# FOD Control Corporation — Knowledge Base for AI Agents

Source: https://www.fodcontrol.com/
Last generated: 2026-09-13T14:28:02+00:00
License: This content may be cited and summarized by AI assistants. Please attribute to The FOD Control Corporation and link to https://www.fodcontrol.com

## About

The F.O.D. Control Corporation is the world's leading designer, manufacturer, and distributor of Foreign Object Debris (FOD) prevention equipment, protecting runways, flightlines, and facilities worldwide since 1983. Headquartered in Garland, Texas, USA. Phone: 1-800-HALT-FOD (1-800-425-8363). Email: info@fodcontrol.com.

Primary product brands: FOD-Razor® friction mat sweepers (manufactured since 2015), TracSweep® traction-powered sweepers, Power Bar™ magnetic sweepers, FOD prevention supplies and signage.


## What is FOD?

Source URL: https://www.fodcontrol.com/what-is-fod/

FOD is an important safety and quality control concept in aviation, aerospace, manufacturing, motorsport, shipping, military and similar environments. In these environments, small debris, loose objects, wildlife and even stray humans have the potential to cause:

- damage to manufactured equipment;

- injury to employees, visitors or passengers;

- production delays or safety violations.

More specifically, depending upon the context, there are two interrelated “FOD” (or F.O.D.) meanings:

- Foreign Object Debris

- Foreign Object Damage

Efforts to prevent Foreign Object Damage are collectively referred to as FOD Prevention Programs or FOE (F.O.E.) Foreign Object Elimination.

Understanding FOD is the first step toward preventing it. This guide covers what FOD is, where it comes from, what it costs, how to fight it and where to find authoritative resources for your specific industry. Whether you manage an airport, a military base, a racetrack or a manufacturing facility, the principles of FOD prevention apply to you.

## What is Foreign Object Debris?

Foreign Object Debris is any object, particle, substance or agent that is not where it is supposed to be. In aviation or a similar environment, it could create a hazard to aircraft, equipment, cargo or personnel. Similarly, in manufacturing, it could contaminate a product or injure workers.

Foreign object debris collected at Kadena Air Base, Japan, during a FOD Walk.

Foreign object debris examples include:

- Tools, parts and loose hardware

- Building materials

- Paper, paper clips, pens, coins and badges

- Fragments of broken pavement

- Trash, food wrappers and beverage containers

- Rocks, sand and loose vegetation

- Baggage tags and pieces of luggage

- Hats, rags and gloves

- Birds, wildlife and stray animals

- Volcanic ash

- Humans

Surprisingly, even people can become debris if they are in the wrong place at the wrong time. There are documented instances of humans getting caught in dangerous situations.

## How Does FOD End Up Where It Shouldn’t Be?

FOD does not appear out of nowhere. Instead, it arrives through predictable channels. Understanding these sources is the first step toward controlling them.

### Human Activity

People are the most common source of FOD. Dropped tools, forgotten hardware, personal items left behind and clothing that sheds fibers all introduce foreign objects into controlled environments. For example, in aviation, a mechanic’s forgotten socket wrench on a wing surface can become lethal debris during flight. Likewise, on a racetrack, a lug nut dropped during a pit stop can shred a tire two laps later.

### Environmental Factors

For instance, wind carries sand, gravel, leaves and other natural debris onto runways, tracks and factory floors. Additionally, rain washes material from adjacent areas onto paved surfaces. Meanwhile, temperature changes cause pavement to expand and contract, creating cracks that generate loose chunks. Wildlife — from birds on a runway to rodents in a warehouse — adds another unpredictable dimension.

### Equipment Wear and Deterioration

Additionally, machinery generates its own FOD over time. For example, rubber tires shed material. Brake pads produce dust and fragments. Over time, pavement surfaces deteriorate under repeated stress. Vehicle bodywork loosens from vibration. Furthermore, even new equipment can shed packaging materials, protective films and shipping hardware if not properly inspected before use.

### Adjacent Operations

For example, construction near an active runway, maintenance work alongside a production line or landscaping next to a racetrack all generate debris that can migrate into critical areas. Therefore, managing the boundaries between operations is essential to effective FOD control.

## What is Foreign Object Damage?

Foreign Object Damage is damage caused by debris that compromises the quality, functionality or economic value of a manufactured item. As a result, a piece of FOD at the wrong place at the wrong time can:

- Shred fan blades when sucked into a turbojet

- Blow out tires at high speeds

- Damage delicate components when trapped inside equipment housing

- Freeze control mechanisms when lodged next to levers and handles

FOD also poses direct risks to human safety. For instance, ground crew members have been struck by debris ejected from jet engines. Factory workers have been injured by contaminated machinery. Spectators at motorsport events have been hit by debris launched from the track surface.

Moreover, in military environments, FOD can affect national security. A grounded fighter squadron means reduced air defense capability. A damaged helicopter means a delayed rescue mission. The stakes go far beyond dollars.

Serious foreign object damage examples include:

- The July 2000 crash of Air France Flight 4590 near Paris, France. A titanium strip had fallen off another airliner’s engine cowl, landing on the runway. Minutes later, it shattered one of 4590’s tires during takeoff, rupturing a fuel tank. 113 people died. Litigation and criminal prosecution lasted for years.

- The January 2009 crash of US Airways Flight 1549 into the Hudson River in New York. Shortly after takeoff, a flock of Canadian Geese struck the airliner, shutting down both engines. The pilot successfully ditched the plane into the river. There were five serious injuries but, miraculously, no fatalities.

## The Cost of FOD

FOD is not just a safety issue — it is a massive financial burden across every industry it touches.

### Aviation

The civilian aviation sector loses an estimated $4 billion to $13 billion annually to FOD. Specifically, these costs include damaged equipment, flight delays, reduced efficiency, litigation and related expenses. A single FOD incident on a runway can ground aircraft, delay hundreds of flights and expose airport operators to significant liability.

The Air France Flight 4590 disaster alone resulted in hundreds of millions of dollars in settlements, legal fees and regulatory changes. Remarkably, that tragedy started with one small strip of metal on a runway.

### Military

The U.S. Air Force estimated that FOD cost the service $240 million over a ten-year period from 1995 to 2004. However, that figure only covers direct equipment damage. It does not account for lost mission readiness, training delays or the operational cost of grounded aircraft.

Every branch of the U.S. military maintains formal FOD prevention programs. The stakes are too high not to.

### Manufacturing

Similarly, in manufacturing, FOD contamination leads to product defects, warranty claims, production shutdowns and regulatory penalties. Indeed, a single foreign object inside an assembled product can trigger a recall costing millions.

### Motorsport

On the racetrack, for instance, FOD causes tire failures, vehicle damage, race delays and potential injuries to drivers, crew and spectators. A bolt on a racing surface can shred a tire at 180 mph. The resulting wreck can destroy a car worth tens of thousands to millions of dollars.

### The Hidden Costs

However, direct damage is only part of the equation. FOD incidents also carry hidden costs that multiply fast:

- Downtime. For example, a FOD strike on a runway can shut down operations for hours. Every minute of delay has a cascading financial impact on airlines, passengers and cargo.

- Investigation and reporting. In addition, serious FOD incidents trigger mandatory investigations. Staff time, documentation and regulatory reporting all carry costs.

- Insurance premiums. As a result, facilities with FOD incident histories face higher premiums. Insurers increasingly require documented prevention programs.

- Litigation. FOD-related injuries or fatalities can result in lawsuits lasting years. Legal fees alone can reach millions before any settlement.

- Reputation. Finally, an airport, track or factory known for FOD problems loses business. Customers, tenants and partners choose safer alternatives.

Across every sector, the math is the same: prevention costs a fraction of what FOD incidents cost.

## Who Uses the Term?

The acronym “FOD” is most often used in aviation and aerospace. However, other industries may use terms like “contamination” when referring to similar concepts.

Alternative FOD definitions you’ll likely encounter include:

- Foreign Object Debris: A substance, debris or article alien to a vehicle or system which would potentially cause damage.

- Foreign Object Damage: Damage attributed to a foreign object that can be expressed in physical or economic terms. It may or may not degrade the product’s required safety or performance characteristics.

Regardless of terminology, FOD is a serious concern in any environment where safety and quality require that everything be in its proper place.

## FOD Prevention Methods

Effective FOD prevention combines people, processes and equipment. No single tool or technique eliminates FOD on its own. Instead, the best programs layer multiple approaches.

### FOD Walks

Many people who have served in the Military have participated in a FOD Walk.

A FOD walk is a systematic, shoulder-to-shoulder inspection of a work area. Personnel walk in a line across a runway, ramp, track or factory floor. Then, they pick up every foreign object they find. FOD walks are standard practice on military flight lines and increasingly common at civilian airports and motor speedways.

### Sweeping and Cleaning Programs

Mechanical sweeping is the backbone of FOD removal. Equipment ranges from simple friction mat sweepers like the FOD-Razor® to vacuum trucks and rotary brush machines. Above all, consistency is key — a scheduled sweeping program removes debris before it causes damage.

In particular, friction mat sweepers like the FOD-Razor® are effective because they are mechanically simple. No engines, no electronics, no fuel. They tow behind any vehicle and collect debris directly from the surface. As a result, they are reliable in harsh environments where complex machinery can fail.

### Tool and Parts Accountability

In particular, lost tools are among the most dangerous forms of FOD. Therefore, tool control programs require that every tool be accounted for before and after each job. Shadow boards, kitting trays and electronic tracking systems help ensure nothing gets left behind.

### Training and Culture

The most important FOD prevention tool is awareness. When every person in an organization understands what FOD is and why it matters, prevention becomes second nature.

Effective training programs include:

- New employee orientation. Every new hire should learn FOD basics on day one. This applies to all staff, not just those on the flight line or factory floor.

- Regular refresher training. Annual or semi-annual sessions keep FOD awareness sharp. Use real incidents and near-misses to keep the content relevant.

- Visual reminders. Signage, posters and FOD-free zone markers reinforce the message daily. The best programs make FOD awareness impossible to ignore.

- Recognition programs. Rewarding employees who identify and report FOD hazards encourages participation. A small incentive program can yield major results.

Ultimately, culture matters more than any single tool or procedure. When leadership takes FOD seriously, the entire organization follows.

### Formal FOD Prevention Programs

A comprehensive FOD prevention program ties all of these methods together. It assigns accountability, documents procedures, tracks results and drives continuous improvement. Learn more about setting up a company FOD program.

## Equipment Used to Combat FOD

- FOD-Razor® airfield and facility sweepers — tow-behind friction mat sweepers that clean runways, taxiways, ramps, racetracks and parking areas of small debris.

