Plan and sequence maintenance/manufacturing tasks to preclude foreign object damage and entrapment of debris or contamination. Documents should contain necessary processes and procedures for controlling and removal of contamination and debris during fabrication and assembly operations. As applicable, the following should be included in work instructions:
1. Practice ‘Clean as you go”.
2. Upon completion of final machining operation, clean or flush the machined component to assure that it is free of debris, and immediately cap or seal exposed openings to deny foreign object entry.
3. Adequately protect hardware and equipment from splatter accumulation during brazing, soldering, welding and like operations.
4. Inspect components and equipment for damage prior to installation and repair as necessary. Always ensure part integrity before installation.
5. Verify required protective devices (dust covers, temporary seals, cushioning, etc.) are present and properly installed. Items with protective devices missing are to be inspected for FOD, cleaned if necessary and protective devices installed.
6. After fluid and pneumatic system lines and tubing are cut and deburred, assure thorough cleaning and cap ends of lines.
7. Inspect for and remove extraneous material as part of the assembly step, conduct a foreign object inspection and remove debris.
8. Inspect production tooling (jigs, fixtures, handling equipment, etc.) to assure it is clean, undamaged and free of foreign material prior to installation and build-up of components or assemblies. Exercise this same care for work stands, ladders, special test equipment, etc., which must be placed on, in, or around production hardware to accomplish specific tasks.
9. Protect products by using POD barriers, foam pads, covers, etc. For instance, cover composites on the wings and place pads between a tool and the aircraft/assembly. Always protect sensitive areas and potential FOD entrapments (engine, open fuel line, harnesses, etc.)
5.0 Test Cell & Special Shops Environment
When products are in a test cell environment, FOD prevention procedures should include, but are not limited to, the following:
1. Practice ‘Clean as you go”.
2. Assure that adequate preventive maintenance is performed on the test facility.
3. Inspect the test cell and facility equipment for deterioration or damage and assure that deficiencies which present a FOD hazard are corrected prior to test cell operations.
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