{"id":12432,"date":"2022-11-10T13:00:54","date_gmt":"2022-11-10T19:00:54","guid":{"rendered":"https:\/\/www.fodcontrol.com\/?page_id=12432"},"modified":"2025-02-14T17:08:51","modified_gmt":"2025-02-14T23:08:51","slug":"controlling-fod-in-a-manufacturing-facility","status":"publish","type":"page","link":"https:\/\/www.fodcontrol.com\/controlling-fod-in-a-manufacturing-facility\/","title":{"rendered":"Controlling FOD In A Manufacturing Facility"},"content":{"rendered":"<h1>Controlling FOD in a Manufacturing Facility<\/h1>\n\t<div id=\"gap-1399230900\" class=\"gap-element clearfix\" style=\"display:block; height:auto;\">\n\t\t\n<style>\n#gap-1399230900 {\n  padding-top: 30px;\n}\n<\/style>\n\t<\/div>\n\t\n\n<h2 id=\"anchor-1\">How To Increase Worker Safety and Product Quality<\/h2>\n<div class=\"row\"  id=\"row-1755135645\">\n\n\n\t<div id=\"col-216541399\" class=\"col medium-8 small-12 large-8\"  >\n\t\t\t\t<div class=\"col-inner\"  >\n\t\t\t\n\t\t\t\n\n<p><img fetchpriority=\"high\" decoding=\"async\" class=\"alignright wp-image-5140\" src=\"https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/Stock\/AS9100-Auditor.png\" alt=\"AS9100 Auditor\" width=\"450\" height=\"300\" srcset=\"https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/Stock\/AS9100-Auditor.png 510w, https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/Stock\/AS9100-Auditor-247x165.png 247w\" sizes=\"(max-width: 450px) 100vw, 450px\" \/>Manufacturing products for aerospace differs from other assembly operations by the strict requirements of product integrity and the processes used to assure safety and reliability.<\/p>\n<p>The potential of introducing foreign object debris in manufacturing during fabrication is very high.<\/p>\n<p>Without even considering tools, employee personal items, drill filings\/chips and all the other possible contributors to FOD in manufacturing facilities, just the number of fasteners used to assemble the structure and install components can measure in at hundreds of thousands.<\/p>\n<p>It takes only one fastener in the wrong place to cause an incident resulting in loss of the aircraft and\/or loss of life. Supervisors and workers cannot merely be told or expected to build a FOD free product, including FOD free assemblies manufacturing.<\/p>\n<h3 id=\"anchor-2\">FOD controls and prevention practices must be established and enforced throughout the entire build process if product integrity is to be assured.<\/h3>\n<p>In a manufacturing environment, cost often drives schedule. After all, to continue building any product it must be profitable. FOD controls in manufacturing facilities often impact costs and schedules. Implementation and maintenance of controls should be planned and formalized as part of the product manufacturing scheme\u2014not as an unpleasant afterthought when things go wrong.<\/p>\n<h3 id=\"anchor-3\">Some of the possible costs to establish and operate an effective FOD Control Program include, but are not limited to:<\/h3>\n<ul>\n<li>Training<\/li>\n<li>Equipment<\/li>\n<li>Design changes<\/li>\n<li>Procedural changes<\/li>\n<li>Workplace organization<\/li>\n<li>Tool and hardware controls<\/li>\n<li>Inspections<\/li>\n<li>Adequate manpower to oversee and maintain the program<\/li>\n<\/ul>\n<p>But what about the savings? They\u2019re yours to claim with a commitment to FOD controls. Once established, an effective program reduces rework, scrap and incidents. Want increased customer satisfaction and sales? What about reputation and the pride of building the best product you can? What about beating the competition and increasing market share? Even if an <i>effective <\/i>FOD Program or Procedure hasn\u2019t been planned and implemented previously in your operation, the time to start is <i>now<\/i><b>. <\/b>FOD control is quality. FOD control is safety. FOD control is integrity. The savings and benefits far outweigh the costs and time expended.<\/p>\n\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\n\t\n\n\t<div id=\"col-739321830\" class=\"col medium-4 small-12 large-4\"  >\n\t\t\t\t<div class=\"col-inner\"  >\n\t\t\t\n\t\t\t\n\n\t<div id=\"gap-1488216629\" class=\"gap-element clearfix\" style=\"display:block; height:auto;\">\n\t\t\n<style>\n#gap-1488216629 {\n  padding-top: 30px;\n}\n<\/style>\n\t<\/div>\n\t\n\n\n\n<div class=\"toc_container\">\n<p class=\"toc_title\">Article Contents<\/p>\n<ul class=\"toc_list\">\n\t<li><a href=\"#anchor-1\" target=\"_self\" rel=\"noopener\">How To Increase Worker Safety and Product Quality<\/a>\n\t<ul>\n\t\t<li><a href=\"#anchor-2\" target=\"_self\" rel=\"noopener\">FOD Controls and Prevention<\/a><\/li>\n\t\t<li><a href=\"#anchor-3\" target=\"_self\" rel=\"noopener\">Possible