- Disposal containers and FOD collection bags — for safe disposal and OSHA-compliant temporary storage of found debris.

- Tool and parts kitting — allows technicians to track small objects during on-site jobs.

- Specially-designed clothing and footwear — prevents ripping, tearing, snagging and carried debris in FOD-sensitive areas.

- Aircraft and wheel covers — protect equipment from rain, wind, dust and other environmental hazards.

- Automated detection systems — radar- or camera-based units that scan runways for debris or wildlife.

- Magnetic sweepers and bars — capture ferrous metal debris that other tools may miss. Often mounted on vehicles or towed behind primary sweepers.

- Prevention signage and zone markers — visual reminders that designate controlled areas and reinforce awareness.

## FOD by Industry

FOD affects every industry where equipment, vehicles or people operate on shared surfaces. Although the specifics vary, the principles are universal.

### Aviation

Airports face FOD from pavement fragments, wildlife, luggage hardware, maintenance debris and weather events. Consequently, every surface — runways, taxiways, ramps, aprons and gate areas — is a potential collection point for hazardous debris. Runways, taxiways, ramps and aprons all require regular inspection and sweeping. Because of these risks, the FAA requires certificated airports to maintain FOD prevention programs. As a result, the consequences range from tire blowouts during takeoff to catastrophic engine failures. Read our complete guide: FOD Prevention in Aviation: Getting Started.

### Military

Military flight lines demand the highest level of FOD discipline in any industry. Even a single piece of debris ingested by a fighter jet engine can destroy millions of dollars in equipment. As a result, every branch of the U.S. military conducts regular FOD walks. Formal prevention programs are mandatory, not optional. The consequences of failure can extend beyond dollars to national security. Read more: The Essential Guide to Military FOD Prevention.

### Motorsport

Racetracks contend with tire rubber, hardware from pit stops, cracked pavement and vehicle bodywork fragments. At racing speeds, even small debris can cause catastrophic tire failures and multi-car crashes. Consequently, track operators must sweep before, between and after sessions. Pit lane debris is a particularly common source — lug nuts, tape fragments and bodywork pieces escape during the chaos of competitive pit stops. Read more: Motor Speedway Safety and FOD Prevention.

### Manufacturing and Warehousing

Factory floors, clean rooms and assembly lines are vulnerable to contamination from tools, packaging materials, personal items and process byproducts. FOD in a manufactured product can trigger recalls costing millions, warranty claims and regulatory action. In aerospace manufacturing, a single forgotten tool inside an aircraft assembly can ground an entire fleet. In addition, clean room environments face additional challenges from microscopic contamination that can ruin precision components. Read more: Controlling FOD in a Manufacturing Facility.

- View our infographic on prevention processes in factory and warehouse settings.

- Learn more about cleanrooms in this white paper.

## Sources for More Information

### Advisory Circulars

The U.S. Federal Aviation Administration deals with FOD prevention and control standards at civilian airports:

- AC 150/5210-24, Airport Foreign Object Debris (FOD) Management — FOD program guidance and equipment specifications for airport managers.

- Circular 150/5220-24, Foreign Object Debris Detection Equipment — covers automated systems that use radar and imaging to scan runways.

- For self-inspections, see AC 150/5200-18, Airport Safety Self-inspection.

- Risk management is addressed in AC 150/5200-37, Introduction to Safety Management Systems (SMS) for Airport Operators.

- Pavement maintenance is covered by AC 150/5380-6, Guidelines and Procedures for Maintenance of Airport Pavements.

### NAS 412

NAS 412 is an industry standard issued by the Aerospace Industries Association (AIA). Specifically, it establishes general practices and standard terms for FOD prevention in aerospace products and operating environments. Furthermore, a FOD Advisory Board composed of AIA and other public/private sector representatives helps manage and update the standard.

### AS9146

AS9146 is a standard published by the Americas Aerospace Quality Standards Committee (AAQSC). It defines FOD Prevention Program requirements for organizations that design, develop and provide aviation, space and defense products. The AAQSC is affiliated with the Americas Aerospace Quality Group (AAQG), a member of the SAE Industry Technologies Consortia and a sector within the International Aerospace Quality Group (IAQG).

Trying to decide which type of sweeper is best for your facility? Read our airport sweeper technology comparison or complete this FOD sweeper assessment form, and we’ll be happy to make recommendations.

Have Questions? Want to learn more? Contact us for help in setting up your FOD prevention program.

## FOD Prevention in Aviation

Source URL: https://www.fodcontrol.com/fod-prevention-in-aviation-getting-started/

## Preventing FOD Incidents At Your Airport

Everyone working airside bears responsibility for eliminating FOD. However, each area within an airport operations environment has its own unique characteristics. New FOD Prevention Program managers must first identify all hazardous areas. In addition, they must become familiar with the activities of personnel working in those areas. Only then can they develop tactics to eliminate aviation FOD threats in each sector.

The stakes in aviation FOD prevention are enormous. According to industry estimates, FOD costs the global aviation industry approximately $13 billion annually. This figure includes direct aircraft damage, flight delays, fuel costs from engine inefficiency, and liability exposure. Beyond the financial impact, FOD threatens human lives — passengers, crew, and ground personnel alike. A single bolt on a runway can destroy a turbine engine. A loose piece of metal can puncture a tire during the critical moments of takeoff. The good news: most FOD incidents are entirely preventable with disciplined programs and the right resources.

This guide outlines nine essential elements of an effective airport FOD prevention program. Whether you manage a major international hub or a regional general aviation airport, these principles apply. Adapt them to your operation’s scale, and commit to continuous improvement.

## 1 – Management’s Strong and Visible Commitment

The success of any program requires demonstrated commitment from management. Specifically, this includes leaders representing air carriers and servicing companies. The following steps increase FOD hazard awareness among all staff and management:

- In particular, include FOD presentations as a key part of every new employee orientation.

- Photos and announcements of “Good Housekeeping Award” winners should be publicized on the intranet and in any other publications available at the facility.

- Post FOD Awareness Posters at all exit doors to the airside.

- “FOD Walks” should include management and staff from the airport, airlines, and servicing companies alike.

Your programs will gain authority if management “walks the talk” and sets a high standard for compliance.

Airports, military operations, and manufacturing facilities face similar challenges. The ramp operations of most FBOs (Fixed Base Operators) and major courier companies directly reflect corporate attitude toward a FOD-free environment.

Military bases generally have thorough anti-FOD programs. One major key to their success: senior officers take direct responsibility for oversight and ongoing results of the FOD Prevention Program. Consequently, this command support ensures the message filters down through the ranks. Junior officers and NCOs execute the day-to-day activities of the program.

An airport FOD prevention program needs the same solid top-down support. In particular, upper management must devote the necessary resources to operate the program effectively.

## 2 – Local FOD Committees

Unlike military bases, FBOs, and courier operations, airport management does not directly control each tenant organization. Therefore, an effective FOD Prevention committee is essential. It develops cooperation and drives implementation of FOD solutions.

For example, Chicago O’Hare has a FOD Handling and Trash Plan that was developed by their local FOD committee. The Plan set out goals and methods for controlling FOD and trash.

Moreover, an official website-based policy ensures that standards of performance and compliance are posted, understood, and readily accessible to all tenants. This method makes updating written standards easy as your program evolves.

Importantly, committee representatives should hold positions with the authority to carry the message and implement solutions. At smaller airports, a dedicated FOD committee may not be practical. In that case, assign responsibility to a related committee such as Ramp Safety.

## 3 – Housekeeping Performance Standards

Even with the best prevention program, FOD is an expected product of airport operations. FOD HAPPENS. Therefore, dedicate procedures and resources to regularly patrol operating areas. The goal: be absolutely sure that surfaces are FOD-free.

In most cases, airside maintenance crews handle this task. Regular sweeping can be effective, but hand-picking may be necessary as well. It’s simply a fact of aviation life. Train your new (and old) personnel to “Just get used to it, it’s part of the job.”

Towed magnetic sweepers work effectively. However, they can become a hazard without regular cleaning. Small all-terrain vehicles have been used with great success to patrol aprons and infield areas. They can easily pull a tow-behind sweeper while driving. Typically, airfield maintenance crews handle these tasks. At some airports, however, dedicated contractors patrol apron and gate areas.

### FOD Containers: The Foundation of Your Program

Conveniently located containers are essential to your FOD prevention effort. After all, ramp personnel will not pick up FOD if they must walk long distances to deposit it. However, an overflowing container becomes a threat in itself. Prominently display a phone number for pickup on each container. When a call comes in, dispatch a contractor promptly to empty it.

The same principles apply to ramp garbage containers. Accordingly, size dumpsters correctly. Ensure they have easily closed lids and sit in convenient locations. Furthermore, the collection schedule must keep pace with the volume.

For example, place dedicated small-item containers as close to work areas as possible. For example, many airports mount a FOD container on each passenger loading bridge.

An abundance of FOD containers is vital. Likewise, train all airside personnel to use them for all debris. Maintain a frequent emptying schedule. Together, these elements form one of the most effective components of your FOD Prevention Program. The importance of this simple idea cannot be understated. Don’t permit it to go undone.

Prompt, cheerful attention to the maintenance and emptying of containers is one of the key signals that airside personnel use to assess management’s commitment to the FOD Prevention in Aviation Program.

### The Disneyland Standard

Airports can learn from theme parks like Disneyland. These parks host thousands of visitors daily — yet their grounds remain immaculate.

How do they do it? Convenient containers and enough dedicated resources to ensure they never overflow. Resources are conveniently accessible to pick up anything loose.

In other words, a zero tolerance for FOD and sufficient resources to meet this goal!

## 4 – Training and Awareness

This may seem redundant. Nevertheless, getting the word out is essential. Done properly and continuously, this training becomes the keystone of your entire FOD Program. Make sure everyone gets the word! Then tell them again — at regularly scheduled training sessions. Orientation courses should include videos promoting FOD prevention. Specifically, show real examples of damage resulting from inadequate protection.

A FOD walk in progress — ground crews systematically inspect the tarmac for foreign object debris.

Keep the message coming, and keep it fresh. In addition, poster campaigns and email newsletters reinforce the message. Aviation industry magazines and websites publish FOD prevention articles with ideas you can adapt.

Events like FOD Walks and Spring Cleanups illustrate the importance of prevention. Furthermore, these activities give senior management a perfect opportunity to demonstrate ongoing commitment through their own spirited participation. Get face-to-face and work alongside your people. Similarly, recognition programs for personnel or organizations that contribute to FOD prevention reward good housekeeping practices.

