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.