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Lockheed Martin FOD Policy, AC-6874
Edwin Pennington
Table of Contents iii
Table of Contents
Introduction to AC-6874 .................................................................................................................. v
Definitions and Acronyms ................................................................................................................ 3
FOD Prevention Training .................................................................................................................. 9
FOD Prevention Minimum Specific Requirements ...................................................................... 9
Dress Code ..................................................................................................................................... 13
Specific Procedure for Pockets: ................................................................................................. 13
Specific Procedure for Personal Packs: ...................................................................................... 13
Specific Procedure for Clothing: ................................................................................................ 13
The Following Personnel are Empty Pocket Exempt: ................................................................ 14
Specific Procedure for Flightline personnel: .............................................................................. 14
FOD Prevention Areas .................................................................................................................... 17
Designating FOD Prevention Areas (FPAs) ................................................................................. 17
Tool Control ................................................................................................................................... 21
Specific Tool Control .................................................................................................................. 21
General Tool Control .................................................................................................................. 21
Manual Tool Control Process (Non-ADU) (Control / Critical): ................................................... 21
MDU Usage Requirements ..................................................................................................... 21
Personal Tool Control (Control / Critical) ................................................................................... 22
Tool / Item Containment (Control / Critical) ............................................................................. 22
Introduction to AC-6874 v
Introduction to AC-6874
This instruction prescribes the methods and procedures for Foreign Object
Damage/Debris (FOD) prevention and elimination during the manufacturing,
modification, and maintenance of aircraft. This instruction applies to Lockheed Martin
Aeronautics Company Fort Worth, partner and subcontractor, personnel in the
performance of support, manufacturing, modification, test, engineering, and flight
operations. FOD Prevention Program Leadership is responsible for revisions to this
instruction, in accordance with AC-4170. Revisions shall be coordinated through
Production Operations, Quality and Mission Success (Q&MS) and Ground Operations
Program Management prior to presentation to the Site GFR for approval. Having
thorough knowledge, the Site FOD Lead and Program FOD Representatives are the
primary points of contact over the FOD prevention process.
Chapter 1 3
Definitions and Acronyms
The following list of definitions establishes a common understanding of the terms and phrases that
apply to this process used throughout this document and any constituent.
Aerospace Ground Equipment (AGE): Aircraft support equipment used during manufacturing,
modification, maintenance and Flight Operations (i.e. hydraulic test stands, pneumatic carts,
stands).
Aircraft in Operations Status: Aircraft with propulsion system installed that are undergoing
maintenance, functional system checks, pre-flight and/or post flight operations located on
Flightline/Ramp/Runstation/Stall.
Aircraft Footprint/ Shadow: A silhouette of the aircraft/product extending 3-15 feet around the
aircraft/product based on Site/Program instructions.
Automatic Dispensing Unit (ADU): An automated device/unit (vending machine) used to house
items to facilitate distribution and tracking of content usage. ADUs can include but are not
limited to Accucabs and Accudrawer.
Aviation Program Teams (APT): For the Purpose of this AeroCode: The Government Team
comprising of: Government Flight Representative (GFR) Aviation Maintenance Manager (AMM)
Contract Safety Specialist (CSS) and Government Quality Representative/Specialist (QAR/QAS)
providing oversight of GFR approved procedures.
Company Issued Personal Items: Items issued to employees and are maintained in the person’s
possession and controlled under the same concept as Personal Items. These items include
Personal Protective Equipment (PPE), Personal Tool Chits, Phones, Pagers, etc.
Consumables: Items/tools that are used-up, or can be re-used to the point of being unserviceable
or disposed of as part of the build process.
Containers: Containers are used to transport Tools/Items to and from the Aircraft/Product. These
devices include Viewtainers, Bags, Snaplid Trays, Tote Trays, Tote bags, Tool Bags, etc.
Controlled Storage Containers / Kits: Storage cabinets, non-personal lockers, and devices used
for housing accountable miscellaneous support equipment, MSP/PLS, Extended Issue Company
Tools/Items, PPE, Consumables and Tools/Items.