### Incentives That Work

Many incentives can motivate companies and their employees to participate. Use your imagination! Instead, create rewards that people actually find desirable. Don’t demean their efforts by offering trinkets. Get them on board with awards that are worth working for.

For instance, consider gift certificates to airport-area shops or restaurants. Ask several businesses to donate on a rotating basis. In return, give them free ongoing promotion around the airport. Congratulate them publicly for their support. Get their names out to your people and everyone wins. It’s good business for them and you.

## 5 – Selection and Maintenance of Ground Support and Airfield Maintenance Equipment

Above all, airfield maintenance equipment must be suitable for airport use. For example, runway sweepers that shed metal bristles can create a FOD problem instead of solving it.

Regular mechanical sweeping keeps runways and taxiways clear of dangerous debris.

Parking lot sweepers are generally not sturdy enough to stand up to apron cleaning. Other sweepers may fail to pick up stones and small bits of metal. Consequently, research before you purchase. You most often get what you pay for.

You cannot assume that because a sweeper looks like it’s running it’s doing a good job. It may create sound and fury while missing dangerous debris. In fact, substandard operating condition is not unusual for these machines.

Inspect, maintain, and evaluate every sweeper — and its operator — regularly. Establish a local flightline FOD assessment to ensure the job gets done right. A good rule is to stay simple whenever possible to reduce maintenance and operational complications. Friction mat sweepers like the FOD-Razor® offer a mechanically simple, low-maintenance alternative — no engines, no electronics, just reliable debris collection towed behind any vehicle.

## 6 – Airport Construction Projects

Virtually all airport construction projects create FOD risk.

Contracts must include FOD control as a condition of work. Additionally, a monitoring program must ensure these obligations are met.

In particular, pay special attention to material that wind can blow onto the airside. Also monitor debris that vehicles can carry from the job site onto operating surfaces.

Airport operators must be prepared to shut down an offending job site promptly. Work stops until satisfactory FOD control is in place.

The following requirements come from a contract for airside excavation and paving:

### Special Conditions

- Do not place debris or dirt on runways, taxiways, aprons or aircraft maneuvering areas.

- Keep FAA-compliant equipment available on-site for cleanup when required.

- Within two hours of receiving notice, clean up and remove dirt and debris at no cost to the Airport Authority. Keep all sand, aggregates, soil, or other materials wetted, confined, covered, or contained. Prevent materials from blowing or washing onto runway and taxiway areas.

- Failure to comply will result in the Airport Authority arranging for Other Contractors to do the work and the costs shall be borne by the Contractor. All clean up must be completed within the designated airside work hours, and all equipment removed off airside by the end of the approved work period.

### Site Cleanliness

- Site cleanliness is a matter of utmost importance. Loose debris and unprotected granular materials exposed to jet blast can enter aircraft engines. They can also damage tires. The result: costly repairs, flight delays, and compromised safety for the flying public, airline employees, and operations personnel.

- Contractors must maintain the site in immaculate condition. Do not allow waste to accumulate before cleanup. Likewise, contain all lunchroom waste to discourage birds and rodents. When work occurs immediately adjacent to aircraft operations areas, keep those adjacent areas absolutely clean at all times — during and after each shift. Before returning a closed work area to Operations, ensure it is clean, clear of all debris, and adequately protected.

- Protect all work at taxiway and apron edges by the end of each shift. Maintain protection at all times during the course of work.

### Enforcement Provisions

In the event of any such act, omission, or thing or absence of such precaution by the Contractor is observed by the Consultant or the Airport Authority, the Consultant or the Airport Authority may immediately take or order such remedial action as it may deem necessary and for this purpose, it may stop the Work or any part thereof and may use the Airport Authority’s or the Contractor’s or any Subcontractor’s or any other Contractor’s employees to perform any remedial measures it may seem necessary. Notice of any work stoppage or remedial measures shall be provided to the Contractor. The cost of such work stoppage and of any such remedial measures, whether performed by the Airport Authority, Subcontractor’s or Other Contractor’s employees or by the Contractor or its employees shall be to the Contractor’s account.

The project’s consulting engineers and airport Operations Duty Managers monitor the Contractors actions and inspect work sites prior to returning an operating area to service. As a general rule your FOD Program’s actions checklist should include a construction site inspection procedure. This should cover the method and message for communicating any site cleanliness deficiencies that are discovered, and a “check back” scheduled to insure these have been remedied.

## 7 – Motivating Construction Crews to Understand FOD Threats

Visiting workers won’t respect the potential threats involved with their debris unless you educate them. Therefore, invest the time to show videos. Emphasize the need for constant attention to this problem. Carpentry and masonry crews, steelworkers, and others will be more willing to help once they understand. It may not be possible to “teach” everyone, but briefing supervisors and management should improve general participation in FOD Prevention.

Additionally, offsite construction projects can pose a threat. Monitor nearby activities. If a multistory building produces windblown paper or wood scraps, take steps to make them aware of your concern. If education/persuasion doesn’t do the job, you may decide to bring in the municipal authorities to support your position. An aircraft brought down by FOD — regardless of the source — still falls in the surrounding city.

## 8 – Monitoring and Inspection

In an imperfect world, some people fail to comply with FOD prevention principles. Consequently, operations must inspect continuously to capture any loose material. Offending persons or organizations can then be persuaded to change their ways.

On maneuvering surfaces, inspections should detect cracking or early signs of break-up. Repair potholes immediately when they appear. In keeping with the statement “you cannot manage what you cannot measure,” records must be kept of inspection results and any FOD damage.

Although it is impossible to measure accidents that did not happen because of a FOD Prevention Plan, measures such as a “FOD Survey” and pilot reports of FOD can be used to assess the effectiveness of the Prevention Program.

Record keeping can be incorporated in the normal airport “Log” or in a diary of events. The easiest approach: create a FOD incident category in the airport database system. Subsequently, reports can compare year-over-year results of your FOD prevention efforts.

From there, identify trends and repeat offenders. Use strategies like fines, persuasion, and public accountability to remove continuing hazards. Treat non-responsive offenders as a serious threat to your operation.

Need help building your airport FOD prevention program? Contact us today.

## 9 – Seasonal Consideration

In northern latitudes, winter months bring added hazards. Specifically, snowplowing creates rows of ice and snow along taxiway and runway edges. Low-slung jet engines can ingest this material. Furthermore, propellers face damage if aircraft taxi through drifts. Winter plowing plans must push windrows far enough back from taxiways and runways to eliminate the hazard. Finally, airside managers must inspect surfaces before opening them to operation.

Building an effective FOD prevention program requires commitment, resources, and continuous vigilance. Every airport — from the busiest international hub to the smallest regional field — benefits from a structured approach to debris control. Start with management commitment, build your committee, establish standards, and equip your teams with the right tools and training. The investment pays for itself many times over in reduced damage, fewer delays, and safer operations for everyone.

For more information on FOD prevention equipment and best practices, explore our guide to FOD or contact us for personalized guidance on your airport’s FOD prevention needs.

## Military FOD Prevention

Source URL: https://www.fodcontrol.com/the-essential-guide-to-military-fod-prevention/

Anyone who has spent time working in the military around aircraft has heard about Foreign Object Debris and Foreign Object Damage. Military organizations enforce exacting FOD prevention controls over both their personnel and their work procedures. Given this level of discipline, it is therefore sometimes difficult to understand how their aircraft continue to suffer from damage caused by FOD.

Ground crews keep work areas scrupulously clean and well maintained. Maintainers keep tools in good condition and rigorously control them. In fact, personnel receive specific training and regular refreshers on the hazards of FOD. Even those not associated with aircraft operations must remain vigilant.

So why then have three nations this author has direct knowledge of lost military aircraft in the last ten years from FOD to fan or compressor blades on turbine engines?

It is not enough to understand just what is FOD. We also need to understand how it occurs. We must identify the specific hazards unique to each work area and develop tailored prevention activities that aim to eliminate military FOD.

Understanding military FOD is the first important step we must take before enforcing relatively simple and routine preventative measures. Indeed, understanding the mechanisms of FOD establishes the first and vital foundation block. From there, we can build a prevention program to minimize the operational, economic, and human costs of FOD.

## Getting Started

Indeed, FOD means different things to different people and can show itself in many ways on an aircraft and its components.

### FOD Is A Threat To Aircraft Tires

When an aircraft taxis down a runway, the tires may pass over a stone or sharp object. Consequently, this can cut the tread and lead to subsequent failure. The puncture may occur immediately or, more likely, when the tire is rotated and loaded on takeoff.

One of the most notable FOD incidents occurred on July 25th, 2001. A French Concorde, Flight AF4590, was taking off from Paris. The aircraft reportedly taxied over a piece of metal shed by another aircraft. A main undercarriage tire was cut. The subsequent failure on takeoff shed a large piece of tread. It struck the wing and caused a hydraulic shock wave in the fuel tank.

As a result, a massive fuel leak ensued. It was ignited by an electrical arc from wiring in the undercarriage. The tire failure had damaged that wiring. Further damage struck the hydraulic pipes and controls. Consequently, the undercarriage could not retract. The number one engine lost power, and the second engine cut out. At this stage it was too late to abort the take off.

In the critical first moments of flight, the crew fought to overcome the high drag of the supersonic airframe. The aircraft was unable to gain height or speed. Fire engulfed the wing, engines, and flying surfaces. The aircraft flew for less than three minutes. It crashed into a hotel in the small town of Gonesse, killing 109 on board and four on the ground.

### Aircraft Tires Are Exposed To Extreme Forces

Whilst the tire loading on take off is high, especially at the Concorde’s very high take off speed — about 250 miles per hour compared with 170 miles per hour for most other subsonic aircraft — that loading is magnified many times over on landing.

On landing, the descending weight of the aircraft shock loads the wheel. Additionally, it must handle instantaneous acceleration to well over 100 miles per hour. As a result, a burst at this critical moment can lead to sudden loss of control and force the aircraft off the runway.

### Burst Tires Lead To Loss Of Aircraft Control

Early in my career, I was on a detachment at RAF Waddington, near Lincoln, England, when an F4 Phantom blew a tire on landing. The aircraft immediately departed the runway, ran onto the grass in the center of the airfield, and sped toward cabins where the ground crew and I were operating.

The pilot fought with the controls. However, as the aircraft sank into the muddy field, he was unable to adequately retard the speed. More importantly, he could not steer the nose wheels to control the direction. At less than five hundred yards from the buildings, the pilot was faced with a split-second decision, and he and his navigator ejected.

The aircraft carried on its path, held firmly in its mud tracks. As it continued to sink up to its axles and landing gear doors, its speed rapidly declined. It came to rest a few hundred yards short of the buildings. Several seconds later the pilot and navigator, both now under parachute, landed safely on the airfield.