Costs<\/a><\/li>\n\t<\/ul>\n\t<\/li>\n\t<li><a href=\"#anchor-4\" target=\"_self\" rel=\"noopener\">Design<\/a><\/li>\n\t<li><a href=\"#anchor-5\" target=\"_self\" rel=\"noopener\">Management Responsibilities<\/a>\n\t<ul>\n\t\t<li><a href=\"#anchor-6\" target=\"_self\" rel=\"noopener\">The FOD Department<\/a><\/li>\n\t\t<li><a href=\"#anchor-7\" target=\"_self\" rel=\"noopener\">Equipment &amp; Tools<\/a><\/li>\n<\/ul>\n\t<\/li>\n\t<li><a href=\"#anchor-8\" target=\"_self\" rel=\"noopener\">Control Areas<\/a>\n\t<ul>\n\t\t<li><a href=\"#anchor-9\" target=\"_self\" rel=\"noopener\">Three Distinct Categories of Operation Are Evident:<\/a><\/li>\n<li><a href=\"#anchor-10\" target=\"_self\" rel=\"noopener\">Fabrication<\/a><\/li>\n\t<li><a href=\"#anchor-11\" target=\"_self\" rel=\"noopener\">Assembly<\/a><\/li>\n\t<li><a href=\"#anchor-12\" target=\"_self\" rel=\"noopener\">Checkout\/Test<\/a><\/li>\n\t<li><a href=\"#anchor-13\" target=\"_self\" rel=\"noopener\">Key Elements<\/a><\/li>\n\t<li><a href=\"#anchor-14\" target=\"_self\" rel=\"noopener\">Workplace Organization<\/a><\/li>\n\t<\/ul>\n\t<\/li>\n\t<li><a href=\"#anchor-15\" target=\"_self\" rel=\"noopener\">The Five S\u2019s of Housekeeping<\/a>\n<ul>\n\t\t<li><a href=\"#anchor-16\" target=\"_self\" rel=\"noopener\">(1) Sorting<\/a><\/li>\n<li><a href=\"#anchor-17\" target=\"_self\" rel=\"noopener\">(2) Standardizing<\/a><\/li>\n\t<li><a href=\"#anchor-18\" target=\"_self\" rel=\"noopener\">(3) Simplifying<\/a><\/li>\n\t<li><a href=\"#anchor-19\" target=\"_self\" rel=\"noopener\">(4) Sweeping<\/a><\/li>\n\t<li><a href=\"#anchor-20\" target=\"_self\" rel=\"noopener\">(5)Self-Discipline<\/a><\/li>\n<\/ul>\n<\/li>\n<li><a href=\"#anchor-21\" target=\"_self\" rel=\"noopener\">The Customer<\/a>\n<ul>\n\t\t<li><a href=\"#anchor-22\" target=\"_self\" rel=\"noopener\">Quality<\/a><\/li>\n<\/ul>\n<\/li>\n<\/ul><\/div>\n\n\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\n\t\n\n<\/div>\n\t<div id=\"gap-567128319\" class=\"gap-element clearfix\" style=\"display:block; height:auto;\">\n\t\t\n<style>\n#gap-567128319 {\n  padding-top: 30px;\n}\n<\/style>\n\t<\/div>\n\t\n\n<a href=\"https:\/\/www.fodcontrol.com\/fod-prevention-plan-template\/\" class=\"button alert is-shade expand\"  >\n\t\t<span>Considering how to start a FOD Program? Use our FOD Prevention Plan Template as a starting point.<\/span>\n\t<\/a>\n\n\n\t<div id=\"gap-520775669\" class=\"gap-element clearfix\" style=\"display:block; height:auto;\">\n\t\t\n<style>\n#gap-520775669 {\n  padding-top: 30px;\n}\n<\/style>\n\t<\/div>\n\t\n\n<h2 id=\"anchor-4\">Design<\/h2>\n<p>Although manufacturing controls are necessary to prevent the introduction of FOD, the design of the structure and sub-assemblies plays a vital role in the ability to inspect and remove foreign objects during and after assembly. If fortunate enough to plan a new product or assembly line, Design Engineering should incorporate FOD removal procedures into each aircraft zone. A \u201cDesign Checklist\u201d with buy off from Manufacturing Engineering is required.<\/p>\n<p>Design is your first and best opportunity to eliminate FOD from the delivered product by planning for inspections, cleaning of cavities and\u00a0<i>designing out\u00a0<\/i>entrapment areas. For older\/ existing structures that didn\u2019t plan FOD Prevention into the product, modifications and overhaul planning should require FOD inspection\/removal steps to be incorporated into each package.<\/p>\n<p>Some aircraft contain known FOD entrapment areas that are impossible to inspect or clean. These aircraft are accidents waiting to happen and should be redesigned and modified or dropped from service. Knowing of foreign objects in a flight article and\/or the potential for damage is next to sin \u2014 it cannot be ignored. The responsibility to identify and report the potential for FOD lies with everyone involved in any phase or process. Management should solicit all employees to report potential FOD as they would any safety or quality concern, and should request design changes if feasible to assure product integrity. <strong><em>Repeat: Design stage is the very best opportunity to keep FOD out of the delivered product.<\/em><\/strong><\/p>\n<h2 id=\"anchor-5\">Management Responsibilities<\/h2>\n<p>Management must be supportive of and responsible for the FOD Prevention Plan and its implementation. All applicable policies and procedures, training programs, and operational guidelines must include reminders for FOD prevention procedures and controls.<\/p>\n<p>Management must demand effective corrective action for FOD incidents, problem areas, and negative trends. Without upper management support and encouragement, FOD Prevention is \u201cjust another program\u201d or passing notion. Strong, deliberate enforcement and backing are necessary if compliance is to become reality.