1 FOE Implementation Basic Process. 2 FOE IMPLEMENTATION PROCESS FLOWCHART.

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FOE ImplementationBasic Process

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FOE IMPLEMENTATION PROCESS FLOWCHART

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FOE ImplementationProcess Flowchart

The FOE Focal Point is selected for every Area to assist in the implementation of the FOE Program and compliance to the requirements.

Verify FOE Area Control Level Assessment

Verify External Signage for

Correct FOD Control Level

Verify Training Requirements

Set Up FOD Metrics

Check Applicable Requirements

Perform FOD Area Sweep Checklist Daily (Med/High)

Perform FOD Area Monthly Self-Assessment

Checklist (Med/High)

Perform Material Control

(Med/High)

Perform Tool Control(High)

Follow Incident Reporting

Flowchart if FOD is Found

FOE Implementation Process Flowchart

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FOE AREA CONTROL LEVEL ASSESSMENT

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FO Control Level Assessment

Get minimum Control Level from Requirements

Complete General Information about the area

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

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FO Control Level AssessmentOverall 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.

Additional Assessments

Area Level Assessment(Baseline)

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FOD METRICS

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FOD Incident Reporting 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

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Standard Reporting Metric (Must be updated monthly and posted):

Monthly & Cumulative To Date FOD Incidents

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC CTD

Month

Tot

al F

OD

Inci

dent

s

Total FOD Incidents

Cumulative To Date (CTD)

3 per. Mov. Avg. (Total FODIncidents)

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FOD Metric Chart Input Data Table (Example Only):

A B C D E FMetric Chart Input Data Worksheet

Month


Foreign Object

Damage

Total FOD

Incidents



J AN 0 0 0 0FEB 0 0 0 0MAR 0 1 1 1APR 2 0 2 3MAY 1 2 3 6J UN 0 0 0 6J UL 2 0 2 8AUG 1 0 1 9SEP 0 1 1 10OCT 0 0 0 10NOV 0 0 0 10DEC 0 3 3 13CTD 13

Totals 6 7 13

<copy cell E4 to desired row in col. E to copy formula>

<update cell F15 for current CTD>

Manually loaded using data from monthly data sheets

Can automate for a specific area if desired

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FOD Metric Monthly Data Sheet (Example Only):J an

# Date Description


Foreign Object

DamageRecorded

By Disposition/Correction Action

1 Describe Incident Here 0 0

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

0 0

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FOE CONTROL AREAIDENTIFICATION

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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

LOW

Medium

Medium

High

Sub-Areas Overall Area

Overall AreaApply Note for

Sub-Areas

FOE Focal Point is responsible to ensure proper area identification

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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

FOE Control AreaPossible Concerns

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Internal Signage

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DAILY FOE AREA SWEEP CHECKLIST

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FOE Area Sweep Checklist

1 Tables and workbenches are free of FO (materials, tools, etc.). These are items not required for the in-process activity.

2 Floor and ceiling is free of debris.

3 Test Equipment is free of debris.

4Equipment (carts, trash cans, etc.) are returned to designated location.

5Unused tools are returned to proper location (i.e., toolboxes and/or shadow boards).

6Hardware is covered/stored properly and safe of FOD risk (any openings, ports, holes, and ducts are covered) when not in use.

8Hardware is safe from small items, consumables or other materials that may create a FOD risk.

9Tool Log Sheets are properly filled out if being used.

10Areas are properly identified and marked off if multiple FO Control Levels are present.

Once

Once

Once

Once

Once

Once

Once

Once

Once

Bldg/Room/Sub-Area

S S CommentsT F

Cost CenterWork Area Name:

Checklist Timing: 10 Minutes Average

Daily FOE Area Sweep Checklist

What to Sweep

For the Week Beginning Monday,

M T W

Frequency per Shift (Working Shifts Only)

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

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MONTHLY FOE SELF-ASSESSMENT CHECKLIST

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FOE Self-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

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MATERIAL CONTROL

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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 Qty Emp # Qty Emp #

Material Control ChecklistProduct: Operation No:

Check-In to Area

Info filled in by the User

Check-Out of Area


Material Control will be the hardest to do!

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TOOL CONTROL

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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

Tool Description (# of items)Date:

Month/Day Emp #Date:

Month/Day Emp #

Controlled Perimeter Tool Checklist:

Check-In to Perimeter


Check-Out of Perimeter


Controlled Perimeter Tool Checklist:Recommended Form - May be Tailored to Site/Area Specific Requirements

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FOD INCIDENT REPORTING

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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

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FOD Incident Reporting Process Flow

FOE

Foc

al

Poi

ntQ

ualit

yS

uppl

y C

hain

M

gt.

Sup

plie

rE

mpl

oyee

FOD IncidentNotify Area Supervision and Quality

Notify FOE Focal Point

Foreign Object Damage or Debris?

In-house or Supplier Caused?

Prepare RCCA action and

complete for closure

Document Incident in Quality History

Record

Disposition and closeout

Prepare Defect Report to supplier

Find root cause and corrective

actionPrepare response

Review and approve

response and prepare response

Damage

Investigate and perform corrective action as required

Discuss incident at team meetings

Prepare RCCA action

Supplier

In-house

Complete RCCA response for

closure

Debris Debris found in High FOD Control

Level Area?

Yes

No

FOD Incident Reporting Process

Incident Reporting

1 FOE Implementation Basic Process. 2 FOE IMPLEMENTATION PROCESS FLOWCHART.

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