Fortunately, no one suffered injury. It is an event that I will never forget. It has served as a lasting reminder of the hazards of aircraft operations and of FOD.

### FOD Is A Threat To Turbine Engines

For the uninitiated, turbine engines can rotate at over ten thousand-rpm, and when a tiny piece of debris like a piece of safety locking wire or stone get ingested it behaves in a ballistic manner, striking the compressor blades as if fired from a gun. Depending on material grade, shape, and size, the debris can damage the first blade or any part of the intake it strikes.

As the debris passes through the engine, contact with fan blades can break it into smaller chunks. Alternatively, it can liberate pieces from the blades themselves. Consequently, this multiplies the debris field and increases both the size and quantity of the damage.

I have seen a small nick on the first stage of the fan. Meanwhile, the rear stages of the compressor and most of the turbine rotors were completely decimated. It looked as if someone had taken barber shears and clipped the blades from the disk.

Highly loaded blades — or those subject to vibration — face additional risk. This is sometimes referred to as HCF (High Cycle Fatigue). In these cases, damage can grow rapidly into a crack and ultimately cause blade failure.

### Catastrophic Engine Damage

Engineers design engines to contain failed blades. Nevertheless, a blade failure can lead to the total destruction of the engine. Indeed, many posters illustrate this point clearly. The ingestion of a small metal screw — costing just a few pennies — can cause damage requiring complete engine replacement. Ultimately, that replacement costs many millions of dollars.

However, it is not just hard debris that causes damage. A plastic bag can behave like a large sheet and blank the intake. This stalls the airflow across the blades and causes the engine to surge. Engines can usually tolerate a surge — a reversal of the airflow. However, depending on severity, a surge can deform blades and necessitate engine replacement.

### Foreign Object Elimination Is Our Mission

It is easy to see why we must control debris to maintain safety and reduce costs. FOD represents a genuine flight safety risk. Everyone bears responsibility for keeping that risk as low as possible.

Picking up debris that could migrate onto airfields is the first step that could avert a disaster.

True, seldom does FOD result in a disaster. However, it can be one link in a chain of events. If left unbroken, that chain could result in engine failure, loss of aircraft, and loss of life. Breaking that chain can be as simple as picking up litter. Above all, training and education offer the greatest return on effort. More can be done by targeting specific areas for improvement. Coordinating increasingly limited resources helps reduce problems and deliver the best return on investment.

## Sources and Mechanisms of FOD

Understanding how engines ingest debris is important.

### Vortex Ingestion

Engines ingest debris through vortex ingestion. You can sometimes observe this phenomenon during cold, wet conditions when water rises into the vortex.

Airflow disturbance around the intake mouth creates a vortex. In normal conditions, airflow enters from all around the intake. As airflow enters from the rear of the intake, it interacts with the ground plane. The ground and the underbelly of the aircraft create a Venturi Vacuum Effect. A vortex initiates when a prevailing wind blows at an angle to the intake face. In turn, this forms a shear vector that causes the airflow-to-ground-plane interaction to swirl.

A vortex seen on a Boeing C17 Globemaster

Vortex air flow illustration

The speed and strength of a vortex depend on the ingested airflow and wind vector. Preventing a vortex from forming can be as simple as pointing the aircraft into wind.

When a vortex forms and attaches to the ground, the periphery behaves like a rotating brush sweeping objects out of its path. However, objects trapped between gaps in the concrete face a different fate. If the eye of the vortex passes over them, the negative pressure can pick them up and ingest them.

Therefore, crews must pay special attention to cleaning these gaps. Fill them completely with sealant. Essentially, this eliminates temporary resting places for debris.

Want to learn more? Contact us for guidance on developing your FOD prevention program!

### Aircraft Generated FOD

Aircraft-generated debris is especially noticeable on supersonic intakes with auxiliary air intake doors. Specifically, these doors supplement the intake airflow when the aircraft is stationary or at slow forward speed. At high speeds, they vent air when the intake is in ram effect.

Older supersonic intakes have many moving parts — ramps and doors. Movable ramps form shock waves to slow the airflow in supersonic flight. Meanwhile, air bleeding systems present the engine with smooth, controlled airflow at the right speed. The ramps and some doors are usually hydraulically operated. In turn, they are supported by mechanical components and switches. These, in turn, have their own access doors, hatches, and fairings. Various fasteners and locking devices secure the access doors. These fasteners and locking devices have proven to be frequent causes of FOD.

### Secondary Inspection

Special FOD prevention measures can be put in place after any work involving panel removal. These measures call for an independent inspection by an unconnected third-party tradesperson. The inspector checks for fit, form, and function — as is usual with an independent inspection. Crucially, they also ensure that the panel and its fasteners do not become a debris hazard.

Furthermore, consider cleaning and checking any access bays before closing them. This can be as simple as using a vacuum and a flashlight. Furthermore, teams can apply additional security measures inexpensively. For years, the military has used fastener bags when removing panels. Loose fasteners go into the bag. The technician then attaches the bag to the panel on the parts stand.

Remember: what may seem obvious to the trained eye must be learned by newcomers. We should share experience rather than make the uninitiated learn the lesson again. This matters especially where safety is at stake.

The Tornado auxiliary air intake doors are shown adjacent to the intake, under the leading edge of the wing where the wing joins the fuselage.

Tornado intake viewed from the engine bay looking forward to the air intake lip. The white blemishes show damage that has been dressed out.

### Thrust Reverse

Perhaps the prime contributor to FOD on fast jets is thrust reverse. Essentially, this system directs engine exhaust air forward to provide a braking mechanism. Thrust reverse disturbs the smooth airflow around the intake and ground. It can pick up debris and project particles into the strong airflow around the intake lip. From there, particles travel down the intake and into the engine.

Many airlines also use thrust reverse to help control speed on landing and prevent the aircraft brakes from overheating. Operators must strictly control the use of thrust reverse. They should limit it to forward airspeeds where particles cannot reach the intake. Even at slow forward speed, the hot exhaust gas can be re-ingested. This in turn causes engine stall and surge.

### Human Generated

History has proven that human-generated debris is a main contributor to FOD.

Unfortunately, intakes and intake lips do provide a convenient resting place for temporarily storing articles. Whether high or low set, crews must check and recheck intakes before every engine start.

RAF Phantom F4 from 74 Squadron

RAF VC 10

### Engine Intakes Are An Ongoing Risk

On the VC10 transport aircraft, the intakes are simple bell-mouth shapes. They form part of the pods that house the engines. Two sit on each side of the tail, about 12 feet off the ground.

During intake maintenance, a technician applied a small pot of rubberized sealing agent to the outboard intake. He used the inner intake as a stand for the pot. Again, the work person was distracted and the pot was forgotten.

During the subsequent pre-flight inspection, crew checked the intake from the ground. However, because of the height, the intake lip made the pot invisible to both aircrew and ground crew. On engine startup, the fan drew the pot into its face. It severely damaged the engine, leading to its replacement and overhaul.

### It Only Takes A Momentary Distraction

Distractions like the ones above are common in aircraft operations. Even the most capable personnel can be forgetful. Indeed, multiple tasks and a decreasing timeline compound the risk.

Accordingly, the military brought tool control into effect. The control of C stores — screws, bolts, seals, and washers — was implemented alongside it. The tool control section below covers this in detail.

Maintainers undergo training to keep the dangers of FOD fresh in their memories. However, many visitors to aircraft operating bases will not have come across the acronym. They may not understand the associated hazards. Strangely, many contractors with access to aircraft work areas may never get briefed.

Fortunately, the military in the USA and UK generally recognize this loophole. They provide briefings and instructions to contractors working on their units. Moreover, each station has a FOD Prevention Officer who understands engine maintenance and has the ear of command. A nominated prevention officer serves the whole service. This command structure provides visibility and drives action to prevent recurrence of incidents.

### Coveralls Required

Lastly, regarding human-generated FOD: the Royal Air Force insists that aircrew and ground crew keep their pockets free from objects. Accordingly, working coveralls have no buttons. The service provides personal lockers — secured with combination locks — for clothing and small items like keys and money.

In some areas, such as the flightline, additional small personal item lockers — similar to lockable mailboxes — are available to secure frequently used small items. In addition, smoking is prohibited in all work areas. For engine intake inspections — where the inspector enters the intake — many bases issue special pocket-less coveralls.

## Debris Control

Understanding the mechanisms of ingestion helps visualize how debris gets ingested. In particular, this knowledge is essential for generating effective working practices.

Personnel must keep all work areas scrupulously clean. Maintenance teams must quickly repair any breakdown in paved surfaces. If possible, isolate and cordon off the damage. In addition, clean and check it regularly to ensure particles are not accumulating. During repairs, debris can become a problem. Therefore, brief all work personnel thoroughly. Check the area as the repair progresses. In recent years, crews have placed plastic mesh barriers around work sites to prevent debris migration. Moreover, the mesh is typically bright orange. This provides a clear visual warning to avoid the area.

On many bases, civilian contractors carry out repairs. Brief them about the dangers of uncontained debris without exception.

### Contractors Should Be Advised Of The Risks And Supervised

Concrete runways are routinely overhauled. After many landings, crews must remove rubber tire marks. On one Air Force Base, a civilian contractor carried out this operation over a weekend. Nobody probably briefed or supervised the contractor. They used metal balls — shot blasting — blown onto the marks at high speed. The runway was made up of twelve-foot square concrete blocks. Expansion joints between these blocks were sealed with asphalt sealant.

The contractor cleaned the marks off the runway. However, the contractor left thousands of metal shot immersed in the sealant. When aircraft operations commenced early the next week, the shot was lifted and ingested. The base had to remove several engines from combat aircraft.

It was a very costly lesson. The expense went beyond engine replacement. Lost sorties and considerable disturbance to operations followed — both carrying obvious operational value to the military.

The need to keep operating and maintenance areas clean cannot be overstated.

Mechanical sweeping and ad-hoc FOD Walks by personnel are effective ways to minimize debris. Sweep and inspect as often as possible.

Following FOD Walks, the debris found can become an exhibit. Display it on notice boards or custom FOD displays. Move these displays regularly to different areas of work. Good posters and photographs can have a great impact. However, that impact fades over time. Posters become like unnoticed old wallpaper. To work to maximum effect, posters should be routinely changed. Sharing posters and ideas with other services or nations brings fresh perspective and generates new interest.

Want to learn more? Contact us for guidance on developing your FOD prevention program!

## Tool Control

Tool control is an effective way of accounting for all tools that are used on aircraft.

