Contractor s Guide for FOD Prevention Program Compliance

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2 Sikorsky Aircraft Corp. stays true to the legacy of Igor Sikorsky with a mission statement that encompasses his passion for safety and innovation: "We pioneer flight solutions that bring people home everywhere...every time." Sikorsky helicopters have saved an estimated 2 million lives since performing the world's first helicopter rescue in Sikorsky Aircraft Unpublished Proprietary Work

3 Table of Contents What is the FOD Prevention Program?... 1 Contractor Responsibility... 1 FOD Prevention Zones... 2 Critical Zones... 2 Sensitive Zones... 2 Awareness Zones... 2 Housekeeping... 3 FOD Containers... 3 Personal Items... 4 Critical Zones... 4 Sensitive Zones... 5 Hardware & Consumables... 5 Tool & Equipment... 6 Parts & Materials... 7 Environmental FOD... 7 Hazardous Materials... 8 Flight Operations... 8 Incident Reporting... 9 Designing Out FOD... 9 Summary Contacts Raffi Fattal, Enterprise FOD Manager Michael Grant, Operations FOD Manager Sikorsky Aircraft Unpublished Proprietary Work

4 What is the FOD Prevention Program? Sikorsky Aircraft is committed to deliver products that are safe and reliable. Foreign Object Damage (FOD) prevention is core to the safety and quality of our products. To ensure that FOD prevention is implemented at every level of product design, manufacturing, repair and operation, every Sikorsky facility has been required to implement a comprehensive FOD Prevention Program that includes contract personnel. FOD This guide provides the basic requirements for contractors to comply with our FOD Prevention Program. As with all company safety and EH&S procedures, compliance is mandatory. The facility or work area you are in may have additional requirements that you will also be required to comply with. As always, contact the area supervisor to ensure that you are aware of all rules and procedures. Contractor Responsibility Contractors are required to employ reasonable care in the execution of the work they were contracted to provide. This includes not creating conditions that present hazards to others or damage to property, product or equipment. It also includes notifying management to any conditions they encounter that are an obvious hazard. The following sections provide the FOD prevention rules that all personnel are required to follow. It is organized by topic to make finding information easier. Any questions can be directed to the contacts listed on the previous page. Sikorsky Aircraft has a long history of producing products that are safe and reliable. We intend to continue that tradition. Please read and follow the FOD prevention procedures contained in this guide to ensure that we deliver products that are FOD free. 1 Sikorsky Aircraft Unpublished Proprietary Work

5 FOD Prevention Zones Sikorsky has implemented a zoning system to establish control measures based on the criticality of the operation. Most areas will have a single zone designation; however, having a zone within a zone is permitted. For example, a fuel cell closure Critical (red) zone can exist within a structure subassembly Awareness (blue) zone. Temporary zones are also permitted. For example, if a fuel cell had to be opened up for rework in Final Assembly, a Sensitive (yellow) zone, that work area would become a Critical (red) zone until the work was completed. The important aspect is that the signs must be visible so you always know what zone you are in. All manufacturing areas must be clearly marked with one of the following signs: Critical Zones Any operation involving a flight aircraft (flight & ground operations) or any assembly of aircraft structure or components that are closed. Examples include fuel cell close-ups, gearbox housing assembly, aircraft floor installation, aircraft painting and flight test operations. Sensitive Zones Areas that assemble aircraft structure or components that are not closed. Examples include aircraft final and major assembly, component assembly and component test. Awareness Zones Manufacturing areas that are not designated as Critical or Sensitive areas are Awareness areas. Examples are aircraft subassembly, machining and detail parts. Sikorsky Aircraft Unpublished Proprietary Work 2

6 Housekeeping A clean work area is the most cost effective measure for preventing FOD. It also makes for a better work environment and shows our customers that we are a world class manufacturing facility. First impressions are lasting so CLEAN: as you go during idle periods at the end of a shift when work is completed Use mechanical cleaning devices for cleaning where possible (brooms, vacuum cleaners, etc.). If you see something that is potential FOD PICK IT UP! Work areas should not be left unattended with debris laying about so clean before you leave. IF EVERYONE PICKED UP FOREIGN OBJECTS THERE WOULD BE NO FOD. FOD Containers FOD containers are an effective means of reducing the potential for FOD. Manufacturing debris (wire, washers, rivet stems, wire ties, screws, etc.) are placed in FOD containers rather than allowing them to drop on the floor or into the aircraft. This not only reduces the opportunity to miss debris in the aircraft, it also reduces clean up time. FOD containers should not be used for general trash. 3 Sikorsky Aircraft Unpublished Proprietary Work

