3-27. Foreign object damage (FOD) program for maintenance operations is a basic requirement for all Army aviation units and will improve operational efficiency, provide for a safer operating environment, and reduce maintenance down time. Personnel who operate, maintain, or service aircraft or aviation GSE are responsible for adhering to the commander’s FOD program. FOD accidents are an unacceptable impediment to Army operations. The FOD officer and NCOIC, placed on orders by the commander, ensure compliance with applicable regulations, SOPs, and manuals. Utilizing the ARMS checklist assists the FOD program leadership in validating each performance measure of the program.
Note. DA PAM 385-90 contains guidance on developing a FOD program and FOD prevention
SOP.
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AUSES3-28. FOD is damage to or malfunction of an aircraft caused by an object that is alien to an area or system or is ingested by or lodged in a mechanism of an aircraft. FOD may cause material damage, or it may cause a system or equipment to become unusable, unsafe, or less efficient. Some examples of FOD are—
z Ingestion of loose hardware or grass by an engine.
z Flight controls jammed by hardware or tools.
z Tires, skids, propellers, or tail rotors damaged by debris on the ramp or taxiway.
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REVENTIONM
EASURES3-29. The objectives of a FOD prevention program are to find and correct potential hazards and to eliminate the causes of FOD. Training, work-site design, discipline, motivation, and follow-up on FOD incidents are essential factors of a sound program. All personnel must take an active role in FOD prevention. FOD prevention must be an essential part of each unit aviation accident prevention program. 3-30. The unit FOD prevention program is documented in writing and must be read by all unit personnel. FOD prevention countermeasures should also be integrated throughout the unit SOP.
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ESPONSIBILITIES3-31. FOD programs must be enforced, observed, and practiced daily. Commanders at all levels are responsible for enforcing FOD programs. They rely on their unit aviation safety officer (ASO) (when assigned), FOD officer/NCO, and unit personnel to make the FOD program effective.
Unit Commander
3-32. When establishing a FOD prevention program, commanders will appoint a FOD prevention officer/NCO to implement the unit FOD prevention program. This may be an additional duty for any unit officer/NCO other than the ASO/aviation safety noncommissioned officer or the aviation maintenance officer.
Unit Foreign Object Damage Officer/Noncommissioned Officer
3-33. The FOD officer/NCO will track scheduled FOD inspections and investigate all known and suspected FOD damage. He monitors the unit tool accountability program, maintains surveillance for unsatisfactory FOD conditions, and takes corrective action immediately. He will delegate specific areas of responsibility (such as a hangar or shop/maintenance work area) to appropriate unit personnel.
3-34. The FOD officer/NCO conducts surveys and documents results (minimum once per month) and inspects all unit areas. He notifies the unit ASO of hazards found during surveys for analysis and control option development. The FOD officer/NCO ensures FOD inspection checklists cover, as a minimum, procedures outlined in the unit FOD SOP. He uses the checklist for each inspection and submits the completed checklist to the unit ASO. Table 3-1 provides a sample unit FOD inspection checklist.
Table 3-1. Sample unit FOD inspection checklist
Biweekly FOD Inspection Checklist SAT UNSAT
1. Are maintenance personnel practicing FOD control procedures IAW unit SOP? 2. Do maintenance personnel conduct a tool inventory after maintenance procedures are complete or at the end of the day?
3. Do NCOs conduct regularly scheduled checks of work areas to ensure FOD prevention measures are observed?
4. Are equipment and material not in use kept clear of maintenance areas?
5. Is equipment available to keep runways, taxiways, hover lane, and parking areas clean? 6. Are runways and other areas normally used for hover and ground operations inspected regularly?
7. Where practical, are inspections made of all landing areas to determine FOD potential? 8. Are all personnel periodically briefed on FOD and prevention techniques?