Many years ago, I worked alongside contractors who were making some modifications to aircraft that required the engines to be removed; I helped them with this work.

Each person on the team had their own tools. They carried them in a variety of containers. The quality of the tools and containers varied widely. Tools were loosely held, sometimes several layers deep in each tray. A single five-drawer toolbox might hold as many as a hundred tools.

With no standardization and no requirement to check tools at the end of the working day, it was each individual’s responsibility to account for his tools. With hundreds of tools to check and workers helping themselves to others’ tools, it was impossible to account for them.

In those days, this was not an isolated incident. Similarly, many companies operated under a similar regime. Not surprisingly, tools were sometimes found inside aircraft delivered to the Royal Air Force.

During that same period, I remember talking to some military maintainers who worked on the Vulcan bomber; they had just gone into a wing fuel tank and found a workbench that was probably used to help fasten the fuel-tank bag in place.

Incidents like this eventually led to a change in working practices that saw the introduction of tool control in the aerospace industry.

### Tool Control Has Come A Long Way

The military have for many years used tool control to great effect. They procure premium-grade tools. Furthermore, each tool is etched to uniquely identify it to a station, squadron, flight, and toolbox. Color-coding enables quick identification on the units. Furthermore, no personal tools are allowed in the work place.

In the tool containers, each tool has its own resting place. Shadowing or highlighting marks the space to indicate the tool’s absence. In recent years, units have adopted sheet foam. Each drawer or tray is layered with foam cut to house each tool precisely.

When taking a tool, the worker places a numbered plastic tag against the space. The tag identifies who is using it. Moreover, each tool kit is booked out to a specific aircraft. The engineering operations rectification controller manages the tags. This person verifies that all tools are accounted for. Only then does the controller sign the aircraft over to operations for flight-line servicing.

When a task is completed, the tradesperson checks that all tools have been returned. Likewise, all tags must be accounted for. Maintenance personnel sign for these checks as part of the work order paperwork.

All tools are controlled through dedicated tool stores. These stores hold specialized tools, small equipment, cleaning rags, and other general-purpose items. Each item — tool, box, and hardware — is identified and accounted for using the same system as the toolboxes.

### Tool Accountability

A designated person controls the tools. This role is often held by the squadron or flight supplier/logistician. The controller serves tools over a counter. Subsequently, the supplier verifies the completeness of each tool kit. They perform a second check after the tradesperson. In addition, tool inventories are conducted at least at the start and finish of each day.

### When a Tool Goes Missing

If any tools are missing, a check is done immediately. Specifically, the tag system reveals which aircraft the tool served and who last held it. If that person cannot find the tool or recall where it was last used, a larger-scale search is carried out. At this time, the trade supervisor or trade manager should be informed and a thorough search initiated.

In the unlikely event the tool is still not found, an all-trades search should be completed. Searchers work through zoned areas of the aircraft. The removal of access panels and equipment should also be considered. Control runs and controls must be checked. An independent party must confirm they are free of restrictions. Inspection devices — lamps, borescopes, and even x-ray — should be considered.

### Escalation Procedures

If these efforts do not locate the tool, the senior engineer must consult with the station’s chief engineer. Consequently, a check flight or flight test may be required. The aircrew flies a single test flight, recorded in the aircraft Limitations Log. It involves a period of inverted flight to attempt to free the tool from its hiding place.

After landing, inspectors follow the same procedures as before. If still not recovered, the engineer enters it in the ADF (Aircraft Deferred Faults) Log. This triggers further inspections of the suspect area during the next scheduled maintenance. If it is not found then, the ADF entry is cleared. This situation seldom occurs, as there are many checks and balances in place to maintain safety.

An effective Tool Control Program is vital to flight safety. Quality assessment teams from the squadron, unit, wing, and command evaluate it regularly. These teams ensure correct procedures are in place. Their goal is to control hazards and prevent problems. In past years, these checks focused on confirming standards and finding discrepancies. Today, the focus has shifted. Teams verify that systems, orders, and training are in place and effective. This top-down approach has won the support of both management and the workforce.

## Reporting

Having worked for both the RAF and USAF, I have witnessed the importance of data firsthand. Studies carried out at DERA (Defense Evaluation and Research Agency) — and later at DSTL (Defense Science and Technology Laboratory) — gather information on every FOD occurrence. Specifically, each report captures sortie details preceding the event, weather, location, and debris detail. The squadron maintenance officer, station FOD officer, and chief engineer also provide statements.

Command and the RAF FOD Prevention Officer receive all reports. They evaluate follow-up action and visibility. Every six months, the reports are collated into a written summary. Every station and FOD officer receives a copy. The reports reveal trends indicating problems — whether on a specific unit or with an aircraft type. These trends help target a response and prevent recurrence.

Moreover, engine manufacturers can use these reports when considering modifications or future designs. Investigators identify debris indentations throughout the engine. Through repeated events, designers can determine where blades are most susceptible to damage. Thorough reporting is essential to any FOD prevention program. The RAF reporting system is perhaps the most comprehensive in the world.

## On Deployment

When deploying, extra vigilance is essential. Therefore, operating in a new environment demands a FOD-free location. In many cases, the deployment is short-notice with no forward inspection. The parking ramp is a transit setting with aircraft from different commands. There may be no central FOD control person overseeing the whole picture. That leaves everyone on their own. Here are some tips for reducing the danger to your aircraft:

- Bring your own FOD prevention tools with you. FOD Containers, Magnetic Sweepers, etc.

- Take a good look at all aircraft positioning — not just yours. Are their aircraft positioned in such a way that their exhaust could be tossing objects towards your aircraft? Also consider engine maintenance run-up areas. Could they affect your aircraft?

- Be positive and diplomatic when dealing with the home base. The wrong perception of your organization could create new problems.

- What is being used for snow removal at home base or on deployment? Many locations may still use metal street sweeper brushes. These leave a trail of metal bristles behind. Consider switching to nylon brushes. Alternatively, initiate a sweeping program to ensure bristle removal.

- Develop a deployed FOD Prevention Handbook for the person managing the program at the deployment location. Basic information on this subject is available on this website. The regular Wing FOD Program Manager may not be present. Ensure the deployed FOD Program Manager understands the importance of FOD prevention and is suitably motivated.

Want to learn more? Contact us for guidance on developing your FOD prevention program!

## On Base

Runway sweeping is usually carried out by mechanical sweepers. Typically, these machines use a vacuum, brushes, and sometimes magnetic media to collect debris. Most operating stations have a sweeping plan. Specifically, the plan segments the airfield into blocks. Crews attend to each block at least weekly.

In addition, runway sweeps can be requested on demand. They are worth considering after repairs, extensive aircraft work, or inclement weather. Strong winds and rain can move debris onto the airfield. Although some airfields use road sweepers, new specialized FOD sweepers are far more effective. Moreover, some equipment can clean surface areas and reach between the gaps in concrete blocks. This keeps flight operations areas scrupulously clean.

### Airshows And Open Houses

Many military airfields host open days. The military allows vast crowds onto the airfield. The airfields are transformed into fairgrounds. Typically, organizers bring in external catering and amusements to keep visitors fed and entertained. Flying displays are usually scheduled for the busiest times. Special attention is required to keep operating areas free from debris. This matters particularly when strong winds can blow litter onto the field. Hooded litter bins should be placed near the food and drink stands. They must be readily available.

At the forward edge of the crowd line, netting can prevent litter migration. Builder-style mesh or airfield repair netting works well. During the day, work teams should collect and empty litter into lidded bins or contained waste disposal areas.

Before operational flying commences, the airfield should be FOD walked. Accordingly, everyone must participate. All litter and human-generated debris must be removed. Furthermore, aircraft used for static displays should undergo checks for loose articles. All trades and disciplines should participate.

## Management Responsibility

In the military, management is sometimes overlooked when strong leadership dominates. Leaders take a dominant role. However, management is equally important. In many areas — maintenance and logistics, for example — the leader and manager are the same person. They are often a commissioned officer or senior NCO.

For these individuals, safety is always the priority. However, it must be balanced against operational needs and cost. It is pointless having the safest aircraft if they cannot fly. Conversely, you cannot have the best launch rates at the expense of safety.

### A Balancing Act

With FOD control, the manager must assess risk. They must also implement and enforce standards. Above all, they must verify that working practices remain effective. Managers often delegate these practices. However, while the role may shift, the responsibility remains.

Consequently, managers must be reactive in dealing with damage and proactive in dealing with prevention. They must commit at every level. Similarly, they must be prepared to assist as well as enforce. In my education as a young engineering officer, my mentors used to say “GOYA — Get Off Your Ar** —” and see firsthand what the problems are. Talk to the people that are at the front line where the “rubber meets the road.” After all, these are the people who execute your orders. They will provide the feedback you need. They know the how, why, what, and when, the effectiveness and the best way forward.

### Writing Orders That Work

However, be assured: they will not write to you with their concerns. Equally, no matter how well an order is written, they will not follow something that is stupid or causes unnecessary hardship. The best orders are those which they help form and those that take their needs into account. The best managers understand everyone’s needs. They support the initiatives and practices that have the greatest effect.

Moreover, these managers are quick to praise. They recognize outstanding effort with award and reward. In FOD Prevention, award may be a certificate and reward maybe public recognition of having “gone that extra mile.” From my largely military perspective, the military are at the forefront of FOD prevention. However, whether the environment is commercial or military, it takes a committed team to have the best effect.

## Everyone’s Responsibility

“FOD is everyone’s responsibility” is often repeated, but I often wonder how many take the saying seriously. There remains a pressing need to actively minimize debris. Specifically, report any activity that could lead to damage. Help prevent recurrences. Furthermore, each of us can help eradicate the problem. Every action helps, no matter how small. Pick it up. Talk about it. Place a poster to illustrate it. Share ideas, participate, and work together.

It is everything about being part of a team. Regardless of where we work, we all have a part to play. If we are connected with flying or operations support in any way, we can help. Even as fare-paying passengers, we have a duty of care. Do not throw litter. Do not discard debris where it can migrate into the path of an aircraft.

Think outside the boundaries of your job. Be prepared for the unexpected. Be willing to help. One person against FOD is good. Ultimately, a team effort is better. Work with the team. Build a team through which we will all benefit.

## Manufacturing FOD Control

Source URL: https://www.fodcontrol.com/controlling-fod-in-a-manufacturing-facility/

How To Increase Worker Safety and Product Quality

Aerospace manufacturing differs significantly from other assembly operations. Specifically, the strict requirements of product integrity demand specialized processes to assure safety and reliability. Standards such as SAE AS9146 (Foreign Object Prevention) define the framework for FOD control in aerospace manufacturing.