Crew Stations: The area from which the pilot (and crew on larger aircraft) operates the aircraft
enclosed by a canopy and/or cabin door. (Confined Crew Stations exist on fighter and
surveillance class aircraft)
Cribs: Company controlled storage, distribution and return points for company provided tools
and/or consumables.
Designee: A person/department assigned/designated responsibility to carry out a specific duty at
the program/site level (e.g. Tool services).
4 Lockheed Martin FOD Policy, AC-6874
Disposal Process: Site/Program level method prescribed for disposal of used or un-used
consumables in identified collection points such as but not limited to Buckets, Bins, Containers,
Cribs, etc.
Extended Issue Company Tools: Tools or Items individually issued on extended cycles not to
exceed 364 days. Examples are Wiring Visors, Head Lamp/Miners Lights etc.
Fabrication: Areas where employees use raw materials to create, manufacture, and modify
aircraft assemblies, sub-assemblies and/or parts.
Flightline / Aircraft Ramps: Designated areas where employees park, store or tow aircraft in the
process to undergo flight and ground operations.
Flight Operations: An aircraft operation that indicates flight is the intent. High-speed taxis and
hover taxis are also flight operations activity.
Foreign Object Damage (FOD): Any damage attributed to a foreign object when expressed in
physical or economic terms, may or may not degrade the product's safety or performance
characteristics.
Foreign Object Debris (FOD): A substance, debris, loose hardware, or article alien to a vehicle
or system that could potentially cause damage.
FOD Awareness Area: Specific geographic points during manufacturing or modification
processes to include but not limited to: the Environment where sub- assemblies undergo
manufacturing or modification processes as part of a series of progressive processes to become a
completed component, or assembly activities without closeout activities and the product will
remain open without any potential for FOD entrapment.
FOD Control Area: Specific geographic points during assembly or modification processes to
include but not limited to the Environment where components and/or assemblies undergo
manufacturing or modification processes as part of a series of progressive processes to become a
completed aircraft.
FOD Critical Area: Specific geographic points or planned call-outs, during assembly,
modification, flight and ground operations processes which the risk for FOD contamination,
entrapment, migration and damage are significant enough to drive the highest levels of
preventative measures.
FOD Incident: The existence of any detrimental condition directly associated to a foreign object.
(Examples: engine damage, mechanisms jamming, contact damage, flow restrictions, or
blockage, and electrical shorting).
FOD Sweep: A structured inspection that verifies compliance of the FOD Prevention and Tool
Control processes.
FOD Walk: An organized check of a specific area to search for and remove any FOD potential to
the Product/Aircraft.
Chapter 1 5
Free Stock Rack / Point of Use (POU): Stations designed to provide distribution points for
consumables to support Production processes.
Ground Operations: Any continued aircraft operation on the ground without the intent of flight.
Kit: A container used to store a set or collection of returnable and non-returnable items for a
specific purpose/use.
Loose Hardware: Unsecured items left on the Aircraft/Product not contained presenting a
potential FOD hazard.
Miscellaneous Support Equipment: Equipment used in daily activities not classified as Test
Equipment. Items such as but not limited to: hand held radios, aircraft communication cords,
head sets, buckets, shoe covers, aircraft protective covers and plugs, HAZMAT Spill Kits,
extension cords, air hoses, tie downs, D-rings/Shackles, drop/spot lights, ladders, stools, creepers
and Shop Aids.
Personal Items: Items personally owned by employees that may accompany them to the work
environment.
Personal Tools: Tools owned by employees of Lockheed Martin Aeronautics, contractors,
partners and vendors. Tools not owned by the Government, Lockheed Martin Aeronautics, or
other corporate contracting companies can include pocketknives and multi-tools.
Positive Tool/Item Control: The act of keeping Tools/Items an individual is responsible for, by
some measure of containment or identification, that prevents Tools/Items from becoming FOD.
Protected Storage: Aircraft or products not being worked that are awaiting delivery, disposition,
transfer, work, or other authorized delays, and are protected from any contamination of FOD.
Run station / Stall: A permanent flightline building or open pad designated for aircraft parking,
maintenance and flightline operations.