<\/p>\n<p>Within the organizational scheme, the FOD Program manager or coordinator should have similar rank and authority as the Safety or Quality manager, and should be independent from manipulation or bias from other operational units (such as Assembly or Test). Some successful programs have FOD reporting to the Quality or Safety manager, but FOD Program management <i>deserves the same status and recognition as those disciplines.\u00a0<\/i><\/p>\n<p>Having all three placed within one organizational unit may be the best profile as they share many similarities such as: inspections for compliance, \u201cshut down\u201d authority, data collection\/trends, customer interface, awareness (promotion) and employee recognition.<\/p>\n\t<div id=\"gap-3957601\" class=\"gap-element clearfix\" style=\"display:block; height:auto;\">\n\t\t\n<style>\n#gap-3957601 {\n  padding-top: 30px;\n}\n<\/style>\n\t<\/div>\n\t\n\n<div class=\"row align-middle align-center\"  id=\"row-155844084\">\n\n\n\t<div id=\"col-1685452734\" class=\"col small-12 large-12\"  >\n\t\t\t\t<div class=\"col-inner text-center\"  >\n\t\t\t\n\t\t\t\n\n\t<div class=\"img has-hover x md-x lg-x y md-y lg-y\" id=\"image_782484095\">\n\t\t\t\t\t\t\t\t<div class=\"img-inner dark\" >\n\t\t\t<img decoding=\"async\" width=\"566\" height=\"314\" src=\"https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/Stock\/orgchart.png\" class=\"attachment-original size-original\" alt=\"Organizational Chart\" srcset=\"https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/Stock\/orgchart.png 566w, https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/Stock\/orgchart-247x137.png 247w, https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/Stock\/orgchart-510x283.png 510w\" sizes=\"(max-width: 566px) 100vw, 566px\" \/>\t\t\t\t\t\t\n\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t\t\n<style>\n#image_782484095 {\n  width: 54%;\n}\n<\/style>\n\t<\/div>\n\t\n\n<p><em>Organizational Chart<\/em><\/p>\n\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\n\t\n\n<\/div>\n\t<div id=\"gap-1528967967\" class=\"gap-element clearfix\" style=\"display:block; height:auto;\">\n\t\t\n<style>\n#gap-1528967967 {\n  padding-top: 30px;\n}\n<\/style>\n\t<\/div>\n\t\n\n<h3 id=\"anchor-6\">The FOD Department<\/h3>\n<p>SOPs (Standard Operating Procedures) and operational guidelines must be developed and kept current.\u00a0FOD inspections\u00a0are required for panel closeouts, manufacturing process spot checks and procedure compliance. Investigations of\u00a0FOD incidents\/mishaps\u00a0can only be performed by an organization with an unbiased eye. FOD inspection\/removal equipment must be operated and maintained by trained specialists. Audit and incident data must be collected, entered into a\u00a0database, information sorted into various report formats, posted on status boards and distributed to key personnel<i>.\u00a0<\/i>Corrective actions for problems\/issues must be tracked and verified as effective. Meetings and briefings must include both management and workers. FOD training programs must be developed and conducted annually (minimum requirement). Awareness and recognition programs must be administered for vitality and worker involvement. This is a formidable list of \u201cmusts,\u201d but all of these elements are necessary to adequately support an effective FOD control effort.<\/p>\n<p>Without a dedicated unit to conduct these activities, the burden on any other organizational unit(s) is difficult, if not impossible, to support. Many companies have tried part-time programs, with FOD Monitors assigned to check work areas at intervals during and at the end of each shift, but these efforts are weak at best. If this approach is used, volunteers should be solicited, not appointed at random. Even when executed and controlled by a conscientious FOD supervisor or coordinator, a part-time FOD effort in manufacturing facilities invariably falls short of a staffed full-time unit.<\/p>\n<p>There is no other way to say it:\u00a0<i>Effective FOD Prevention is an investment\u00a0<\/i>and\u00a0<i>a commitment.<\/i><\/p>\n<p>The number of people required to support a full-time FOD effort will vary depending on the type of operation, number of aircraft in production, the level of FOD control required, and of course, budget available. As a rule of thumb, consider having an inspector for every five aircraft in production. In addition, a clerk to handle data entry\/retrieval and a supervisor\/manager to oversee the operation is necessary. FOD is serious business. Don\u2019t try to avoid doing it right. Appoint a fully staffed FOD department and give it the authority, support and tools needed to do the job\u00a0<i>without compromise<\/i>.