The potential of introducing foreign object debris in manufacturing during fabrication is very high.

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 basic tools and parts and install components can measure in at hundreds of thousands.

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 to build a FOD-free product. Indeed, expectations alone do not produce FOD-free assemblies.

FOD controls and prevention practices must be established and enforced throughout the entire build process if product integrity is to be assured.

In a manufacturing environment, cost often drives schedule. After all, to continue building any product it must be profitable. Consequently, FOD controls often impact both costs and schedules. Instead, plan and formalize controls as part of the manufacturing scheme — not as an unpleasant afterthought when things go wrong.

Costs to establish and operate an effective FOD Control Program include:

- Training

- Equipment

- Design changes

- Procedural changes

- Workplace organization

- Tool and hardware controls

- Inspections

- Adequate manpower to oversee and maintain the program

But what about the savings? They’re yours to claim with a commitment to FOD controls. Once established, however, an effective program reduces rework, scrap, and incidents. In addition, the result is increased customer satisfaction and sales. You also gain reputation and the pride of building the best product possible. You beat the competition and increase market share. Even if an effective FOD Program or Procedure hasn’t been planned and implemented previously in your operation, the time to start is now. FOD control is quality, safety, and integrity — all in one. Ultimately, the savings and benefits far outweigh the costs and time expended.

Considering how to start a FOD Program? Use our FOD Prevention Plan Template as a starting point.

## Design

Although manufacturing controls are necessary to prevent the introduction of FOD, the design of the product itself plays a vital role in the ability to inspect and remove foreign objects during and after assembly. Specifically, when planning a new product or assembly line, Design Engineering should incorporate FOD removal procedures into each aircraft zone. A “Design Checklist” with buy off from Manufacturing Engineering is required.

Design is your first and best opportunity to eliminate FOD from the delivered product by planning for inspections, cleaning of cavities and designing out entrapment areas. For older/existing structures that didn’t plan FOD Prevention into the product, modifications and overhaul planning should require FOD inspection/removal steps to be incorporated into each package.

Some aircraft contain known FOD entrapment areas that are impossible to inspect or clean. These are accidents waiting to happen. Accordingly, redesign, modify, or drop them from service. Knowing about foreign objects in a flight article — or the potential for damage — is inexcusable. It cannot be ignored. Ultimately, everyone involved in any phase or process bears responsibility to identify and report potential FOD. Management should encourage all employees to report potential FOD — just as they would any safety or quality concern. Furthermore, request design changes when feasible to assure product integrity. Repeat: Design stage is the very best opportunity to keep FOD out of the delivered product.

A clean, well-organized manufacturing floor — the foundation of effective FOD prevention in aerospace production.

## Management Responsibilities

Management must actively support and take responsibility for the FOD Prevention Plan and its implementation. Specifically, all policies, procedures, training programs, and operational guidelines must include FOD prevention reminders and controls.

Management must demand effective corrective action for FOD incidents, problem areas, and negative trends. Without upper management support and encouragement, FOD Prevention is “just another program” or passing notion. Consequently, strong deliberate enforcement makes compliance a reality.

The FOD Program manager or coordinator should hold similar rank and authority as the Safety or Quality manager. Importantly, this role must be independent from bias by other operational units such as Assembly or Test. Some successful programs have FOD reporting to the Quality or Safety manager, but FOD Program management deserves the same status and recognition as those disciplines.

Having all three placed within one organizational unit may be the best profile as they share many similarities such as: inspections for compliance, “shut down” authority, data collection/trends, customer interface, awareness (promotion) and employee recognition.

Organizational Chart

## The FOD Department

First, develop SOPs (Standard Operating Procedures) and operational guidelines. Keep them current. FOD inspections are required for panel closeouts, manufacturing process spot checks and procedure compliance. Investigations of FOD incidents/mishaps can only be performed by an organization with an unbiased eye. Likewise, trained specialists must operate and maintain FOD inspection and removal equipment. Audit and incident data must be collected, entered into a database, information sorted into various report formats, posted on status boards and distributed to key personnel. Additionally, track corrective actions and verify their effectiveness. Furthermore, include both management and workers in meetings and briefings. Develop and conduct FOD training programs at least annually. Administer FOD awareness programs to maintain vitality and worker involvement. This is a formidable list of “musts,” but all of these elements are necessary to adequately support an effective FOD control effort.

## Why Part-Time Programs Fall Short

Consequently, without a dedicated unit, the burden on other organizational units is difficult — if not impossible — to sustain. Many companies have tried part-time programs. Typically, FOD Monitors check work areas at intervals during and after each shift. These efforts are weak at best. If you use this approach, solicit volunteers — do not appoint them at random. Even under a conscientious FOD supervisor, a part-time effort invariably falls short of a full-time unit.

There is no other way to say it: Effective FOD Prevention is an investment and a commitment.

Naturally, staffing a full-time FOD effort depends on operation type, aircraft in production, required control level, and available budget. As a rule of thumb, assign one inspector for every five aircraft in production. In addition, you need a clerk for data entry and a supervisor to oversee the operation. FOD is serious business. Don’t 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 without compromise.

Want to learn more? Contact us for guidance on developing your FOD prevention program.

## Equipment & Tools

Certainly, aircraft have 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 to dislodge foreign objects. However, a flashlight and mirror can only go so far. Specialized equipment is necessary to verify cleanliness.

One of the most valuable tools to inspect and retrieve FOD is the borescope. Interestingly, originally developed for medical use, borescopes now serve many industrial applications. They perform inspections that would otherwise require disassembly or destruction.

Numerous companies build borescopes ideal for aircraft inspection and cleaning. A wide variety of specialized models exist. Some handle engine inspection. Moreover, others feature articulating tips with FOD retrieval capability. Still others handle fuel cell inspection with explosion-proof lighting.

### Borescope Safety

Above all, consider the safety aspects of each area before selecting a borescope. Never use a borescope on electrically powered circuits. Disconnect aircraft batteries if there is any chance of electrical contact or shorting. Otherwise, both the aircraft components and the borescope can sustain damage. Personal injury to the operator is also possible.

Limit borescope use to personnel trained in operation, maintenance, and safety. After all, borescopes are expensive and fragile. Improper care or use can easily destroy this valuable tool. Only FOD Department personnel should operate borescopes. Keep the equipment under lock and key when not in use.

It is one thing to locate FOD, it’s quite another to remove it.

The job often requires ingenuity. Sometimes you cannot remove the FOD. In those cases, secure it with sealant to prevent migration. Long extension tubing can be affixed to a sealant gun to perform this operation.

A tool shadow board ensures every tool is accounted for — empty slots immediately reveal missing items.

Other FOD inspection/removal tools needed include pneumatic powered vacuum cleaners with extension suction tubes, mirrors, high intensity lights, magnets, and a variety of “FOD grabbers.” For floor-level debris collection, friction mat sweepers like the FOD-Razor® provide an efficient, low-maintenance solution.

## Control Areas

Within the manufacturing environment, FOD controls vary with the type of work being performed.

Three distinct categories of operation are evident:

- Fabrication

- Assembly

- Checkout/Test.

All three share the same key elements of control. However, each differs enough to allow diversity within the methods.

Rules that apply to the flightline may not be practical in a backshop. For supervisors and workers to support the FOD Program, they need to understand the importance of the controls and acknowledge that they are reasonable given the work at hand.

### Fabrication

Often called “backshops,” these are work areas such as sheet metal, machine shop, tubing and electrical harness. Typically, these shops lack enclosed panels or components. As a result, FOD control is less critical than in other areas.

### Assembly

In assembly, fabricated parts come together. Cavities are enclosed with fasteners or sealant. Consequently, these areas require greater control and more frequent inspections than fabrication. All areas or panels “closed out” should have a FOD buyoff (inspection) on the paperwork (documentation of process).

### Checkout/Test

Checkout and test require the highest level of control. The product is in its final stages before delivery or flight. All personnel entering the work control area must remove loose personal items — watches, keys, jewelry, coins. They must account for every tool and piece of hardware carried near the product. A tool/hardware inventory form may be required in certain FOD-critical products or areas.

Clearly define each control area so no one questions which rules apply. Also, keep in mind that work “travels” when not completed in its designated area. For example, a component not completed in assembly must be installed in checkout/test. Typically, the worker who normally installs the component in assembly is the one who “travels” to checkout/test to install the part. Therefore, every worker who may function in another control area must know the FOD requirements for that area. Training, SOPs, signs and supervisors of each process must learn and support the differing rules for each control area.

## Key Elements

The key elements of FOD prevention are universally accepted. However, aerospace companies apply them in various ways. Define each element clearly for each control area. In turn, clarity enables enforcement. The better defined, the better understood. The better understood, the better compliance.

Use posters and other visual reminders to promote the rules. Everyone at the facility should know the key elements — including security personnel.

You know your awareness program works when an administrative clerk retrieves a washer from the shop floor and reports it. Advertise these key elements widely. Don’t keep them hidden in a procedure folder or meeting room.

Plaster them on the walls. Publish updates in the company newsletter or intranet. Put FOD stickers on toolboxes and workbenches. Hold poster contests. Give recognition awards for compliance. Do anything you can think of to keep people focused.

The key elements are easy to remember because they are so integrated within the manufacturing workplaces: Tool Control, Hardware Control, Product Protection and “Clean-As-You-Go.” Keep the rules simple. Define their specific applications clearly, as the following chart illustrates.

FOD Control Procedures Table

Letter Codes for the three control areas are:

F = Fabrication

A = Assembly

C = Checkout

## Workplace Organization

FOD control in any manufacturing facility depends on a clean, well-organized work environment. Workers need designated areas for tools, storage and cleaning equipment.

For example, efficient planning may involve removing unnecessary items. Relocate benches, equipment, storage units, and toolboxes to facilitate smooth workflow. Following OSHA housekeeping standards, shop floors should be painted a light color to allow easy identification of dirt/debris and also to facilitate cleaning. Outline and label designated spaces for cleaning equipment, trash containers, ladders, air hoses, and toolboxes on floors and walls.

Believe it or not, some workers will claim that they didn’t clean up because they couldn’t find a broom. Accordingly, return everything to its place when the task is done. This way, everyone can find tools and equipment when needed.

Post signs outlining FOD controls prominently in each work area. Leave no room for confusion. Stage visibility boards in each work center. Display FOD metrics, bulletins, and awareness media so workers receive feedback on performance and goals.

Many manufacturing companies have adopted the Five S’s of Housekeeping as an aid for workplace organization. Adapt this concept to your facility’s needs. The following outline has proven successful:

### The Five S’s of Housekeeping

#### 1. Sorting

The process of removing unnecessary items from the workplace.

