Transcript No Slide Title

FOE Implementation
Basic Process
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FOE IMPLEMENTATION
PROCESS FLOWCHART
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FOE Implementation
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 FOE Area
Control Level
Assessment
Perform FOD Area
Sweep Checklist
Daily (Med/High)
Verify External
Signage for
Correct FOD
Control Level
Perform FOD Area
Monthly SelfAssessment
Checklist (Med/High)
Verify Training
Requirements
Perform Material
Control
(Med/High)
Set Up FOD
Metrics
Perform Tool
Control
(High)
Check Applicable
Requirements
Follow Incident
Reporting
Flowchart if FOD
is Found
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FOE AREA
CONTROL LEVEL ASSESSMENT
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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
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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
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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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FOD Incident Reporting
Metric
 Standard Reporting Metric (Must be updated monthly and posted):
Monthly & Cumulative To Date FOD Incidents
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Total FOD Incidents
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Cumulative To Date (CTD)
Total FOD Incidents
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3 per. Mov. Avg. (Total FOD
Incidents)
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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
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FOD Incident Reporting
Metric
 FOD Metric Chart Input Data Table (Example Only):
A
B
C
D
Metric Chart Input Data Worksheet
E
F
 Manually loaded using data
from monthly data sheets
Month
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
Foreign
Object
Debris
0
0
0
2
1
0
2
1
0
0
0
0
Foreign
Total
Object
FOD
Damage Incidents
0
0
1
0
2
0
0
0
1
0
0
3
0
0
1
2
3
0
2
1
1
0
0
3
CTD
Totals
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7
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Cumulative
Cumulative
To Date
To Date (CTD)
(CTD)
0
0
1
3
6
6
8
9
10
10
10
13
13
 Can automate for a specific
area if desired
<copy cell E4 to
desired row in col. E
to copy formula>
<update cell F15 for
current CTD>
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FOD Incident Reporting
Metric
 FOD Metric Monthly Data Sheet (Example Only):
Jan
#
1
Date
Description
Describe Incident Here
Foreign
Object
Debris
Foreign
Object
Damage
0
0
Recorded
By
Disposition/Correction Action
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3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
0
0
23
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FOE CONTROL AREA
IDENTIFICATION
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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
Overall Area
Sub-Areas
Medium
LOW
High
Overall Area
Apply Note for
Sub-Areas
Medium
FOE Focal Point is responsible to ensure proper area identification
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FOE Control Area
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
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Internal Signage
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DAILY FOE AREA SWEEP
CHECKLIST
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FOE Area Sweep Checklist
Daily FOE Area Sweep Checklist
Checklist Timing: 10 Minutes Average
Bldg/Room/Sub-Area
Work Area Name:
Cost Center
What to Sweep
Frequency per Shift
(Working Shifts Only)
Tables and workbenches are free of FO (materials,
1 tools, etc.). These are items not required for the inprocess activity.
Once
2 Floor and ceiling is free of debris.
Once
3 Test Equipment is free of debris.
Once
4
Equipment (carts, trash cans, etc.) are returned to
designated location.
Once
5
Unused tools are returned to proper location (i.e.,
toolboxes and/or shadow boards).
Once
Hardware is covered/stored properly and safe
6 of FOD risk (any openings, ports, holes, and
ducts are covered) when not in use.
Once
8
Hardware is safe from small items, consumables or
other materials that may create a FOD risk.
Once
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Tool Log Sheets are properly filled out if being
used.
Once
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Areas are properly identified and marked off if
multiple FO Control Levels are present.
Once
For the Week Beginning Monday,
M
T
W
T
F
S
S
Comments
 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
Material Control Checklist
 Consumables too large to be lost Product:
Operation No:
or impractical to count can be
accounted for using visual
confirmation (examples include
Kimwipes, tape, glue)
Material
Check-In to Area
Check-Out of Area
Info filled in by the User
Info filled in by the User
Qty
Emp #
Qty
Emp #
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
Controlled Perimeter Tool Checklist:
Recommended Form - May be Tailored to Site/Area Specific Requirements
Controlled Perimeter Tool Checklist:
Tool Description (# of items)
Check-In to Perimeter
Check-Out of Perimeter
Info filled in by the User
Info filled in by the User
Date:
Month/Day
Emp #
Date:
Month/Day
Emp #
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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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Incident Reporting
FOD Incident Reporting Process
Employee
FOD Incident Reporting Process Flow
FOD Incident
Notify Area
Supervision
and Quality
Notify FOE
Focal Point
Foreign Object
Damage or Debris?
Debris
Supplier
Supply Chain
Mgt.
Quality
FOE Focal
Point
Damage
In-house or Supplier
Caused?
Document Incident
in Quality History
Record
Disposition and
closeout
Supplier
Debris found in
High FOD Control
Level Area?
No
Yes
In-house
Prepare RCCA
action and
complete for
closure
Investigate and
perform corrective
action as required
Discuss incident at
team meetings
Complete RCCA
response for
closure
Prepare RCCA
action
Prepare Defect
Report to supplier
Find root cause
and corrective
action
Review and
approve
response and
prepare response
Prepare response
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