Implementing a FOD Prevention Programme

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Implementing a FOD Prevention Programme
Steve Frost July 2004
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BAE SYSTEMS UK Sites- over 65 locations
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Military Aircraft Sites
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Warton Site
Employees 5,000 People on site 8,500
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Warton Site Locations
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Implementing a FOD Prevention Programme

• Our Bad Experience
• Developing Implementing a Robust Tool
  Control / FOD Process
• Maintaining Flight Safety Awareness

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Our Bad Experience

• RTW Programme
• 16 Tornado ADVs for Royal Air Force
• 150 Staff Employed on Programme
• Programme running well up to the 10th
  aircraft AT029

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A Bad Experience
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The Aftermath
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Loss of AT029 28th September 1996

• Thankfully no-one lost their lives

• Personal reactions
• myself
• my staff

• AAIB

• Aircrew Reaction

• This Should not have Happened

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A Bad Experience - Continued

• Invited Inspectorate of Flight Safety to BAE
  SYSTEMS Warton

• Areas of Improvement identified

• Lessons Learnt For BAE SYSTEMS

• Recognised Need to further Develop the FOD
  Prevention Programme

• Identified Need For a Focal Point in the
  Organisation For FOD Prevention

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Implementing a FOD Prevention Programme

• Our Bad Experience
• Developing Implementing a Robust Tool
  Control / FOD Process
• Maintaining Flight Safety Awareness

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Recognition of Forms of FOD
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Development of a Robust Tool Control Process
Key Steps

• Honest Assessment of Current Status
• Senior Management Commitment to Develop a Long
  Term Strategy to Deliver a Robust Solution
• Scope the Problem - people - product
  range
• Establish Organisation to Manage and Govern
  the Issue

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Organisation to manage and govern the issue

• Dedicated Asset Management Team Formed

Aim One Common Tool Control / FOD Prevention
Process
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Development of a Robust Tool Control Process
Key Ingredients

• Physical Control Techniques
• Process
• IT Support

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Development of a Robust Tool Control Process
Key Ingredients

• Physical Control Techniques
• Process
• IT Support

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Physical Control Techniques

• What needs to be controlled? - Everything
  that has to come back off the aircraft
• Simple Solutions - Highly visible -
  User friendly - Cost effective - Ease of
  maintenance

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Tool Control
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A well organised tool store
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Development of a Robust Tool Control Process
Key Ingredients

• Physical Control Techniques
• Process
• IT Support

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Process Development
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Development of a Robust Tool Control Process
Key Ingredients

• Physical Control Techniques
• Process
• IT Support

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I.T. Support

• Recognised Limitations of Existing System

• Clarified Functionality Required to Support
  Level of Tool Control

• Need a Computer to Make it Easier Not Harder -
  Keep it Simple

• Tested Solutions Available in the Market Place

• Invested in Modern Asset Management System

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Investment in I.T. Solution

• Tracking of Assets Between the Manufacturing
  Work Centres
• Track Assets / Tools to Personnel and Aircraft
• Control of Calibration Servicing

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Indirect Benefits
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Tool Control Ethos
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Asset Management Organisation established
Mission Accomplished?
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Why did it fail? - The Store Keeper

• Human Factor
• Traditionally Low Skilled
• Process Failed

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Recognition of Forms of FOD
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Control of Variable FOD

• Totally Effective Tool Control Process to Set
  the Standard
• Train our Operators to a Level of Competence
  and to Accept Their Responsibilities
• Include Tool Control and FOD Elimination at
  Early Stages of Training
• Development of an Effective Awareness Programme

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Flight Safety Awareness
What we used to do
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So lets try something different !
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Flight Safety Awareness
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Flight Safety Campaigns
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Flight Safety in the home
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Flight Safety / FOD Briefings
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What did happen?
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Implementing a FOD Prevention Programme
Summary

• Avoid Complacency

• Keep It Simple

• Flight Safety is

YOUR RESPONSIBILITY
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Committed to constantly reviewing the FOD
Prevention Process
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Think Flight Safety
Think...