<\/p>\n\t<div id=\"gap-1407401599\" class=\"gap-element clearfix\" style=\"display:block; height:auto;\">\n\t\t\n<style>\n#gap-1407401599 {\n  padding-top: 30px;\n}\n<\/style>\n\t<\/div>\n\t\n\n<a href=\"https:\/\/www.fodcontrol.com\/contact-us\/\" class=\"button alert is-shade box-shadow-3 box-shadow-5-hover expand\"  style=\"border-radius:5px;\">\n\t\t<span>Want to learn more? Contact us for guidance on developing your FOD prevention program.<\/span>\n\t<\/a>\n\n\n\t<div id=\"gap-738050773\" class=\"gap-element clearfix\" style=\"display:block; height:auto;\">\n\t\t\n<style>\n#gap-738050773 {\n  padding-top: 30px;\n}\n<\/style>\n\t<\/div>\n\t\n\n<div class=\"row align-middle align-center\"  id=\"row-1478905702\">\n\n\n\t<div id=\"col-1338641561\" class=\"col medium-6 small-12 large-6\"  >\n\t\t\t\t<div class=\"col-inner\"  >\n\t\t\t\n\t\t\t\n\n\t<div class=\"img has-hover x md-x lg-x y md-y lg-y\" id=\"image_1467412492\">\n\t\t\t\t\t\t\t\t<div class=\"img-inner dark\" >\n\t\t\t<img decoding=\"async\" width=\"1600\" height=\"1303\" src=\"https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/Stock\/inspection.jpg\" class=\"attachment-medium size-medium\" alt=\"FOD Manufacturing\" srcset=\"https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/Stock\/inspection.jpg 1600w, https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/Stock\/inspection-768x625.jpg 768w, https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/Stock\/inspection-1536x1251.jpg 1536w, https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/Stock\/inspection-247x201.jpg 247w, https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/Stock\/inspection-510x415.jpg 510w\" sizes=\"(max-width: 1600px) 100vw, 1600px\" \/>\t\t\t\t\t\t\n\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t\t\n<style>\n#image_1467412492 {\n  width: 100%;\n}\n<\/style>\n\t<\/div>\n\t\n\n\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\n\t\n\n\t<div id=\"col-255034815\" class=\"col medium-6 small-12 large-6\"  >\n\t\t\t\t<div class=\"col-inner\"  >\n\t\t\t\n\t\t\t\n\n<h3 id=\"anchor-7\">Equipment &amp; Tools<\/h3>\n<p>Because aircraft have so many difficult areas to inspect and clean, specialized equipment and tools are necessary to assure a FOD free product. Some manufacturers rotate or shake the entire aircraft assembly at various stages to dislodge foreign objects, but a flashlight and mirror can only go so far. Specialized equipment is necessary to verify cleanliness.<\/p>\n<p>One of the most valuable tools to inspect and retrieve FOD is the borescope. This tool was originally developed to inspect within the human body but is now used in many industrial applications to perform inspections that otherwise would not be possible without dis-assembly or destruction.<\/p>\n<p>Numerous companies build borescopes that are ideal for aircraft inspection and cleaning. A wide variety of borescopes are available with specialized uses; some are designed for engine inspection, some have articulating tips with FOD retrieval capability and some are ideal for fuel cell inspection with explosion-proof lighting units.<\/p>\n\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\n\t\n\n<\/div>\n<p>It is important to consider the safety aspects of the area to be inspected before deciding on the borescope to be used. Never use a borescope on electrically powered circuits. It is recommended that aircraft batteries be disconnected if there is any chance of electrical contact or shorting. Not only can aircraft components and the borescope be damaged, but personal injury to the borescope operator is also possible.<\/p>\n<p>Limit the use of borescopes to those persons trained in the operation, maintenance and safety characteristics of the equipment. Borescopes are expensive and fragile; improper care or use can easily damage or destroy this valuable tool. It is recommended that borescopes be used only by the FOD Department personnel, who should keep the equipment under lock and key when not in use.<\/p>\n<blockquote>\n<p>It is one thing to locate FOD, it\u2019s quite another to remove it.<\/p>\n<\/blockquote>\n<p>Ingenuity is often required. Sometimes FOD cannot be removed and must be secured with sealant to assure it will not migrate or get loose. Long extension tubing can be affixed to a sealant gun to perform this operation.<\/p>\n<p>Other FOD inspection\/removal tools needed include pneumatic powered vacuum cleaners with extension suction tubes, mirrors, high intensity lights, magnets and a variety of \u201cFOD grabbers.