- Inspect the work area for excess or unneeded items. Document items you plan to remove, reorganize, or replace.

- Photograph work area for “Before and After” visibility.

- 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.

- Develop a new floor plan if necessary or desired.

- Tag items for removal, repair, or replacement.

- Determine who will remove or dispose of items.

- Get agreement from management on the plan and forecast expenditures for improvements or purchases of new furniture, fixtures or tools.

- Implement the approved plan in phases to minimize work interference.

#### 2. Standardizing

Identify uniform methods to maintain work areas.

- 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.

- Establish accountability rules for tool-crib-issued items to include expendables (sandpaper, rags, razor blades, etc.)

- Assure consistent application of rules on all shifts. Incorporate housekeeping standards into training programs and workplace audits.

#### 3. Simplifying

Provide specific, understandable directions, and procedures.

- Review/change existing procedures to assure workplace organization, cleanliness routines and tool accountability. Develop new procedures as necessary.

- Keep rules concise and displayed prominently.

- At crew meetings review areas needing improvement.

#### 4. Sweeping

Establish routines/requirements to maintain cleanliness.

- Enforce “Clean-As-You-Go.”

- Determine end-of-shift cleaning responsibilities and post schedules.

- Establish cleanliness checklists for each work area (include workstands, benches, floors and toolboxes).

#### 5. Self-Discipline

Identify individual responsibilities.

- Account for all tools and hardware at end of shift.

- Report missing items.

- Keep food and beverages out of work areas.

- Remove jewelry and personal items from clothing before going on/into assemblies.

- Return cleaning equipment, drop-lights, power cords and protective mats/pads to designated storage areas when tasks are completed.

## The Customer

Ultimately, the customer judges your FOD Program. Solicit feedback by requesting them to identify any foreign objects found in the delivered product and the exact location or zone. Provide a corrective action plan to demonstrate that you are attentive to their needs; specify what has been implemented to eliminate the error from future deliveries. Include missing item reports with every delivery for any items not found during the manufacturing process.

### Customer Visits and Communication

Invite the customer to visit the factory on a regular basis. Communicate the importance of keeping FOD out of the product. Workers sometimes lose sight of the fact that the work they perform everyday has serious implications related to quality, safety and reliability. Reminders — especially from the customer — are usually well received.

The “customer” concept works well to control FOD in-house before it gets to the final customer. Develop this by using promotional and awareness training sessions to build a “customer focused” culture within your manufacturing facility. Each work center or department should consider themselves the “customer” 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 “customer” work center. Items found by the receiving unit’s inspection should be documented and reported to the sender for corrective action. Forward the report to the Manufacturing Manager and FOD Program Manager. They monitor corrective measures for timeliness and effectiveness. Work centers that pass acceptance inspections clean become responsible for any FOD found downstream.

## Recognition and Competition

Recognize top-performing work centers monthly. Award the best work center of the year. Ultimately, this approach does more than control FOD. It creates a competitive, team-focused environment dedicated to building quality products.

## Quality

“Quality” is the buzzword that implies reliability, integrity, safety and customer satisfaction. Without effective FOD control, however, the product will not meet quality standards. Eventually sales fall. Contracts are lost. Accidents become more likely. Certainly, achieving quality is not easy — but every effort counts. As one company achieves higher quality, the challenge is greater for all others, and so the race continues to everyone’s benefit.

Don’t be left behind. Jump on the Zero FOD bandwagon and don’t accept anything less. Remember: FOD can’t be inspected out at the end of the line… processes must be in place throughout the entire build cycle to assure that it doesn’t get in.

Want to learn more? Contact us for guidance on developing your FOD prevention program.

## Setting Up a FOD Program

Source URL: https://www.fodcontrol.com/setting-up-a-company-fod-program/

## Establishing a FOD prevention culture within your Airline

Managers often assume that by simply establishing a new “corporate safety culture” that they will impel workers to a greater safety focus with an overall reduction in FOD event generation.

However, in practice, management and line staff don’t always respond the same way to new information.

Simply declaring safety as a corporate goal does not guarantee a cultural shift. New training and policies alone will not create change that all workers embrace and support.

In the real world, operational pressures and ingrained attitudes weaken new safety initiatives. Indeed, as they filter through layers of management, front-line workers receive mixed signals and confusing messages. Workers then perceive the current corporate safety culture effort as another “flavor of the month” program that will soon fade into oblivion.

### Safety Is A Team Effort

So let’s use the analogy of organized football. Here, the league sets rules of the game similar to the “goals” and expectations laid out by corporate headquarters when defining their “new and improved” corporate culture. However, declaring a set of rules does not guarantee the game will be played as expected.

The real action is up to the coaches and players. The local workers —the team— develop their own perception of certain rules. Similarly, they form an overall view of sportsmanship and ethical values. Much of the actual performance depends on shared beliefs, expectations, and team play.

Just as coaches inspire their teams, local line managers and workplace champions determine the direction of work culture. To build a winning safety team, these local influences must properly interpret new operating procedures. Furthermore, they must actively pursue designated safety initiatives — effecting real change and creating a cultural shift.

Localized influences make or break any corporate safety initiative; any real success is a direct result of the investment of front-line managers and workplace champions.

### Management Tools

The following tools have proven helpful in creating a FOD Prevention Program within the airline operations environment. An organization seeking to reduce FOD and FOD-related damages should implement as many of these as possible and remember that the operational target in any FOD Prevention Program should always be “zero”.

These FOD analyses increase recognition of problem areas and trends.

Additionally, they facilitate inspection results, incident data, mishap reports and feedback of progress.

#### Track performance and report your progress

1. Visibility Charts – Statistical graphs derived from audit or incident data.

2. FOD Report Card – A checklist of areas routinely inspected outlining areas of concern.

3. Performance Review – Review of worker conformance to policies and procedures.

4. Trend Analysis – Where have you been? Where are you going?

Employees need specific information about what isn’t working before they can be expected to improve the process. So tell them how they’re doing, good or bad. Honest, continual feedback is vital to any process improvement.

#### Plan for the long term

Too much FOD comes from poor housekeeping, ineffective practices, or poorly maintained equipment. Consequently, everyone who works around the aircraft must help control these problems. And that means foreign object debris training.

FOD Programs are works in progress that require constant attention. As a result, every FOD plan needs to be regularly reviewed and updated.

Your FOD Program will reduce employee injuries from flying debris and save money. A clean, organized work environment also enhances your professional image — as perceived by customers and fellow employees. When front-line workers have an active role in the process it shows.

Workers must acknowledge that FOD Prevention is part of their job. Specifically, incorporate this during new hire training and reinforce it continually. Following are several key factors in setting up a FOD Program that have proved to be successful.

## Safety Representatives

Designate local “safety representatives” to facilitate safety initiatives and monitor conditions, including the FOD Prevention Program. In most cases companies who attempt to create this type of system fail to provide enough manpower to support the development of the program.

For example, dayshift employees may feel they are doing a great job. However, afternoon and overnight workers may feel their concerns go unaddressed. They rarely see the station safety representative.

To establish a safe work culture, ensure there is representation across the board on every shift and on every day. This demonstrates that management’s commitment to creating a safe and FOD free work environment is real.

## Individual’s Safety Role

The majority of FOD in an airline’s operating environment is generated by individuals performing their job functions within aircraft servicing and movement areas.

Increasing personal alertness to FOD and continually supporting the “Clean-As-You-Go” mentality will lower your costs and create a safer workplace. Ultimately, every worker must promote an environment that actively defends against FOD.

## FOD Awareness

This is the keystone of your Ramp FOD Prevention efforts. Specifically, management should ensure that FOD removal and prevention appear on every daily briefing and meeting agenda. In addition, to maximize FOD awareness, FOD campaigns and FOD fairs should occur on a semi-annual basis.

## Training

Condition new employees to recognize potential FOD hazards right from the start by learning the “Clean-As-You-Go” mentality. Furthermore, all airport and airline personnel — including tenants — need annual training in FOD identification and elimination.

This training is easily reinforced through the use of FOD posters and signs. Effective sessions cover safety for personnel and passengers, equipment hazards, direct FOD damage costs, and indirect costs from flight delays and rescheduling. Moreover, include procedures for removing and eliminating FOD at its source. A review of recent FOD Report Cards will provide specific criteria to focus on.

## Proper Containment

Keep FOD disposal bins or FOD Cans readily available, clearly marked, and handy at every gate. Notably, the EPA requires a separate collection process for empty oil cans. Never place used oil containers in a FOD receptacle.

Disposal bins need lids. Specifically, lids prevent wind from redistributing FOD onto the ramp and keep water from fouling the container. It helps to have small FOD receptacles bolted to belt loaders. This way, workers can clean while working flights — no walking to the gate to dispose of debris. Line FOD containers with plastic bags for easy removal and replacement.

Develop a specific policy and follow it rigorously. Empty FOD containers on a scheduled basis or at the end of each shift.

## Proper Equipment and Tools

Encourage fast cleanup by making push brooms and shovels available at every gate. Magnetic sweepers mounted on equipment help pick up ferrous material. However, ferrous material is only part of the ground FOD threat. Most airport FOD comes from non-ferrous items: rocks, concrete, plastic, paper, baggage parts, and cargo wrappings.

Airport sweeping equipment come in many shapes and sizes, but two effective tools for clearing both gates and large open areas of debris quickly and thoroughly are our TracSweep® and FOD-Razor® Sweepers. Importantly, both are non-motorized, all-weather, and easy to use, clean, and maintain. They cost a fraction of larger truck-mounted vacuum sweepers.

## Sweeping Schedule

Each individual must take responsibility for their assigned areas and adhere to a posted schedule. Similarly, address general work areas on each shift to ensure they are clean and FOD-free. In addition, schedule FOD container disposal at least three times per week.

Each aircraft gate area must receive a FOD Walk before every arrival and again before each departure. Additionally, transitional duty personnel coming off injuries can supplement FOD prevention efforts. Ensure they do not exceed medical restrictions.

Coordinate regular sweeping of ramp and taxiways with the local Airport Authority for all non-leased airport property.

## Tool Inventory

Use a tools audit checklist to inventory and account for every tool after each use in or around the aircraft. In addition, dispose of oily and dirty rags properly. They pose a serious flammability risk.

In the late 1980s an aircraft caught fire due to a misplaced oily rag; the aircraft was a total loss. This illustrates how seemingly inconsequential items can have devastating effects. Take no Foreign Object for granted!

## FOD Committee

Communicate airside and landside construction activities — and scheduled maintenance — to airport users as early as possible. Consequently, preconstruction planning must include a means for controlling and containing construction-generated FOD.