9. Do aircrews and operating personnel report unsatisfactory conditions when first encountered?
Biweekly FOD Inspection Checklist SAT UNSAT
10. Is the unit receiving United States Army Combat Readiness Center (USACRC) publications and posters on FOD?
11. Do unit bulletin boards contain information on FOD? 12. Do work areas have FOD posters displayed?
13. Are FOD containers with locally manufactured “STAY SHUT” lids conveniently located around the hangar area?
14. Are FOD containers prominently labeled?
15. Are the tools accounted for after the work is completed?
16. Are maintenance personnel familiar with the FOD prevention program in the unit? 17. Are operational hazard reports (OHRs) being submitted on FOD problems when encountered?
18. Are the inlet and outlet covers used when required?
19. Are all crewmembers and maintenance personnel motivated and committed to FOD prevention?
20. Are tool room personnel monitoring tool accountability and serviceability of tools?
Unit Aviation Safety Officer
3-35. The unit ASO (when assigned) will monitor and survey the FOD program to ensure effectiveness and adherence. Whenever possible, the unit safety officer attends unit safety meetings to address potential FOD problems, prevention, or investigations. The unit safety officer briefs new personnel on their responsibility for FOD prevention and keeps the commander and FOD officer/NCO informed on FOD issues.
Unit Maintenance Personnel
3-36. Unit personnel must take an active role in FOD prevention and be responsible and accountable for actions taken when performing aircraft maintenance. Unit personnel will use the “clean-as-you-go” approach to maintenance, making a thorough check of the area after each task is completed.
3-37. Maintainers will ensure aircraft openings (such as ports, lines, holes, and ducts) are properly protected to keep foreign objects from accidentally entering and ensure tools, hardware, and other equipment are accounted for at the end of each maintenance operation. Inspect equipment before use to ensure it will not cause damage. Ensure care is taken when installing any piece of test equipment.
3-38. Unit maintenance personnel will check engine inlet screens for loose, trapped, or broken objects that may produce FOD. When in doubt, they will immediately report FOD and potential FOD to the first-line supervisor. Unit personnel will place all residues and objects that may produce FOD in the proper container.
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ROCEDURES3-39. When an aircraft ingests foreign objects or fluids, FOD has occurred. Assigned personnel will ensure the following hazards are avoided during all aspects of aviation maintenance operations:
z Grease on work shoes/boots – FOD can lodge in the grease and transfer to the aircraft or GSE. z Litter – police litter (such as nuts, bolts, cotter pins, safety wire, and rivets) in the work areas to
minimize or eliminate the potential of damage to the aircraft, GSE, or personnel.
z Jewelry – ensure no jewelry (such as rings, watches, identification. tags, and pin-on rank) is worn during maintenance, inspections, and servicing of aircraft and GSE.
Investigation and Reporting
3-40. FOD hazards are reported through the OHR or accident investigation system. These data should be communicated to first-line supervisors, to the FOD officer/NCO, and ASO for immediate resolution. If there is a question about whether potential or suspected FOD hazards need to be reported, report it. The FOD officer/NCO/ASO will assist unit personnel in selecting an appropriate course of action.
Foreign Object Prevention in Maintenance Areas
3-41. Once the air inlet and compressor sections have been removed for maintenance, they are inspected before they are reinstalled. Unit TI will conduct inspections of the air inlet and compressor sections before installation of said components. Engine inlet covers are on all aircraft at all times unless the aircraft is being inspected or the engine inlet or exhaust area is being worked on.
3-42. Bolts, nuts, rivets, fasteners, screws, washers, safety wire, and other residue are disposed of in receptacles marked for FOD materials. These receptacles should be conspicuously placed on the flight line and in the hangar. Tools and supplies are accounted for upon completion of maintenance actions to prior to MOCs/MTFs.
3-43. Oil spills and grease spots are cleaned up immediately after they occur and reported to the spill response team for evaluation. Enforcing this policy will reduce accidents in maintenance areas.
Foreign Object Damage Walk Procedures
3-44. FOD walks are mandatory; maximum participation is encouraged to include all available crewmembers (aviators and crew chiefs). All FOD containers are emptied and FOD collected at the completion of the unit FOD walks.