1 foe implementation basic process. 2 foe implementation process flowchart
TRANSCRIPT
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FOE ImplementationBasic Process
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FOE IMPLEMENTATION PROCESS FLOWCHART
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FOE ImplementationProcess Flowchart
The FOE Focal Point is selected for every Area to assist in the implementation of the FOE Program and compliance to the requirements.
Verify FOE Area Control Level Assessment
Verify External Signage for
Correct FOD Control Level
Verify Training Requirements
Set Up FOD Metrics
Check Applicable Requirements
Perform FOD Area Sweep Checklist Daily (Med/High)
Perform FOD Area Monthly Self-Assessment
Checklist (Med/High)
Perform Material Control
(Med/High)
Perform Tool Control(High)
Follow Incident Reporting
Flowchart if FOD is Found
FOE Implementation Process Flowchart
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FOE AREA CONTROL LEVEL ASSESSMENT
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FO Control Level Assessment
Get minimum Control Level from Requirements
Complete General Information about the area
Identify Potential FOD Risks to the Product
Identify any additional FOD controls that will used beyond the Requirements and identify any exceptions
Provide any instructions for FOD prevention that are special to the hardware
List the Approvals of the Assessment as required. Examples are FOE Focal Point, Section Manager, Engineering, Program Manger
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FO Control Level AssessmentOverall Approach
Complete a FO Control Level Assessment for the area first to determine FOE Control Level of the overall area (baseline).
This level is noted on the external area signage board This assessment should handle all hardware and operations that you would normally expect to
process and perform. Revise assessment as required (add rev letter – DO NOT OVERWRITE any assessments).
For cases of hardware or processes that do not fit into the overall area assessment performed above, generate an additional assessment to specifically address that hardware or process and understand the FO Control Level required as well as list any special instructions/exemptions.
Additional Assessments
Area Level Assessment(Baseline)
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FOD METRICS
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FOD Incident Reporting Metric
Definitions:
Foreign Object Debris
FOD A substance or article alien to the product or assembly that has the potential to cause damage or degrade the product’s required safety and/or performance characteristics.
Foreign Object Damage
FOD Any damage attributed to a foreign object that can be expressed in physical or economic terms which may or may not degrade the product’s required safety and/or performance characteristics.
FOD Incident An Instance where Foreign Object Damage or Debris (FOD) is found
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FOD Incident Reporting Metric
Standard Reporting Metric (Must be updated monthly and posted):
Monthly & Cumulative To Date FOD Incidents
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JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC CTD
Month
Tot
al F
OD
Inci
dent
s
Total FOD Incidents
Cumulative To Date (CTD)
3 per. Mov. Avg. (Total FODIncidents)
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FOD Incident Reporting Metric
FOD Metric Chart Input Data Table (Example Only):
A B C D E FMetric Chart Input Data Worksheet
Month
Foreign Object Debris
Foreign Object
Damage
Total FOD
Incidents
Cumulative To Date (CTD)
Cumulative To Date (CTD)
J AN 0 0 0 0FEB 0 0 0 0MAR 0 1 1 1APR 2 0 2 3MAY 1 2 3 6J UN 0 0 0 6J UL 2 0 2 8AUG 1 0 1 9SEP 0 1 1 10OCT 0 0 0 10NOV 0 0 0 10DEC 0 3 3 13CTD 13
Totals 6 7 13
<copy cell E4 to desired row in col. E to copy formula>
<update cell F15 for current CTD>
Manually loaded using data from monthly data sheets
Can automate for a specific area if desired
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FOD Incident Reporting Metric
FOD Metric Monthly Data Sheet (Example Only):J an
# Date Description
Foreign Object Debris
Foreign Object
DamageRecorded
By Disposition/Correction Action
1 Describe Incident Here 0 0
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0 0
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FOE CONTROL AREAIDENTIFICATION
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FOE Control Areas
Required for FOE Control Levels different from posted level on signage (for Higher or Lower Areas)
Use signage, floor markings and/or stanchions to identify area
LOW
Medium
Medium
High
Sub-Areas Overall Area
Overall AreaApply Note for
Sub-Areas
FOE Focal Point is responsible to ensure proper area identification
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Other users working in the Area may not know enough about FOD control levels yet to notify the FOE Focal Point or other Area personnel when a higher (or lower) level of control is needed
It is important that we educate the users to ensure understanding and compliance to the new FOE policy/work instruction at all times
The FO Control Level Assessment should capture the possibility of requiring a Control Level change to accommodate a configuration change (planned or unplanned) with the product
FOE Control AreaPossible Concerns
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Internal Signage
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DAILY FOE AREA SWEEP CHECKLIST
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FOE Area Sweep Checklist
1 Tables and workbenches are free of FO (materials, tools, etc.). These are items not required for the in-process activity.
