REG NASA-LLIS-0666-2000 Lessons Learned Foreign Object Debris (FOD) Program at KSC.pdf

1、Best Practices Entry: Best Practice Info:a71 Committee Approval Date: 2000-03-06a71 Center Point of Contact: KSCa71 Submitted by: Wil HarkinsSubject: Foreign Object Debris (FOD) Program at KSC Practice: Enhance the Reliability of Flight Hardware Processing Systems by including in the Program a relia

2、ble Foreign Object and Debris (FOD) policy and related procedures for use during launch and landing operations, vehicle and payload processing, and maintenance activities at designated areas of Kennedy Space Center (KSC) and off-site landing facilities under KSC responsibility.Programs that Certify

3、Usage: This practice has been used on the Space Shuttle Program as well as military and civilian aircraft operations. KSC use includes all processing areas: three Orbiter Processing Facilities (OPFs), Vehicle Assembly Building (VAB), Launch Pads 39 A no ingress or egress obstacles; no unmarked or un

4、identified tools, parts, equipment, chemicals, etc.; no unsecured or untethered items above ground level; no unkempt areas; no hazards; nothing left in the area that does not have a specific purpose for work in process or functional requirement or is not stored properly.4. 5. Only authorized personn

5、el with valid requirements to perform work or surveillance will be allowed in the controlled work areas.6. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-7. Personnel entering into the designated flight hardware operational processing area will prac

6、tice the “clean as you go“ method, cleaning up assigned tools, parts, equipment, worksite, etc. as practical, during and at the end of the assigned task and/or shift.8. 9. Organizations having possession of hardware inventories and/or tools and equipment will be responsible for those items and have

7、a closed-loop tracking system, with tools and equipment traceable to location and user.10. 11. The user is responsible for the physical location of all items carried into the flight hardware operational processing area and will be held accountable.12. 13. Perform random inventory of toolbags upon in

8、gress and egress of the flight element for compliance with the requirements. Report discrepancies.14. 15. Each employee is expected to practice safety and good housekeeping habits and prevent FOD at all times in the designated flight hardware areas.16. 17. Each operational processing area will have

9、a FOD control board to hold clipboards for daily checklists and related FOD prevention data. FOD boards will be kept neat and clean.18. 19. All personnel will view the KSC FOD Prevention Video and sign a personal commitment to “Clean As You Go“. A copy will be on record in individual administrative

10、files.20. 21. Site Managers will be appointed by the Site Director.22. 23. FOD prevention walkdowns will be scheduled on a regular basis in all operational processing areas by the Site Manager and the Site FOD Prevention Office. The Site Manager or delegate will attend all FOD prevention walkdowns.

11、The work area will be checked for potential hazards and anything out of place that could potentially cause damage to flight hardware or injury to personnel. In addition to the scheduled walkdowns, daily walkdowns will be conducted by Site FOD Monitors.24. 25. Site FOD Monitors will be selected for e

12、ach shift at regular shift meetings, on a volunteer basis. Alternates will be appointed to cover absenteeism. Monitor duty will last for 1 month and will be in addition to normal work responsibilities. Before an employee can be selected for a second time, each work group member will have the opportu

13、nity to serve as Site FOD Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-Monitor.26. 27. Ensure that FOD prevention is stressed with subcontractors prior to award of contracts, have subcontractors sign a letter agreeing to follow the “clean as you g

14、o“ method, and post a copy of this letter on the jobsite.IncentivesAs an incentive for good performance, rewards are given out. At SPC, the reward is a “FOD Buster Chit“. These chits are good for a $1 credit at the KSC cafeterias or mobile snack trucks. This provides positive reinforcement for the F

15、OD program, and recognizes and encourages continued good performance.OrganizationsThe Shuttle Processing Contractor is a member of National Aerospace FOD Prevention, Inc. The National Aerospace FOD Prevention, Inc. is a non-profit educational association. The organizations primary goal continues to

16、be to promote awareness of the dangers of FOD and provide the aerospace industry with information on preventing foreign object damage to aircraft and aerospace vehicles with proven practices. Members are from military aerospace companies, as well as commercial aerospace companies, the various branch

17、es of the military itself, defense contractors and commercial business. A National Aerospace FOD Prevention Conference is held annually. The conferences have speakers on various topics, interactive learning sessions, and exhibitors. Member companies share their FOD program experiences, successes, an

18、d training programs with other with other members for the mutual benefit of all concerned.The annual conference promotes FOD prevention by keeping personnel who build or use aerospace products informed about the best practices in eliminating foreign objects. Topics discussed at the conferences and i

19、n the newsletter include Preventive Practices, Measuring Performance, Training, Material Handling and Parts Protection, House Keeping, Tool Accountability, Hardware Control, Lost Items, Hazardous Materials, Design Considerations, Assembly Operations, Reporting & Investigation.The National Aerospace

20、FOD Board of Directors and the National Aerospace FOD Prevention Conference have been vital sources for disseminating current and effective FOD prevention ideas and techniques.ConclusionsAll flight hardware operational processing personnel are responsible for supporting the Site FOD Provided by IHSN

21、ot for ResaleNo reproduction or networking permitted without license from IHS-,-,-Monitors and their supervisors to ensure the effectiveness of FOD prevention. Compliance will be monitored by random walkdowns conducted in addition to the scheduled walkdowns.The KSC/SPC FOD program has been successfu

22、l.a71 By involving all hands-on employees, the Shuttle processing operations FOD Prevention Program has been able to Lead by Example.a71 a71 Operational areas reflect pride in ownership, accountability and a safe, clean work environment.a71 a71 Awareness has significantly improved and Hazards have b

23、een reduced.a71 a71 Astronauts are reporting exceptionally clean Orbiters.Technical Rationale:A FOD program reduces costs in lost tools, damaged equipment, schedule impacts due to rework, and reducing unnecessary risks in a business that is inherently risky.References:1. National Aerospace FOD Preve

24、ntion Newsletter - FAST, P.O. Box 5489, Pine Mtn., CA 932222. Kennedy Space Center Handbook for the Foreign Object Control Program - KHB 5330.10Impact of Non-Practice: Since implementing a comprehensive FOD program, FOD incidents have decreased significantly from levels prior to the program. The lac

25、k of such a program can result in unacceptable performance of equipment, scrapping of otherwise usable hardware, expenditure of unnecessary resources, and possible schedule delays, or major penalties which could include loss of mission capability, injury to personnel or loss of life, and damage to,

26、or loss of, the shuttle vehicle.Related Practices: Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-N/AAdditional Info: Approval Info: a71 Approval Date: 2000-03-06a71 Approval Name: Eric Raynora71 Approval Organization: QSa71 Approval Phone Number: 202-358-4738Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-