SIM-PAC: Systematic Inventory Management of Production Aid Commodities is a method of
automated Tool/Item control via the ADU or Manned Crib process utilizing CribMaster software
providing an electronic means of tracking usage, traceability and accountability.
FOD Free Audit: An additional FOD free verification step validating a FOD-free product
applied at the discretion of the program management.
Temporary Holding Device: Items used while work is in progress to secure parts or assemblies
during
Manufacturing / Modification and Maintenance processes
Test Equipment: Includes Testers, Manufacturing Test Equipment (MTE), Special Test
Equipment (STE), and Functional Test Equipment (FTE).
Tool Control: Serialized or uniquely identified items that require returning to point of issue.
These are durable tools, special test equipment, gauges, etc. and have a unique serial number
identification etched on the item or container housing items too small to etch and systematically
established in Crib Master or inventory method.
6 Lockheed Martin FOD Policy, AC-6874
Touch Labor / Hands-on: Physical access to the product in performance of Assembly,
Inspection, Test, Maintenance, Modification and Operation.
Tool/Item Usage Inventory Sheet (TUIS): A company approved form used for documentation
that provides a control measure for Tools/ Items not otherwise controlled via Chit process or
electronic control method.
Tool Reporting System (TRS): A system utilized by some program as a means of tracking tool
activity functions.
Unit of Issue: Unit of Issue is the number and type of container that an item is distributed from
and the quantity is identified on the container
Work In Progress (WIP): An in process work task or series of tasks within a planned operation
with no defined interruptions that is in progress with exception of authorized stoppage such as
breaks, lunch and dinner.
Working Environment: The areas, regardless of FOD Designation, where actual hands-on/touch
labor work is being performed which involves any kind of FOD potential activity.
Chapter 2 9
FOD Prevention Training
FOD Prevention Minimum Specific Requirements
This section applies to sites, programs and operations performed by LM Aeronautics personnel or
contractors, sub-contractors and partners who perform modification, engineering, manufacturing,
maintenance on aircraft and those personnel who support LM Aero products/aircraft.
Site/Program FOD organizations are responsible for communicating any FOD process related
issues, changes, alerts, directives, memos and etc. throughout their respective Site/Programs and
to DCMA/GFR. Each of the following subsections detail the minimum requirements that all LM
Aero Site/Programs must establish written instruction level AeroCodes to address the methods
and procedures of accomplishing the specified requirements in this AeroCode.
FOD PREVENTION TRAINING
FOD Training begins with any Aircraft manufacturing or modification training. In Aircraft
manufacturing and modification training, any hands-on task should incorporate a FOD Free
validation by the instructor to pass the training satisfactorily. All additions, deletions, or
modifications to FOD Training courses require approval by LM Aeronautics Q & MS Senior
Manager of FOD and Ground Operations (or designee) prior to implementation and during
annual review. Failure to adhere to the FOD Prevention Program policies contained in this
AeroCode could result in the immediate de-certification of employees.
Table 2. FOD Training Matrix
Course Attended By Frequency Instruction
Method
FOD Touch Certification
Black Badge Identifier
Classroom
Course#204225ILT00
FOD Touch
Recertification
Course#208187WPL00
All Production Labor Personnel and their
Immediate supervision must attend. FOD
Reps, Designated Specialists and
Engineers requiring routine hands-on
access to the Aircraft/Product including
Contractor/Vendor as specified by
Site/Programs must attend.
Initial Certification
Annual
Annual Recertification
Initial
Classroom
Instructor
Facilitated
Annual
Recertification:
CBT/ WPL
FOD Awareness
Course#204238WPL00
No Badge
All LM Aeronautics personnel, partners
and/or contractor/vendor requiring access
to the FOD Critical/Control Environments
and are not performing touch labor
activities must attend.
Annual Compliance
If not FOD Touch
Certified
CBT/WPL
FOD Leadership
Course#205108WPL00
No Badge
All Supervisory or Lead Personnel
overseeing hands-On, touch-labor
personnel directly supporting the
Manufacturing, Modification and
Operations Environment must attend.
