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Implementing a FOD Prevention Programme

Implementing a FOD Prevention Programme. Steve Frost July 2004. Brough. Warton. Samlesbury. Woodford. BAE SYSTEMS UK Sites - over 65 locations. 4 Sites across the UK Over 9,000 employees Products include:. Typhoon Hawk JSF Nimrod Harrier Tornado New Business.

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Implementing a FOD Prevention Programme

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  1. Implementing a FOD Prevention Programme Steve Frost July 2004

  2. Brough Warton Samlesbury Woodford BAE SYSTEMS UK Sites- over 65 locations

  3. 4 Sites across the UK • Over 9,000 employees • Products include: • Typhoon • Hawk • JSF • Nimrod • Harrier • Tornado • New Business Military Aircraft Sites

  4. Typhoon Harrier Hawk Joint Strike Fighter Tornado Nimrod MRA4 Warton Site Employees 5,000 + People on site 8,500 +

  5. Specialist Areas Customer Solutions & Support • RCS Range • EWTF • Radar / Radio Test • International Programmes • Project Al Yamamah • Military Air Solutions & Support • Land & Sea • Training Solutions Typhoon • Business Centre • Avionic System Development • Development Aircraft 2 • Final Assembly Hawk • Final Assembly • Acceptance / Delivery Test & Development Flying Centre Aerodynamic Wind Tunnels RAF Typhoon Contractorised Support • Low Speed • High Speed • Tornado • Hawk • Harrier • Typhoon • Jaguar • Customer Training • (Hawk / PC9) • RAF Pilots & ground crew • OCU & OEU • Full Industry Support Systems Technology • Systems Development • Advanced Technologies • Systems Integration Aircraft Preparation Areas • Engine Running Bays • EMI / EMC Range • APU / ECS Ground Runs Tornado • RAF MLU Harrier Nimrod Safety Ranges • RTW Progs • Systems Integration • Programme Management • Gun Firing Range • Explosive Equipment Warton Site Locations

  6. Implementing a FOD Prevention Programme • Our Bad Experience • Developing & Implementing a Robust Tool Control / FOD Process • Maintaining Flight Safety Awareness

  7. Our Bad Experience • RTW Programme • 16 Tornado ADV’s for Royal Air Force • 150 Staff Employed on Programme • Programme running well up to the 10th aircraft “AT029”

  8. A Bad Experience

  9. The Aftermath

  10. Loss of ‘AT029’ 28th September 1996 • Thankfully no-one lost their lives • Personal reactions • myself • my staff • AAIB • Aircrew Reaction • This Should not have Happened

  11. A Bad Experience - Continued • Invited Inspectorate of Flight Safety to BAE SYSTEMS Warton • Areas of Improvement identified • Lessons Learnt For BAE SYSTEMS • Recognised Need to further Develop the FOD Prevention Programme • Identified Need For a Focal Point in the Organisation For FOD Prevention

  12. Implementing a FOD Prevention Programme • Our Bad Experience • Developing & Implementing a Robust Tool Control / FOD Process • Maintaining Flight Safety Awareness

  13. Identifiable • Identifiable • Variable Recognition of Forms of FOD

  14. Development of a Robust Tool Control Process Key Steps • Honest Assessment of Current Status • Senior Management Commitment to Develop a Long Term Strategy to Deliver a Robust Solution • Scope the Problem - people - product range • Establish Organisation to Manage and Govern the Issue

  15. Material Components Best Practice Supply Chain Processes Resource Information Scheduling Tooling Organisation to manage and govern the issue • Dedicated Asset Management Team Formed Aim: One Common Tool Control / FOD Prevention Process

  16. Development of a Robust Tool Control Process Key Ingredients • Physical Control Techniques • Process • IT Support

  17. Development of a Robust Tool Control Process Key Ingredients • Physical Control Techniques • Process • IT Support

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

  19. Established Long Term Partnership with a Tool Supplier • Decision to Invest in Tool Kits for Every Tradesman • Focus on Standardisation, Simplicity of Control and • Personal Responsibility and Ownership Tool Control

  20. A well organised tool store

  21. Development of a Robust Tool Control Process Key Ingredients • Physical Control Techniques • Process • IT Support

  22. FODCONTROL STANDARD Logistics Asset Management Engineering Quality Control TOOLCONTROLPROCEDURE Process Development IT Support WORKINSTRUCTIONS Production Supervisors Purchasing Shop Floor Representatives Process Development

  23. Development of a Robust Tool Control Process Key Ingredients • Physical Control Techniques • Process • IT Support

  24. I.T. Support • Recognised Limitations of Existing System • Clarified Functionality Required to Support Level of Tool Control • Need a Computer to Make it Easier Not Harder - Keep it Simple • Tested Solutions Available in the Market Place • Invested in Modern Asset Management System

  25. Asset Management System Investment in I.T. Solution • Tracking of Assets Between the Manufacturing Work Centres • Track Assets / Tools to Personnel and Aircraft • Control of Calibration & Servicing

  26. Standard Tooling • Manpower Efficiency • Minimal Replacement Costs Specialist Tooling • Effective Tooling Management Throughout the Supply Chain • Effective Management of Tooling Inventories • Full Visibility of Tooling Registers Indirect Benefits

  27. Right Tool Right Place Right Time Right Condition Physical Control Process I.T. Support Tool Control Ethos

  28. Well Organised Tool Store FODCONTROL STANDARD ITSolution Physical Controls Simple Robust Process TOOLCONTROLPROCEDURE F A I L E D WORKINSTRUCTIONS Asset Management Organisation established Mission Accomplished?

  29. Corrective Actions • Redefined their roles and responsibilities • Trained and Proved Competencies • Issue Licence (renewable annually) for Flight Line Tool Store Keepers Why did it fail? - The Store Keeper • Human Factor • Traditionally Low Skilled • Process Failed

  30. Identifiable • Variable Recognition of Forms of FOD

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

  32. Standard FOD Signs • Flight Safety Boards and Media • Airworthiness / Quality Bulletins • Low Impact Poster Material Flight Safety Awareness What we used to do

  33. So let’s try something different !

  34. Flight Safety Awareness

  35. Flight Safety Campaigns

  36. Flight Safety in the home

  37. Flight Safety / FOD Briefings

  38. What did happen?

  39. Implementing a FOD Prevention Programme Summary • Avoid Complacency • Keep It Simple • Flight Safety is YOUR RESPONSIBILITY

  40. FLIGHT SAFETY A Journey that never ends Committed to constantly reviewing the FOD Prevention Process

  41. Think Flight Safety Think...

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