7 The standard FOD container for Sikorsky is shown in the picture below. These yellow bags are located in the hangars and certain manufacturing areas throughout the facility. Contractors are encouraged to use these if working near aircraft or components where the bags are located. Contractors can also use any of the trash containers located throughout the facility unless debris removal by the contractor is stated in the contract. Personal Items Personal items include things such as watches, jewelry, pens, portable music devices, etc. These items can pose a serious hazard to aircraft systems and components. A simple pen can jam flight controls or short out an electrical system. Personal items also represent a significant safety hazard, jewelry and other items can snag while working on aircraft or machinery causing serious injury. The pen is mightier than the sword Edward Bulwer-Lytton ( ) The best method for controlling personal items is to not take anything into a Critical or Sensitive area that is not necessary. Leave all non-essential items at your desk, in you locker, etc. A non-essential item is anything that is not necessary to do your job. The specific method for controlling or securing personal items can vary from work area to work area so know the procedures for the area you are in Critical Zones Non-essential personal items cannot be taken on an aircraft. Verify that any items that you must take on the aircraft, such as glasses, hearing aids, etc., are in your possession when you depart the aircraft. Sikorsky Aircraft Unpublished Proprietary Work 4

8 Sensitive Zones All personal items must be secured prior to getting on an aircraft. This can be accomplished by placing them in pockets with zipper closures, placing all items in a waist pouch, etc. Hardware & Consumables Nearly all modern commercial aircraft use gas turbine engines. Turbine engines run at very high speeds (~20,000 rpm) to produce high thrust to weight. These engines are extremely reliable, but are very susceptible to FOD. The engine pictured here had to be replaced because of a single screw was left in the engine intake. One BLACK HAWK engine costs over $681,000 not counting the indirect costs such as labor, schedule delays, etc. Uncontrolled hardware is the number one FOD issue at Sikorsky according to the metrics hands down. There is no excuse for damage to engines and other aircraft components from hardware and consumables since it is completely preventable. By simply keeping track of hardware and consumables while you work, you can prevent FOD. Take only what you need Kit where possible Do not store in tool boxes Ensure correct type, size, etc. Collect wrappers, debris, etc. All containers for hardware and consumables should be designed to prevent accidental spillage and kept closed when not in immediate use. Prevent FOD from hardware and other sources by following the rules and utilizing clean-as-you-go. 5 Sikorsky Aircraft Unpublished Proprietary Work

9 Tool & Equipment You can gauge the quality of a technician by the way they maintain their tools and equipment. Someone that keeps their tools and equipment clean, organized and in good repair is also someone more likely to adhere to FOD prevention procedures. This tool box was an actual before picture at a Sikorsky location before the tool control program was implemented. This condition for a tool box is no longer acceptable in Critical or Sensitive zones, and it is strongly discouraged everywhere else. A tool lost from a box in this sort of disarray would easily go unnoticed. This is a correctly shadowboxed tool box from a company contracted to perform maintenance at Sikorsky. This not only makes it easy to notice if a tool is missing, it keeps tools from getting damaged from other tools during transport. Some areas require that contractor s toolboxes are photographed prior to entry into a Critical (red) or Sensitive (yellow) area. This practice is highly encouraged. The toolbox pictured here was found to have a small punch missing. A review of the pictures revealed that the punch was not in the box when it was brought into the area. This prevented a search of multiple aircraft work areas for a nonexistent lost tool that would have interfered with aircraft production and resulted in thousands of dollars in labor costs. Take pride in your profession by looking professional our customers judge us by what they see. Remember, if you follow the tool control procedures you will not leave a tool in the aircraft; and if you leave a tool in the aircraft -- you will have no excuse. Sikorsky Aircraft Unpublished Proprietary Work 6