Annual Compliance CBT/WPL
Super FOD Qualification
All Personnel that perform Final FOD
Audit Inspections as specified by their
applicable Sites and Programs must
attend.
Initial Qualification
2 Year Re-Qualification
Training
method
determined by
program
Contractor/Vendor Non
Aircraft/Product Related
All outside contractors requiring access to
the facility must attend.
Prior to gaining vendor
badge upon arrival
CBT/WPL or
Read/Sign
Chapter 3 13
Dress Code
Compliance to FOD Prevention Dress Code is required when accessing FOD Critical or FOD
Control FPA. Personnel must remain outside of the FOD Critical or FOD Control FPA at all
times if not compliant with FOD Dress Code.
Specific Procedure for Pockets:
Pockets will remain empty and personal items secured in a company provided
personal pack.
Employees may carry wallets in a pocket that sits below the waist.
Specific Procedure for Personal Packs:
Employees may remove and set aside personal packs while performing assigned
task.
Employees must remove personal packs or armband badge holders prior to
entering confined spaces such as the crew station, engine inlet/exhaust, or fuel
tanks.
Employees may not access their personal packs during aircraft engine operations.
Employees will keep personal packs closed at all times while in contact of an
aircraft. If employees must access their personal pack, leave the aircraft area to
do so.
Specific Procedure for Clothing:
Employees may not wear clothing with ornamental accessories (detachable or
sewn on) due to the potential FOD hazard.
Employees may not wear jewelry in FOD Control and Critical designated areas.
Employees may wear medical alert jewelry required for existing medical
conditions.
Badges must always be visible in personal pack or in an armband badge holder.
When an engine exists in the aircraft or a coating applied to the intake,
employees must wear coveralls when accessing this area. In addition, employees
must wear coveralls in engine exhaust as well. Coveralls shall be made of one-
piece construction with pockets sewn shut, no metal or plastic components
(buttons or zippers) and cover the body from neck to ankles and wrist to wrist.
Shoe covers shall be worn when stepping on upper aircraft surfaces unless the
surface unless protected by mats or temporary panels with a non-slip quality.
14 Lockheed Martin FOD Policy, AC-6874
The Following Personnel are Empty Pocket Exempt:
Aircrew wearing flight suits with pockets that seal and badge stowed or in an
Arm Band Badge Holder.
Emergency and security personnel responding to an emergency may secure all
personal effects inside their pockets.
Personnel working in aircraft paint hangars or booths will not wear a personal
pack if it interferes with protective clothing or equipment. However, employees
must have empty pockets.
Visitors may utilize a visitor personal pack (neck wallet) or standard personal
pack or no pack at all provided someone is accountable for the visitors’ items.
The empty pocket requirement is still applicable to visitors.
Military personnel need not remove rank insignia, badges, wings, patches, and
ribbons but must account for such items upon leaving FOD areas.
Specific Procedure for Flightline personnel:
On the flight line, the red line between the ramp and roadway denotes the
boundary of the restricted active aircraft operations area.
East of the red line is a FOD Control zone; within 5 foot of the aircraft is FOD
Critical.
FOD dress code requirements will apply unless waivered by FOD Prevention
Program Management.
Personal Packs (company issued) are required on the Flight Line for containing
personal items.
Personnel can take lunches, backpacks with personal items, etc., when transiting
to and from their work areas and at designated break areas within the run
stations. (Transiting personnel shall remain outside the footprint of the aircraf
Chapter 4 17
FOD Prevention Areas
Designating FOD Prevention Areas (FPAs)
FOD Awareness, FOD Control and FOD Critical will be the standard FPA nomenclature for
describing levels of risk associated to Aircraft/Product.
Operations performed in an area and the associated FOD risks will dictate FPA
designation.
Clearly marked signage (at a minimum) will identify each FPA (excluding flight
line).
FPA designations signify the control methods required to protect the
Aircraft/Product.
Requirements for “Non Designated Areas” are included as defined by the FOD
Prevention Program
FPA designation changes or deactivation / re-activation requests must be coordinated
with Program FOD Prevention Representative and/or Site FOD Lead and requires
GFR notification.