\u201d<\/p>\n<h2 id=\"anchor-8\">Control Areas<\/h2>\n<p>Within the manufacturing environment, FOD controls vary with the type of work being performed.<\/p>\n<h3 id=\"anchor-9\">Three distinct\u00a0categories\u00a0of operation are evident:<\/h3>\n<ul>\n<li>Fabrication<\/li>\n<li>Assembly<\/li>\n<li>Checkout\/Test.<\/li>\n<\/ul>\n<p>Although all share the same key elements of control, each category differs enough to allow diversity within the control methods.<\/p>\n<p>Rules that apply to the flightline may not be practical in a backshop. For supervisors and workers to support the FOD Program,\u00a0<i>they need to understand the importance of the controls and acknowledge that they are reasonable\u00a0<\/i>given the work at hand.<\/p>\n<h3 id=\"anchor-10\">Fabrication<\/h3>\n<p>Often called \u201cbackshops,\u201d these are work areas such as sheet metal, machine shop, tubing and electrical harness. Typically, these shops do not have enclosed panels or components; therefore, FOD control is less critical than in other manufacturing areas.<\/p>\n<h3 id=\"anchor-11\">Assembly<\/h3>\n<p>These are areas where fabricated parts are put together and cavities are enclosed with fasteners or sealant. These areas require greater control and more frequent inspections and cleaning than Fabrication areas. All areas or panels \u201cclosed out\u201d should have a FOD buyoff (inspection) on the paperwork (documentation of process).<\/p>\n<h3 id=\"anchor-12\">Checkout\/Test<\/h3>\n<p>This requires the highest level of control because the product is in its final stages preceding delivery or flight. Assurances must be made that all personnel entering the work control area remove all loose\/unsecured personal items, e.g., watches, keys, jewelry and coins, and account for all tools and hardware carried near the product. A\u00a0tool\/ hardware inventory\u00a0form may be required in certain FOD-critical products or areas.<\/p>\n<p>It is important to clearly define the control areas so there is no question about which rules apply. Also, keep in mind that work \u201ctravels\u201d when not completed in its designated area. For example, a component not completed or available in assembly must be installed in checkout\/test. Typically, the worker who normally installs the component in assembly is the one who \u201ctravels\u201d to checkout\/test to install the part. Therefore, it is critical that all workers who may function in another control area be familiar with the FOD control requirements for any area in which they may work. Training, SOPs, signs and supervisors of each process must learn\u00a0<i>and support\u00a0<\/i>the differing rules for each control area.<\/p>\n<h3 id=\"anchor-13\">Key Elements<\/h3>\n<p>The key elements of FOD Prevention are universally accepted but applied in various ways throughout the aerospace industry. To cooperate with the control areas addressed above, each element must be dissected and articulately defined to allow clarity and ease of enforcement. The better defined, the better understood. The better understood, the better compliance.\u00a0<\/p>\n<p>Posters and other visual reminders should be used to promote the rules. Everyone working at the facility should know and understand the key elements\u2026 including security personnel.<\/p>\n<p>You know your FOD Awareness Program is working when a washer is retrieved from the shop floor and reported by an administrative clerk!\u00a0 The key elements are something to advertise. Don\u2019t keep them hidden in a procedure folder or meeting room.<\/p>\n<p>Plaster them on the walls, publish info bits in the company newsletter or on the intranet, make up or purchase FOD stickers to put on toolboxes and work benches, have poster contests, give recognition awards for compliance and do anything else you can think of to keep people focused.<\/p>\n<p>The key elements are easy to remember because they are so integrated within the manufacturing workplaces:\u00a0<i>Tool Control, Hardware Control, Product Protection\u00a0<\/i>and \u201cClean-As-You-Go.\u201d\u00a0 Keeping the rules simple is important. So is defining their specific applications, as you can see from the following Chart.