Columbus Engine Center Driving F'O'D' Prevention

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Columbus Engine CenterDriving F.O.D. Prevention

• Presented by
• George Truitt
• Rene Crowder

United Technologies Corporation, Pratt Whitney
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V2500 Engine Maintenance Facility

• Location
• Columbus, Georgia
• 90 miles south of Atlanta
• Pop approx. 250K
• Site
• 340 Acre Campus
• Opened in 1984
• 770,000 Total Sq. Ft.
• Columbus Engine Center
• V2500 Overhaul
• 150,000 Total Sq. Ft.
• 298 Employees

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V2500 Engine Maintenance Facility
22K 32K Thrust Rating
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Session Overview

• FOD Prevention
• Driving FOD Prevention
• 25th National FOD Conference Influences
• FOD Prevention Initiatives

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FOD Prevention

• Why Are We Here?
• Leveraging Best Practices
• Knowledge Sharing
• Program Building
• Benchmarking
• FOD Event
• Other

Dont let FOD prevent you from supporting your
customer!
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FOD Prevention is Like
Driving a Car!

• Point A to Point B
• Awareness
• Controls

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25th National FOD Prevention Conference Influences
What would it take for Management to support and
even participate in your FOD Program?

• Leadership is the Key to Driving FOD Prevention
• Track Sessions
• Interactive Learning Sessions
• Networking
• Exhibits
• Tour Events
• Third Party Assessment

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FOD Prevention Initiatives

• Training
• FOD Council
• FOD Coordinator
• Tool Controls
• Work Bolt Accountability
• Blanking Projects
• FOD Alerts
• Assessments
• Metrics
• FOD Posters
• Incentives
• Policies and Procedures

Time, Money, Commitment
Pay Now or Pay Later
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Training

• Bi-Annual FOD Awareness Training
• Facility Maintenance FOD Training
• FOD Awareness Training for Contractors

Our Focus is to Create a FOD-Free Working
Environment
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FOD Council Employee Involvement is Key
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FOD Coordinator

• On Patrol Driving
• Assessments
• Project Teams
• Metrics
• Benchmarking
• Training

• Qualifications
• Passionate
• Dedicated
• Knowledgeable
• Vigilant
• Persistent
• Creative
• Team Player
• Dog Owner

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Tool Controls

• No Personal Tools
• Visual Accountability
• Accountability Forms
• Tool Control Assessments
• Missing Tool Reporting Procedures
• FOD-Proof Tooling

Columbus Engine Center Custom Design
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Opportunities Work Bolt Controls
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Work Bolt Controls

• Visual Accountability
• Tool / Hardware Color Coding
• Storage Containers
• Descriptive Labeling

Descriptive Labeling
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Open Cavities
Opportunity
Solution
Working to Change the Way We View FOD Prevention
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Blanking Hardware Free / Total Closure
Opportunity
Solution
HPT MODULE
DIFFUSER CASE
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Blanking Kits Custom Designed Covers
Opportunity
Solution

• Benefit
• Elimination of covers requiring hardware
• Total closure of cavities
• Supplier
• Universal Plastics

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Covers
Opportunity
Solution
LPT STAND
FAN CASE MODULE
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Parts Protection
Opportunity
Solution

• Opportunity
• IDG Shaft unprotected
• Solution
• Designed Blanking Cover for IDG Shaft
• No hardware required

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Caps and Plugs
THINK Out-of-the-Box
Dont let your cap become FOD
Eliminated 60 of Cap and Plug Usage
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Repair Kits
Opportunity
Solution

• Expect resistance
• Repair activities are not exempt
• Engage and challenge

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Repair Shops

• Consumable Record
• Allows tracking of consumables

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FOD Alerts
Pneumatic Air Wrench
Detail that migrated
RTV applied to preclude migration
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FOD Critical Areas

• Only materials used to support the build process
  may enter the posted FOD CRITICAL AREA
• Shop Signs / Posters / Floor Markings
• Apply to work benches, areas or cells where the
  highest level of FOD prevention measures are
  required

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FOD Posters Promoting Awareness
Got Tools ?
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FOD Audits

• Derived categories from FOD Prevention Handbook
  and Quality Audit checklist
• Six FOD Risk categories
• Parts Protection
• Housekeeping
• Hardware Accountability
• Tool Controls
• Policy and Procedures
• Repeat Findings

Accurate Data Thorough Analysis Effective
Action
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FOD Metrics
2005 Top Three Goals

• Setting targets and meeting goals
• Mapping our journey

SAMPLES
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Incentives

• Awards / Recognition
• Eagle Award
• Appreciation Award
• Verbal Recognition
• Ownership

Doris Thornell receives Pratt Eagle Award for
designing V2500 FOD Cover
ELVIS the FOD HOG
Motivation Customer Satisfaction Job Security
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COLUMBUS ENGINE CENTER
Q U E S T I O N S