Designation of temporary performance of FOD Critical operations will be at or above
the level of FOD Control.
FPA Deactivation: Areas will deactivate to “Non Designated” status anytime the position is
vacant of an aircraft or product for extended periods of in activity. Employees will adhere to
all housekeeping practices during deactivated conditions. Upon completion of work, prior to
an aircraft/product is positioned, the area must be accepted by Production Supervision and
reactivated coordinated through the FOD Prevention Program or designee.
FPA designations can apply to specific operations to mitigate a risk during closeout. Once the
Operation or Task is complete, the FOD FPA designation can revert to the original FPA
designation.
It is permissible to possess food and drink in designated areas only. Allowable drinks in
closable containers are acceptable in the working environment such as benches and
worktables, but shall remain outside of the footprint/shadow of the Aircraft/Product. Aircrews
are responsible for any food/drinks carried aboard the aircraft. Employees performing engine
run operations may take drinks in closable containers into the crew station.
Chapter 5 21
Tool Control
Specific Tool Control
Tool Control relies on the principles of traceability, accountability, storage or disposal
processes. After task completion or the end of shift, tool users involved in manufacturing,
modification or maintenance processes must ensure all tools brought into the work
environment return to the point of issue or are disposed of properly.
This procedure does not apply to Tool Use in Non FPA Designated Areas such as
Construction areas, Transportation Shops, Facilities Maintenance, Tool Manufacturing
Shops, Machine Shop, Fabrication and Maintenance Shops
Employees may utilize Manual Tool Control or Automated Tool Control Systems
interchangeably as required due to ADU System outage.
Note: Both ADU/and or MDU containers assigned to supporting a specific completed
Aircraft/Product must have contents verified and a visual confirmation that any tools
chitted/signed out are not on the aircraft prior to Assembly line move, Engine Operation
or Flight Operation. Every employee having a tool chitted/signed out of the toolbox will
physically show the tool(s) or otherwise prove its location.
General Tool Control
Applicable to Control and Critical FPA designations
Personnel shall keep a master inventory of all Tools/Items electronically and/or
manually within the tool/item transaction/issue point (ADU, MDU). Inventory
must reflect, by end of shift, any permanent changes to the contents.
Configure MDU Shadowed Tool Boxes for easy identification for tool/item
location in a method that clearly highlights tool/item location and if a tool/item is
missing.
Tools will have either a unique identifier number for ADU or MDU number
providing traceability and ownership.
Identify tools not controlled by SIM-PAC with badge number, user name, or kit
number by etching, permanent marker or equivalent.
Manual Tool Control Process (Non-ADU) (Control / Critical):
MDU Usage Requirements
MDU containers must have an attached inventory of containers contents.
MDU containers are not useable during annual inventory checks.
Personnel shall issue MDU containers by Chit, Sign-Out, or by CribMaster
process.
When not in use, lock all lockable MDU containers.
22 Lockheed Martin FOD Policy, AC-6874
Tool users shall visually verify the inventory accuracy of toolboxes checked out
at point of issue and time of return.
MDU containers become the user’s responsibility upon acceptance of the MDU
from the issuing source.
Personal Tool Control (Control / Critical)
Tool Fabrication Personnel required to remove personal tools from Non FOD Designated
areas into Control / Critical FPA’s will follow this instruction.
Personal tools shall be inventoried and identified/etched with the owner’s LM
Aero six (6) digit employee badge number if size of tool permits and logged on a
Form 12406 (TUIS).
Tool / Item Containment (Control / Critical)
Employees will transport tools in an appropriate container as determined by the
environment and type of item.
Keep PLS/tools/items, appropriately contained. Use protective
mats/covers/devices to protect product.
If an employee drops an item into the product, employees must retrieve it. If not
retrievable, notify area supervisor.
Tools / items will be removed from the product at breaks, lunch / dinner,
reassignment of task, or end of shift
Removed PLS should be attached to removed parts/panels, or bagged and
attached to aircraft, so it interferes with the installation of the removed part/panel
or where it can be easily detected.