<\/p>\n\n\t<section class=\"section\" id=\"section_1516596759\">\n\t\t<div class=\"section-bg fill\" >\n\t\t\t\t\t\t\t\t\t<div class=\"section-bg-overlay absolute fill\"><\/div>\n\t\t\t\n\n\t\t<\/div>\n\n\t\t\n\n\t\t<div class=\"section-content relative\">\n\t\t\t\n\n<div class=\"row row-large align-center\"  id=\"row-546079207\">\n\n\n\t<div id=\"col-857552862\" class=\"col medium-2 small-12 large-2\"  >\n\t\t\t\t<div class=\"col-inner text-right\"  >\n\t\t\t\n\t\t\t\n\n\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\n\t\n\n\t<div id=\"col-260697510\" class=\"col medium-10 small-12 large-10\"  >\n\t\t\t\t<div class=\"col-inner\"  >\n\t\t\t\n\t\t\t\n\n\t<div class=\"img has-hover x md-x lg-x y md-y lg-y\" id=\"image_133750126\">\n\t\t\t\t\t\t\t\t<div class=\"img-inner dark\" >\n\t\t\t<img loading=\"lazy\" decoding=\"async\" width=\"542\" height=\"648\" src=\"https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/forms\/FOD-Table.png\" class=\"attachment-original size-original\" alt=\"FOD Table\" srcset=\"https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/forms\/FOD-Table.png 542w, https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/forms\/FOD-Table-247x295.png 247w, https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/forms\/FOD-Table-510x610.png 510w\" sizes=\"(max-width: 542px) 100vw, 542px\" \/>\t\t\t\t\t\t\n\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t\t\n<style>\n#image_133750126 {\n  width: 75%;\n}\n<\/style>\n\t<\/div>\n\t\n\n<p class=\"lead\" style=\"padding-left: 240px\"><em>FOD Table<\/em><\/p>\n<p style=\"padding-left: 120px\"><strong>Letter Codes for the three control areas are:<br \/><\/strong><\/p>\n<p style=\"padding-left: 240px\">F = Fabrication<\/p>\n<p style=\"padding-left: 240px\">A = Assembly<\/p>\n<p style=\"padding-left: 240px\">C = Checkout<\/p>\n\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\n\t\n\n<\/div>\n\n\t\t<\/div>\n\n\t\t\n<style>\n#section_1516596759 {\n  padding-top: 30px;\n  padding-bottom: 30px;\n  background-color: rgb(193, 193, 193);\n}\n#section_1516596759 .section-bg-overlay {\n  background-color: rgba(255, 255, 255, 0.85);\n}\n<\/style>\n\t<\/section>\n\t\n<div class=\"row align-middle align-center\"  id=\"row-533090441\">\n\n\n\t<div id=\"col-1326758794\" class=\"col medium-6 small-12 large-6\"  >\n\t\t\t\t<div class=\"col-inner\"  >\n\t\t\t\n\t\t\t\n\n<h3 id=\"anchor-14\">Workplace Organization<\/h3>\n<p>FOD control in any manufacturing facility depends on a clean, well-organized work environment. Workers need\u00a0designated areas for tools, storage and cleaning equipment.<\/p>\n<p>Planning for efficiency may involve removing unnecessary items, relocating benches, equipment, storage units and toolboxes to facilitate smooth workflow and logical sequencing. Shop floors should be painted a light color to allow easy identification of dirt\/debris and also to facilitate cleaning. Designated spaces for cleaning equipment, trash containers, ladders, air hoses and toolboxes should be outlined and labeled on floors and walls.<\/p>\n<p>Believe it or not, some workers will claim that they didn\u2019t clean up because they couldn\u2019t find a broom. It is important to have everything returned to its place when the task is completed so that it can be found easily when needed.<\/p>\n<p>Signs that outline FOD controls for each work area should be prominently posted so no one questions the rules.\u00a0 Visibility boards to display FOD metrics, bulletins and awareness media should be staged in each work center so that workers have information and feedback related to performance and goals.<\/p>\n\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\n\t\n\n\t<div id=\"col-920749879\" class=\"col medium-6 small-12 large-6\"  >\n\t\t\t\t<div class=\"col-inner\"  >\n\t\t\t\n\t\t\t\n\n\t<div class=\"img has-hover x md-x lg-x y md-y lg-y\" id=\"image_494179992\">\n\t\t\t\t\t\t\t\t<div class=\"img-inner image-cover dark\" style=\"padding-top:100%;\">\n\t\t\t<img loading=\"lazy\" decoding=\"async\" width=\"1600\" height=\"1068\" src=\"https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/Stock\/bigstock-industrial-cutting-tools-in-fr-42312658.jpg\" class=\"attachment-medium size-medium\" alt=\"Tool Room\" srcset=\"https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/Stock\/bigstock-industrial-cutting-tools-in-fr-42312658.jpg 1600w, https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/Stock\/bigstock-industrial-cutting-tools-in-fr-42312658-768x513.jpg 768w, https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/Stock\/bigstock-industrial-cutting-tools-in-fr-42312658-1536x1025.jpg 1536w, https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/Stock\/bigstock-industrial-cutting-tools-in-fr-42312658-247x165.jpg 247w, https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/Stock\/bigstock-industrial-cutting-tools-in-fr-42312658-510x340.jpg 510w\" sizes=\"(max-width: 1600px) 100vw, 1600px\" \/>\t\t\t\t\t\t\n\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t\t\n<style>\n#image_494179992 {\n  width: 100%;\n}\n<\/style>\n\t<\/div>\n\t\n\n\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\n\t\n\n<\/div>\n<p>Many manufacturing companies have adopted the Five S\u2019s of Housekeeping as an aid for workplace organization. It is a concept that can be adapted to meet the needs and level of involvement desired. The following outline is one derivation that has been used successfully:<\/p>\n<h2 id=\"anchor-15\">The Five S\u2019s of Housekeeping<\/h2>\n<h3 id=\"anchor-16\">1. Sorting<\/h3>\n<p>The process of removing unnecessary items from the workplace.