2 Floor and ceiling is free of debris.
3 Test Equipment is free of debris.
4Equipment (carts, trash cans, etc.) are returned to designated location.
5Unused tools are returned to proper location (i.e., toolboxes and/or shadow boards).
6Hardware is covered/stored properly and safe of FOD risk (any openings, ports, holes, and ducts are covered) when not in use.
8Hardware is safe from small items, consumables or other materials that may create a FOD risk.
9Tool Log Sheets are properly filled out if being used.
10Areas are properly identified and marked off if multiple FO Control Levels are present.
Once
Once
Once
Once
Once
Once
Once
Once
Once
Bldg/Room/Sub-Area
S S CommentsT F
Cost CenterWork Area Name:
Checklist Timing: 10 Minutes Average
Daily FOE Area Sweep Checklist
What to Sweep
For the Week Beginning Monday,
M T W
Frequency per Shift (Working Shifts Only)
FOE Focal Point performs or assigns task Must be performed daily for all Medium and High areas Elements may be combined with area 6S program (if performed daily) Records must be retained Anything found must be fixed or addressed on the checklist Template and sweep elements may be tailored to a specific area
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MONTHLY FOE SELF-ASSESSMENT CHECKLIST
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FOE Self-Assessment Checklist
FOE Focal Point performs or assigns task Must be performed monthly for all Medium and High Records must be retained Anything found must be addressed on the Corrective Actions sheet Template and self-assessment elements may be tailored to a specific area Impractical to do for temporary Medium/High areas unless area is in place at time of assessment No requirement to post the self-assessment checklist Pareto chart as a Metric
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MATERIAL CONTROL
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Material Control
Required for FOE control Levels Medium and High Try to make Material Control area as small as possible Use floor markings or stanchions to identify area Log in/Log out guidelines Requirement was developed primarily for screws, nuts, bolts, q-tips and
other small parts instead of glues, paints and sealants Make Log in/Log out sheet that is specific to the operation Consumables too large to be lost
or impractical to count can be accounted for using visual confirmation (examples include Kimwipes, tape, glue)
Material Qty Emp # Qty Emp #
Material Control ChecklistProduct: Operation No:
Check-In to Area
Info filled in by the User
Check-Out of Area
Info filled in by the User
Material Control will be the hardest to do!
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TOOL CONTROL
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Tool Control
Required for FOE control Level of High only Try to make Tool Control area as small as possible Use floor markings or stanchions to identify area Shadowboxing is best method but it may not be practical in an Engineering Lab Controlled Perimeter List is the easiest to implement Lost tools must be reported immediately
Tool Description (# of items)Date:
Month/Day Emp #Date:
Month/Day Emp #
Controlled Perimeter Tool Checklist:
Check-In to Perimeter
Info filled in by the User
Check-Out of Perimeter
Info filled in by the User
Controlled Perimeter Tool Checklist:Recommended Form - May be Tailored to Site/Area Specific Requirements
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FOD INCIDENT REPORTING
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Incident Reporting
Follow the FOD Incident Reporting Process Flowchart
All FOD Incidents are required to be reported
Know the definition of FOD to avoid unnecessary reporting
Report a metric for every FOD Incident
Share information with others
Don’t be afraid to report an Incident (root cause analysis is important)
FOE Focal point needs to know about all FOD Incidents
If Foreign Object Damage is found, stop work on the hardware, report incident and initiate an investigation. Resume work when authorized
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FOD Incident Reporting Process Flow
FOE
Foc
al
Poi
ntQ
ualit
yS
uppl
y C
hain
M
gt.
Sup
plie
rE
mpl
oyee
FOD IncidentNotify Area Supervision and Quality
Notify FOE Focal Point
Foreign Object Damage or Debris?
In-house or Supplier Caused?
Prepare RCCA action and
complete for closure
Document Incident in Quality History
Record
Disposition and closeout
Prepare Defect Report to supplier
Find root cause and corrective
actionPrepare response
Review and approve
response and prepare response
Damage
Investigate and perform corrective action as required
Discuss incident at team meetings
Prepare RCCA action
Supplier
In-house
Complete RCCA response for
closure
Debris Debris found in High FOD Control
Level Area?
Yes
No
FOD Incident Reporting Process
Incident Reporting