10 Parts & Materials We buy and manufacture a wide variety of very expensive aircraft parts. Many of these parts are easily damaged if improperly handled. Even a small scratch can cause a major failure over a number of cycles (rotations, takeoff and landings, etc. Damaged parts, rework and scrap costs Sikorsky millions of dollars each year. We can eliminate many of these costs by following material handling procedures and being cognizant of parts in the vicinity of activities such as building maintenance. While our finished products are designed to be robust and reliable, many aircraft components are vulnerable to contamination prior to installation. Even minute particles in a hydraulic system operating at 3000 psi can cause eventual failure. Welding, for example, produces splatter that can easily migrate to finished products if proper procedures are not followed. MAKE SURE THAT THERE ARE NO PARTS THAT WILL BE EXPOSED TO CONTAMINATION BEFORE YOU START WORK. Environmental FOD Wind can blow sand or dust into bearings, flight controls and other susceptible equipment. We all love nature, and animals; and most people agree that animals deserve a safe habitat - but not in our products! Be cognizant of aircraft with open covers and panels before starting work that could kick up dust. Keep facility doors and windows closed as much as environmental conditions will permit. 7 Sikorsky Aircraft Unpublished Proprietary Work

11 Hazardous Materials Hazardous materials are necessary in some of our manufacturing processes, but these materials, if used incorrectly, or if put in contact with unintended components, can cause damage. Be sure you know what you are using and how to use it; and remember that proper disposal of hazardous waste is not only important for preventing FOD, it's the law! Flight Operations Debris on the flight field can damage a helicopter blade or be ingested into an engine resulting in hundreds of thousands of dollars in damage including labor and other indirect costs. This makes keeping the flight field clean is just as important as keeping critical manufacturing areas clean. Therefore, make sure your personal items are secured around operating aircraft. Know and follow all flight operations procedures. And if you see any debris on the flight field, notify Security, Flight Operations personnel or a supervisor. Everyone has a responsibility to minimize the hazards to aircraft: Obey all flight area rules Pick up and dispose of foreign objects Report any unsafe conditions immediately Check vehicles for debris before entering flight areas Ensure items are secured before entering flight areas: * Containers are closed * Equipment is firmly secured to vehicle Sikorsky Aircraft Unpublished Proprietary Work 8

12 Incident Reporting We can t prevent FOD if we don t know about deficiencies BEFORE they result in damage! Identifying defects early allows for implementation of control measures (changes to procedures, additional inspections, etc.) and the prevention of FOD. An incident is any situation that if not corrected could result in FOD. Examples include: Debris on the airfield Exposed parts in the vicinity of building maintenance Working on or near aircraft with uncontrolled tools Untrained personnel in FOD control areas IF YOU SEE ANYTHING THAT COULD RESULT IN FOD, CONTACT A SUPERVISOR OR ONE OF THE CONTACTS LISTED IN THE FRONT OF THIS GUIDE. Designing Out FOD Why do we want to design out FOD? Because the best defense is a good offense! Eliminating hazards through design selection is the #1 preferred method to mitigate hazards (Source: MIL-STD- 882D, Standard Practice for System Safety). This is also known as Murphy Proofing". The interlock systems that are standard on most vehicles today are an example of this. These systems do not let you start the vehicle unless the brake pedal is depressed (automatic transmission) or the clutch pedal is depressed (manual transmission). This eliminates the risk of someone starting the vehicle and having it accelerate unexpectedly. Eliminating potential FOD through design means less burden on the workforce and a reduced probability of failure since human error is no longer in the equation. Therefore, you are encouraged to make suggestions for eliminating (or reducing) FOD potential through design or procedural changes. 9 Sikorsky Aircraft Unpublished Proprietary Work

13 Summary FOD can cause damage, serious injury or death, costs the aerospace industry billions of dollars and is 99% preventable. Every Sikorsky employee and contract worker has a responsibility to ensure that we provide safe products that are FOD free. Think about the person who might have seen the piece of metal on the Concorde runway and didn t bother to pick it up. He or she would have to live with knowing he could have prevented the crash, but didn't. Don t be responsible for the next incident... follow established procedures and always clean as you go. FOD Sikorsky Aircraft Unpublished Proprietary Work 10

14 NOTES 11 Sikorsky Aircraft Unpublished Proprietary Work