section Manager, Engineering, Program Manger 5

FO Control Level Assessment Overall Approach Complete a FO Control Level Assessment for the area first to determine FOE Control Level of the overall area (baseline). This level is noted on the external area signage board This assessment should handle all hardware and operations that you would normally expect to process and perform. Revise assessment as required (add rev letter DO NOT OVERWRITE any assessments). For cases of hardware or processes that do not fit into the overall area assessment performed above, generate an additional assessment to specifically address that hardware or process and understand the FO Control Level required as well as list any special instructions/exemptions. Area Level Assessment (Baseline) Additional Assessments 6

FOD METRICS 7

FOD Incident Reporting FOD Incident Reporting Metric Metric Definitions: Foreign Object Debris FOD A substance or article alien to the product or assembly that has the potential to cause damage or degrade the product s required safety and/or performance characteristics. Foreign Object Damage FOD 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. FOD Incident An Instance where Foreign Object Damage or Debris (FOD) is found 8

FOD Incident Reporting FOD Incident Reporting Metric Metric Standard Reporting Metric (Must be updated monthly and posted): Monthly & Cumulative To Date FOD Incidents 15 14 Total FOD Incidents 13 Example Cumulative To Date (CTD) 12 3 per. Mov. Avg. (Total FOD Incidents) 11 Total FOD Incidents 10 9 8 7 6 5 4 3 2 1 0 JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC CTD Month 9

FOD Incident Reporting FOD Incident Reporting Metric Metric FOD Metric Chart Input Data Table (Example Only): A B C D E F Metric Chart Input Data Worksheet Manually loaded using data from monthly data sheets Cumulative To Date (CTD) Foreign Object Debris 0 0 0 2 1 0 2 1 0 0 0 0 Foreign Object Damage 0 0 1 0 2 0 0 0 1 0 0 3 Total FOD Incidents 0 0 1 2 3 0 2 1 1 0 0 3 Can automate for a specific area if desired Cumulative To Date (CTD) 0 0 1 3 6 6 8 9 10 10 10 13 Month JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC <copy cell E4 to desired row in col. E to copy formula> 13 CTD <update cell F15 for current CTD> 6 7 13 Totals 10

FOD Incident Reporting FOD Incident Reporting Metric Metric FOD Metric Monthly Data Sheet (Example Only): Jan Foreign Object Debris Foreign Object Damage Recorded By # Date Description Disposition/Correction Action Describe Incident Here 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 0 0 23 24 11

FOE CONTROL AREA IDENTIFICATION 12

FOE Control Areas FOE Control Areas Required for FOE Control Levels different from posted level on signage (for Higher or Lower Areas) Use signage, floor markings and/or stanchions to identify area Overall Area Sub-Areas Example Medium LOW Apply Note for Sub-Areas High Overall Area Medium FOE Focal Point is responsible to ensure proper area identification 13

FOE Control Area FOE Control Area Possible Concerns Possible Concerns Other users working in the Area may not know enough about FOD control levels yet to notify the FOE Focal Point or other Area personnel when a higher (or lower) level of control is needed It is important that we educate the users to ensure understanding and compliance to the new FOE policy/work instruction at all times The FO Control Level Assessment should capture the possibility of requiring a Control Level change to accommodate a configuration change (planned or unplanned) with the product 14

Internal Signage Internal Signage Example 15

DAILY FOE AREA SWEEP CHECKLIST 16

FOE Area Sweep Checklist FOE Area Sweep Checklist Daily FOE Area Sweep Checklist Bldg/Room/Sub-Area Work Area Name: Cost Center Frequency per Shift (Working Shifts Only) For the Week Beginning Monday, Checklist Timing: 10 Minutes Average What to Sweep M T W T F S S Comments Tables and workbenches are free of FO (materials, tools, etc.). These are items not required for the in- process activity. Once 1 Once 2 Floor and ceiling is free of debris. Once 3 Test Equipment is free of debris. 4Equipment (carts, trash cans, etc.) are returned to designated location. Once 5Unused tools are returned to proper location (i.e., toolboxes and/or shadow boards). Once Hardware is covered/stored properly and safe of FOD risk (any openings, ports, holes, and ducts are covered) when not in use. Once 6 8Hardware is safe from small items, consumables or other materials that may create a FOD risk. Once 9Tool Log Sheets are properly filled out if being used. Once 10Areas are properly identified and marked off if multiple FO Control Levels are present. Once FOE Focal Point performs or assigns task Must be performed daily for all Medium and High areas Elements may be combined with area 6S program (if performed daily) Records must be retained Anything found must be fixed or addressed on the checklist Template and sweep elements may be tailored to a specific area 17

MONTHLY FOE SELF-ASSESSMENT CHECKLIST 18

FOE Self FOE Self- -Assessment Checklist Assessment Checklist FOE Focal Point performs or assigns task Must be performed monthly for all Medium and High Records must be retained Anything found must be addressed on the Corrective Actions sheet Template and self-assessment elements may be tailored to a specific area Impractical to do for temporary Medium/High areas unless area is in place at time of assessment No requirement to post the self-assessment checklist Pareto chart as a Metric 19

MATERIAL CONTROL 20

Material Control Material Control Required for FOE control Levels Medium and High Try to make Material Control area as small as possible Use floor markings or stanchions to identify area Log in/Log out guidelines Requirement was developed primarily for screws, nuts, bolts, q-tips and other small parts instead of glues, paints and sealants Make Log in/Log out sheet that is specific to the operation Consumables too large to be lost or impractical to count can be accounted for using visual confirmation (examples include Kimwipes, tape, glue) Material Control Checklist Product: Operation No: Check-In to Area Check-Out of Area Info filled in by the User Info filled in by the User Material Qty Qty Emp # Emp # Example Material Control will be the hardest to do! 21

TOOL CONTROL 22

Tool Control Tool Control Required for FOE control Level of High only Try to make Tool Control area as small as possible Use floor markings or stanchions to identify area Shadowboxing is best method but it may not be practical in an Engineering Lab Controlled Perimeter List is the easiest to implement Lost tools must be reported immediately Controlled Perimeter Tool Checklist: Recommended Form - May be Tailored to Site/Area Specific Requirements Controlled Perimeter Tool Checklist: Check-In to Perimeter Check-Out of Perimeter Info filled in by the User Info filled in by the User Date: Month/Day Date: Month/Day Tool Description (# of items) Emp # Emp # 23

FOD INCIDENT REPORTING 24

Incident Reporting Incident Reporting Follow the FOD Incident Reporting Process Flowchart All FOD Incidents are required to be reported Know the definition of FOD to avoid unnecessary reporting Report a metric for every FOD Incident Share information with others Don t be afraid to report an Incident (root cause analysis is important) FOE Focal point needs to know about all FOD Incidents If Foreign Object Damage is found, stop work on the hardware, report incident and initiate an investigation. Resume work when authorized 25

Incident Reporting Incident Reporting FOD Incident Reporting Process FOD Incident Reporting Process Flow Employee Notify Area Supervision and Quality Debris found in High FOD Control Level Area? Debris No Notify FOE Focal Point Foreign Object Damage or Debris? FOD Incident Damage Yes FOE Focal Investigate and perform corrective action as required Point Discuss incident at team meetings Prepare RCCA action and complete for closure In-house or Supplier Caused? In-house Quality Document Incident in Quality History Record Complete RCCA response for closure Disposition and closeout Prepare RCCA action Supplier Supply Chain Review and approve response and prepare response Prepare Defect Report to supplier Mgt. Supplier Find root cause and corrective action Prepare response 26