<\/p>\n<ol>\n<li style=\"list-style-type: none\">\n<ol>\n<li>Inspect the work area for excess or unneeded items. Document items to be removed, reorganized or replaced.<\/li>\n<li>Photograph work area for \u201cBefore and After\u201d visibility.<\/li>\n<li>Review the list and photos with all workers in the area to be reorganized. Get agreement from the majority on what is to be changed. Solicit ideas for improved workflow and order.<\/li>\n<li>Develop a new floor plan if necessary or desired.<\/li>\n<li>Tag items to be removed, repaired or replaced.<\/li>\n<li>Determine who will remove or dispose of items.<\/li>\n<li>Get agreement from management on the plan and forecast expenditures for improvements or purchases of new furniture, fixtures or tools.<\/li>\n<li>Implement the approved plan in phases to minimize work interference.<\/li>\n<\/ol>\n<\/li>\n<\/ol>\n<h3 id=\"anchor-17\">2. Standardizing<\/h3>\n<p>Identify uniform methods to maintain work areas<\/p>\n<ol>\n<li style=\"list-style-type: none\">\n<ol>\n<li>Designate areas for cleaning equipment, ladders, toolboxes, hoses, parts and support equipment. Areas should have signs or painted spaces on floors or walls. Provide necessary shelving or cabinets.<\/li>\n<li>Establish accountability rules for tool-crib-issued items to include expendables (sandpaper, rags, razor blades, etc.)<\/li>\n<li>Assure consistent application of rules\u00a0<i>on all shifts<\/i>. Incorporate housekeeping standards into training programs and workplace audits.<\/li>\n<\/ol>\n<\/li>\n<\/ol>\n<h3 id=\"anchor-18\">3. Simplifying<\/h3>\n<p>Provide specific, understandable directions, and procedures.<\/p>\n<ol>\n<li style=\"list-style-type: none\">\n<ol>\n<li>Review\/change existing procedures to assure workplace organization, cleanliness routines and tool accountability. Develop new procedures as necessary.<\/li>\n<li>Keep rules concise and displayed prominently.<\/li>\n<li>At crew meetings review areas needing improvement.<\/li>\n<\/ol>\n<\/li>\n<\/ol>\n<h3 id=\"anchor-19\">4. Sweeping<\/h3>\n<p>Establish routines\/requirements to maintain cleanliness.<\/p>\n<ol>\n<li style=\"list-style-type: none\">\n<ol>\n<li>Enforce \u201cClean-As-You-Go.\u201d<\/li>\n<li>Determine end-of-shift cleaning responsibilities and post schedules.<\/li>\n<li>Establish cleanliness checklists for each work area (include workstands, benches, floors and toolboxes).<\/li>\n<\/ol>\n<\/li>\n<\/ol>\n<h3 id=\"anchor-20\">5. Self-Discipline<\/h3>\n<p>Identify individual responsibilities.<\/p>\n<ol>\n<li style=\"list-style-type: none\">\n<ol>\n<li>Account for all tools and hardware at end of shift.<\/li>\n<li>Report missing items.<\/li>\n<li>Keep food and beverages out of work areas.<\/li>\n<li>Remove jewelry and personal items from clothing before going on\/into assemblies.<\/li>\n<li>Return cleaning equipment, drop-lights, power cords and protective mats\/pads to designated storage areas when tasks are completed.<\/li>\n<\/ol>\n<\/li>\n<\/ol>\n<div class=\"row align-middle align-center\"  id=\"row-702591969\">\n\n\n\t<div id=\"col-2080976224\" class=\"col medium-6 small-12 large-6\"  >\n\t\t\t\t<div class=\"col-inner\"  >\n\t\t\t\n\t\t\t\n\n\t<div class=\"img has-hover x md-x lg-x y md-y lg-y\" id=\"image_1936416436\">\n\t\t\t\t\t\t\t\t<div class=\"img-inner dark\" >\n\t\t\t<img loading=\"lazy\" decoding=\"async\" width=\"510\" height=\"340\" src=\"https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/Stock\/bigstock-worker-in-protective-uniform-c-42755299-510px-1.jpg\" class=\"attachment-large size-large\" alt=\"FOD Control\" srcset=\"https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/Stock\/bigstock-worker-in-protective-uniform-c-42755299-510px-1.jpg 510w, https:\/\/www.fodcontrol.com\/wp-content\/uploads\/Content\/Stock\/bigstock-worker-in-protective-uniform-c-42755299-510px-1-247x165.jpg 247w\" sizes=\"(max-width: 510px) 100vw, 510px\" \/>\t\t\t\t\t\t\n\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t\t\n<style>\n#image_1936416436 {\n  width: 100%;\n}\n<\/style>\n\t<\/div>\n\t\n\n\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\n\t\n\n\t<div id=\"col-251185693\" class=\"col medium-6 small-12 large-6\"  >\n\t\t\t\t<div class=\"col-inner\"  >\n\t\t\t\n\t\t\t\n\n<h2 id=\"anchor-21\">The Customer<\/h2>\n<p>Ultimately, the judge of your FOD Program will be the customer.