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Implementing a FOD Prevention Programme

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Implementing a FOD Prevention Programme Steve Frost July 2004 BAE SYSTEMS UK Sites - over 65 locations Military Aircraft Sites Implementing a FOD Prevention Programme ... – PowerPoint PPT presentation

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Title: Implementing a FOD Prevention Programme


1
Implementing a FOD Prevention Programme
Steve Frost July 2004
2
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3
BAE SYSTEMS UK Sites- over 65 locations
4
Military Aircraft Sites
5
Warton Site
Employees 5,000 People on site 8,500
6
Warton Site Locations
7
Implementing a FOD Prevention Programme
  • Our Bad Experience
  • Developing Implementing a Robust Tool
    Control / FOD Process
  • Maintaining Flight Safety Awareness

8
Our Bad Experience
  • RTW Programme
  • 16 Tornado ADVs for Royal Air Force
  • 150 Staff Employed on Programme
  • Programme running well up to the 10th
    aircraft AT029

9
A Bad Experience
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The Aftermath
11
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

12
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

13
Implementing a FOD Prevention Programme
  • Our Bad Experience
  • Developing Implementing a Robust Tool
    Control / FOD Process
  • Maintaining Flight Safety Awareness

14
Recognition of Forms of FOD
15
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

16
Organisation to manage and govern the issue
  • Dedicated Asset Management Team Formed

Aim One Common Tool Control / FOD Prevention
Process
17
Development of a Robust Tool Control Process
Key Ingredients
  • Physical Control Techniques
  • Process
  • IT Support

18
Development of a Robust Tool Control Process
Key Ingredients
  • Physical Control Techniques
  • Process
  • IT Support

19
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

20
Tool Control
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A well organised tool store
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Development of a Robust Tool Control Process
Key Ingredients
  • Physical Control Techniques
  • Process
  • IT Support

24
Process Development
25
Development of a Robust Tool Control Process
Key Ingredients
  • Physical Control Techniques
  • Process
  • IT Support

26
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

27
Investment in I.T. Solution
  • Tracking of Assets Between the Manufacturing
    Work Centres
  • Track Assets / Tools to Personnel and Aircraft
  • Control of Calibration Servicing

28
Indirect Benefits
29
Tool Control Ethos
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Asset Management Organisation established
Mission Accomplished?
31
Why did it fail? - The Store Keeper
  • Human Factor
  • Traditionally Low Skilled
  • Process Failed

32
Recognition of Forms of FOD
33
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

34
Flight Safety Awareness
What we used to do
35
So lets try something different !
36
Flight Safety Awareness
37
Flight Safety Campaigns
38
Flight Safety in the home
39
Flight Safety / FOD Briefings
40
What did happen?
41
Implementing a FOD Prevention Programme
Summary
  • Avoid Complacency
  • Keep It Simple
  • Flight Safety is

YOUR RESPONSIBILITY
42
Committed to constantly reviewing the FOD
Prevention Process
43
Think Flight Safety
Think...
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