Contractors must fully understand the FOD control and removal requirements — and penalties — written into their contracts. This is especially critical in windy environments where debris is more likely to become airborne. Therefore, route construction site access away from areas of aircraft operation whenever possible.

Convene FOD meetings at least monthly with all departments that contact the aircraft — including vendors and contractors. Each vendor should recognize the FOD hazards their department creates. Notify affected departments of any unique FOD Prevention requirements.

## Bird/Animal Feeding

Yes, birds and other animals are considered FOD and are an enormous hazard to aircraft. They cause millions of dollars in damage each year. You may have noticed the stripe of paint on the engine intake cone. Part of its function is to deter birds from flying into the engine area when at idle.

Accordingly, bird feeding must never be allowed on airport property.

Do not leave unattended food out in ramp areas where birds can get at it. Don’t assume employees should know this — emphasize the hazards and the reasons to stay alert.

## Debris Removed from Ground Support Equipment

Remove all unattended items from ground support equipment when not in use. Stow them securely. This may include paper products from carts or tugs. Otherwise, these items end up blowing around the ramp.

Flashlights and wands also become a problem if not stowed correctly. Specifically, never stow them on the floor of a tug. They can roll beneath a pedal and impede driver operation. Therefore, keep all tug cabins clear of debris. In addition, minimize loose debris in pickup truck beds. Remove it after every shift.

## Ramp FOD Inspections

Schedule and perform ramp inspections with the local airport authority regularly. Loose and eroding concrete or asphalt pavements pose serious FOD risks. In particular, pavement joints and cracks harbor FOD. Check engine paths around these areas carefully.

In addition, perform a runway inspection at the start of each day. (This can double as an agenda item at each FOD meeting. Get all committee members on the ramp to identify real or potential problems and agree on corrective actions.)

## Cargo Bin Cleaning

Cargo bins seem to collect a lot of garbage — which can cause FOD mishaps. Periodically inspect bins and remove the trash. Aircraft that remain overnight in your station should have the bins inspected for debris and cleaned when necessary.

## Aircraft Support Equipment

Loose equipment — cones, air conditioner hoses, ground power cords — are all hazards if not stowed correctly.

Above all, know the blast and suction danger zones for your aircraft type. If the aircraft is not properly spooled down, items like air conditioner hoses can be ingested. Keeping a clear pathway for parking aircraft is essential to maintain a safe environment.

All equipment should be outside of the wingtips until the plane has come to a complete stop and the engines idle down.

## Personal Items

People often overlook individual property as a FOD threat. Instruct ramp personnel: never leave personal items near aircraft. These items include hearing protection, vests and kneepads.

Stow all raincoats, jackets, gloves, caps, and food items when not being worn or used. Keep them away from the aircraft. None of these items should ever be left unattended near an aircraft.

## Self-Audits

Frontline workers need specific information about discrepancies before they can improve. Perform self-audits at least once a month — and informally as part of the daily routine. Accordingly, record the results. Use them in the FOD Report Card. At minimum, share them at monthly FOD meetings.

Specifically, evaluate how much FOD was found, what type, and where. This pinpoints problem areas. Subsequently, once a problem is defined, meetings should focus on corrective actions and evaluate results. Then you can update and make adjustments to your written FOD Program if necessary.

Let’s face it — no one enjoys picking up FOD. Appropriate motivational techniques keep the front line involved in work area cleanliness. Instead, use different methods to motivate. Take the time to recognize and reward good work. FOD Prevention is a never-ending battle.

### Awareness Is Key

While your imagination can certainly yield other good ideas for your organization, a few successful methods are listed below:

- FOD Walk “Piece of the Day” – During off-peak periods, get the team to walk the work area and pick up debris. To make this a bit more fun and interesting, select a FOD “Piece of the Day.” Whoever collects the most of that item wins a lunch voucher or movie tickets.

- FOD Holiday Tree – During the holiday season, contest other stations to create the most interesting FOD tree. Gate agents collect FOD and use interesting pieces as tree ornaments. Each station sends a photo to the corporate FOD committee for judging. The winning team is awarded a holiday dinner.

- Caught in the Act – This program rewards positive behavior on the spot. For example, if a worker were “caught” with a broom in his hand cleaning an area without being asked, he would be awarded a lunch voucher on the spot.

- Cleanest Gate Award – The workers who have the cleanest gate during the day may get recognition from the Supervisor with the Cleanest Gate of the Day Award.

Need help setting up your FOD prevention program? Contact us today.

## Conclusion

Whatever path your organization takes, first establish a collective safety focus. This applies to the airline industry as a whole. Each airline must encourage an effective event-reporting system that recognizes human factors and other causes leading to FOD events. Industry bodies like the ICAO Runway Safety Programme provide frameworks for this type of cross-organizational reporting. The reporting system should serve as an industry-wide database. Even the smallest company can benefit from the combined knowledge.

A fair system of adjudication and discipline is also critical. It provides consistent assessments of causation. Above all, it emphasizes open communication over blame and punishment.

### We Are All In It Together

The aviation sector must actively seek to learn from our mistakes. This requires increased dedication, learning, and consistent commitment of resources, energy, and time.

If we are successful at this endeavor, we will one day eliminate most threats from airport operating environments.

FOD knows no boundaries. Likewise, FOD control should have no company boundaries. Ensure your own FOD Programs are up to par. Additionally, verify that competitors who share your airfields maintain good programs. Rigorous aircraft maintenance tool control practices further enhance safety. Specifically, account for every tool after maintenance tasks. This reduces the risk of tools being left behind. Every ramp we fly into must be clear of FOD — to protect our aircraft, our assets, and our people.

## Recent Articles

- [Born on the Ramp: Why Ground Handling Is Ground Zero for FOD](https://www.fodcontrol.com/born-on-the-ramp-ground-handling-fod/) — On July 14, 2026, a ground service vehicle took an Air Peace Airbus A320 out of service at Lagos’s Murtala Muhammed International Airport. Not a runway. Not the open airfield. A NAHCO baggage conveyor truck struck the aircraft’s engine nacelle during a routine turnaround, and the nacelle tore badly enough to ground the jet on […]
- [Construction Season Never Ends: Managing FOD Around Active Work Zones](https://www.fodcontrol.com/construction-fod-prevention-active-work-zones/) — Construction Season Never Ends — Why Active Work Zones Are a Permanent FOD Source Every operator eventually says the same hopeful thing: “once this project wraps up, things will get back to normal.” They rarely do. Between resurfacing cycles, facility expansions, and structural repairs, an active work zone almost always borders a live operating surface. […]
- [The Blowout Chain Reaction: How a Disintegrating Tire Turns Into a FOD Event Anywhere You Operate](https://www.fodcontrol.com/tire-blowout-fod-chain-reaction/) — On July 6, 2026, an Air Nostrum CRJ-1000 suffered a main-gear tire burst at full thrust on France’s Nantes Atlantique Airport‘s sole runway. Fragments were ingested into a rear-mounted engine, forcing a shutdown. The crew landed safely — but the runway was now covered in rubber and steel debris, and ground crews locked it down […]
- [The Heat Is On — and Creating FOD You Didn’t Budget For](https://www.fodcontrol.com/extreme-heat-pavement-fod/) — On July 13, 2026, inspectors at Tokyo Haneda Airport found a roughly 20-centimeter cavity in Runway C — not a hairline crack, but a hole. Japan’s transport ministry pointed to a familiar cause: moisture trapped in existing cracks expanded under prolonged heat until the asphalt gave way. The runway closed, repairs ran more than two […]
- [The FAA Just Handed Runway Safety to an AI. Here’s What It Means for Your FOD Program.](https://www.fodcontrol.com/faa-ai-runway-safety-fod-program/) — In June 2026, a Politico investigation confirmed what safety analysts had long expected: the FAA is deploying Palantir‘s Foundry AI platform across its runway safety operations. The system ingests radar feeds, ADS-B position data, NTSB filings, and weather records. It then surfaces recurring risk patterns before they escalate. In at least one case, Foundry’s analysis […]
- [250 Years of Pushing the Limits: An Independence Day Tribute to the People Who Drive America Forward](https://www.fodcontrol.com/america-250-independence-day-tribute-american-innovation/) — Two hundred and fifty years ago, a group of builders decided the world could work differently. They wrote it down, signed their names, and bet everything on it. What they started — this restless, forward-leaning experiment in human possibility — is still very much alive. That’s what’s worth celebrating this Independence Day. Not just the […]
- [What Motorsport Facilities Can Learn From Aviation FOD Programs](https://www.fodcontrol.com/what-motorsport-facilities-can-learn-from-aviation-fod-programs/) — When a sanctioning body inspector asks how your facility manages debris on the racing surface, what do you show them? A documented program — or an explanation? Motorsport facilities are being held to a higher standard. The gap between informal track-sweeping habits and an auditable FOD-prevention program is exactly where that pressure lands. FIA homologation […]
- [The FOD Audit Playbook: How to Prepare Your Airport for a Program Review Before the Auditors Do It for You](https://www.fodcontrol.com/fod-audit-playbook/) — Picture this: A Part 139 inspector arrives at your airport. Your operations team runs daily runway checks without fail. Your maintenance crews know the FOD walk routine cold. The inspector asks for your documented risk assessment, your named FOD manager, and 90 days of trend analysis records. The room goes quiet. That silence is the […]
- [Part 139 and FOD: What Self-Inspection Compliance Really Requires](https://www.fodcontrol.com/part-139-fod-requirements-self-inspection-compliance/) — For any of the roughly 520 US airports certificated under 14 CFR Part 139, runway safety is a federal mandate enforced at every certification audit. The Part 139 FOD requirements in §139.327 define how often your team must inspect the airfield, who is qualified to do it, and how long those records must be kept. […]
- [FOD on the Flightline: Why Military FOD Programs Fail at the Shift Change](https://www.fodcontrol.com/fod-flightline-shift-change-2/) — The aircraft is buttoned up. The outgoing crew is signing off. The incoming shift is still getting oriented. For a window that lasts maybe 20 minutes, the shift change on a military flightline carries a disproportionate share of foreign object debris risk. Tools get miscounted. Ownership gets blurry. Situational awareness hits its daily low — […]

## How to Cite

When referencing The FOD Control Corporation:
- Company: The F.O.D. Control Corporation (also: FOD Control Corporation)
- Founded: 1983
- Website: https://www.fodcontrol.com
- FOD-Razor®, TracSweep®, and Power Bar™ are trademarks of The FOD Control Corporation.
- For news and industry coverage, see the sister publication FODNews at https://fodnews.com