&nbsp;<a href=\"https:\/\/www.fodcontrol.com\/fod-program-resources\/forms-and-templates\/customer-feedback-form\/\">Solicit feedback<\/a>&nbsp;by requesting them to identify any foreign objects found in the delivered product and the exact location or zone. Provide a&nbsp;<a href=\"https:\/\/www.fodcontrol.com\/fod-program-resources\/forms-and-templates\/corrective-action-plan\/\">corrective action response<\/a>&nbsp;to demonstrate that you are attentive to their needs; specify what has been implemented to eliminate the error from future deliveries. With all deliveries, include missing item reports for any items not found or retrieved during the entire manufacturing process.<\/p>\n<p>Invite the customer to visit the factory on a regular basis. Communicate the importance of keeping FOD out of the product. Workers&nbsp;<i>sometimes lose sight of the fact that the work they perform everyday has serious implications&nbsp;<\/i>related to quality, safety and reliability. Reminders, especially from the customer, are usually well received and understood.<\/p>\n\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\n\t\n\n<\/div>\n<p>The \u201ccustomer\u201d concept works well to control FOD in-house before it gets to the\u00a0<i>final\u00a0<\/i>customer. Develop this by using promotional and awareness training sessions to build a \u201ccustomer focused\u201d culture within your manufacturing facility. Each work center or department should consider themselves the \u201ccustomer\u201d of the preceding department. As the component or assembly moves from one work center to another, it then receives a FOD check before leaving, and another acceptance FOD check at the receiving \u201ccustomer\u201d work center. Items found by the receiving unit\u2019s inspection should be documented and reported to the sender for corrective action. The report should also be forwarded to the Manufacturing Manager and the FOD Program Manager who will monitor the timeliness and effectiveness of the corrective measures. Work centers that do not find FOD in their acceptance inspections are then responsible for any FOD found by their customer down the line. Work centers with the best customer deliveries should be recognized in some formal way monthly and group awards given to the best work center of the year. This approach to FOD Prevention not only controls FOD, it creates a competitive, team-focused environment of building quality products.<\/p>\n<h3 id=\"anchor-22\">Quality<\/h3>\n<p>\u201cQuality\u201d is the buzzword that implies reliability, integrity, safety and customer satisfaction. Without an effective FOD Control Program in the manufacturing arena, the product will not meet quality standards. Eventually sales will fall, contracts will be lost or not awarded and accidents\/incidents become more likely. Achieving quality is not easy but every effort must be made to get there. As one company achieves higher quality, the challenge is greater for all others, and so the race continues <i>to everyone\u2019s benefit<\/i>.<\/p>\n<p>Don\u2019t be left behind. Jump on the Zero FOD bandwagon and don\u2019t accept anything less. Remember: FOD can\u2019t be inspected out at the end of the line\u2026 processes must be in place throughout the entire build cycle to assure that it doesn\u2019t get in.<\/p>\n\t<div id=\"gap-1540777286\" class=\"gap-element clearfix\" style=\"display:block; height:auto;\">\n\t\t\n<style>\n#gap-1540777286 {\n  padding-top: 30px;\n}\n<\/style>\n\t<\/div>\n\t\n\n<a href=\"https:\/\/www.fodcontrol.com\/contact-us\/\" class=\"button alert is-shade box-shadow-3 box-shadow-5-hover expand\"  style=\"border-radius:5px;\">\n\t\t<span>Want to learn more? Contact us for guidance on developing your FOD prevention program.<\/span>\n\t<\/a>\n\n\n\t<div id=\"gap-457355404\" class=\"gap-element clearfix\" style=\"display:block; height:auto;\">\n\t\t\n<style>\n#gap-457355404 {\n  padding-top: 30px;\n}\n<\/style>\n\t<\/div>\n\t","protected":false},"excerpt":{"rendered":"","protected":false},"author":287,"featured_media":12086,"parent":0,"menu_order":1,"comment_status":"closed","ping_status":"closed","template":"","meta":{"om_disable_all_campaigns":false,"footnotes":""},"class_list":["post-12432","page","type-page","status-publish","has-post-thumbnail","hentry"],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v23.0 (Yoast SEO v25.4) - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>FOD Prevention in Manufacturing: Procedures &amp; Controls<\/title>\n<meta name=\"description\" content=\"Improve product quality and worker safety in your manufacturing facility with our expert guide. 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