SAE AS 9146-2017 Foreign Object Damage (FOD) Prevention Program - Requirements for Aviation Space and Defense Organizations.pdf

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4、0 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/standards.sae.org/AS9146 AEROSPACE STANDARD AS9146 Issued 2017-04 Technically equivalent writings published in al

5、l IAQG sectors. Foreign Object Damage (FOD) Prevention Program - Requirements for Aviation, Space, and Defense Organizations RATIONALE Foreign Object Damage (FOD) is a major concern in the aviation, space, and defense industry. While there is a large amount of information and guidance available abou

6、t the prevention of FOD, no requirements standard exists. This standard identifies FOD Prevention Program requirements that can be flowed down in contractual agreements. FOREWORD To assure customer satisfaction, the aviation, space, and defense industry organizations must produce and continually imp

7、rove safe, reliable products that meet or exceed customer and regulatory authority requirements. The globalization of the industry and the complexity of resulting organizations supply chains have complicated this objective. End-product organizations face the challenge of assuring the quality of, and

8、 integrating, product purchased from suppliers throughout the world and at all levels within the supply chain. Furthermore, suppliers and processors, within the industry, face the challenge of delivering product to multiple customers having varying quality expectations and requirements. The aviation

9、, space, and defense industry established the International Aerospace Quality Group (IAQG) for the purpose of achieving significant improvements in quality and safety, and reductions in cost, throughout the value stream. This organization includes representation from aviation, space, and defense com

10、panies in the Americas, Asia/Pacific, and Europe. The IAQG benchmarked industry best practices and guidance to develop the requirements of this FOD Prevention Program standard. This document standardizes FOD Prevention Program requirements to the greatest extent possible and can be used at all level

11、s of the supply chain by organizations around the world to mitigate FOD risk to aviation, space, and defense products and services. SAE INTERNATIONAL AS9146 Page 2 of 7 TABLE OF CONTENTS RATIONALE 1 FOREWORD 1 1. SCOPE 3 2. APPLICABLE DOCUMENTS . 3 3. TERMS AND DEFINITIONS . 3 4. FOREIGN OBJECT DAMA

12、GE PREVENTION PROGRAM REQUIREMENTS . 4 4.1 Program Management 4 4.2 Operations . 5 4.3 Area Designation . 5 4.4 Training and Personnel Access 5 4.5 Product Protection . 6 4.6 Housekeeping and Clean-As-You-Go . 6 4.7 Consumables, Hardware, and Personal Items Accountability and Control . 6 4.8 Tool Ac

13、countability and Control . 7 5. NOTES 7 5.1 Revision Indicator 7 SAE INTERNATIONAL AS9146 Page 3 of 7 1. SCOPE This standard defines FOD Prevention Program requirements for organizations that design, develop, and provide aviation, space, and defense products and services; and by organizations provid

14、ing post-delivery support, including the provision of maintenance, spare parts, or materials for their own products and services. It is emphasized that the requirements specified in this standard are complementary (not alternative) to customer, and applicable statutory and regulatory requirements. S

15、hould there be a conflict between the requirements of this standard and applicable statutory or regulatory requirements, the latter shall take precedence. 2. APPLICABLE DOCUMENTS The following documents should be considered for the application of this document. For dated references, only the edition

16、 cited applies. For undated references, the latest edition of the referenced document, including any amendments applies. 9100 Quality Management Systems Requirements for Aviation, Space, and Defense Organizations 9110 Quality Management Systems Requirements for Aviation Maintenance Organizations 912

17、0 Quality Management Systems Requirements for Aviation, Space, and Defense Distributors NOTE: Equivalent versions (e.g., AS, EN, JISQ, SJAC, NBR) of the IAQG standards listed above are published internationally in each sector. IAQG Supply Chain Management Handbook (SCMH) Foreign Object Prevention Pr

18、ogram Guidance Material (http:/www.sae.org/iaqg/) ISO 9000:2015 Quality management systems Fundamentals and vocabulary 3. TERMS AND DEFINITIONS 3.1 Clean-As-You-Go Practice of cleaning the immediate work area of the product at appropriate intervals to eliminate the accumulation or migration of Forei

19、gn Objects (FOs) that may potentially become entrapped within the product i.e., Foreign Object Debris (FOd) or cause damage (i.e., FOD). 3.2 Consumables Supplies, materials, and miscellaneous items required for product and operations processes that are expected to be consumed during work performed o

20、r discarded after useful function. 3.3 Foreign Object (FO) An alien substance or article (e.g., tools, consumables, hardware, product protective devices, personal items, product process debris, operations debris, environmental debris) that could potentially enter and/or migrate into/on the product o

21、r system becoming FOd and potentially cause FOD, if not removed and controlled. 3.4 Foreign Object Damage (FOD) Any damage attributed to FOd that can be expressed in physical or economic terms, which could potentially degrade the product or systems required safety and/or performance characteristics.

22、 3.5 Foreign Object Debris (FOd) Any FO that has entered and/or migrated into/on the product or system, and could potentially cause FOD, if not removed and controlled. SAE INTERNATIONAL AS9146 Page 4 of 7 3.6 Hardware Bill of Materials (BOM) parts used in operations (e.g., standards, fasteners, nuts

23、, rivets, washers, screws, bolts, spacers, cotter keys, wire terminals, wire terminal connectors). 3.7 Housekeeping A process to maintain general cleanliness and ensure all work areas are orderly and free of potential FOs at appropriate intervals. 3.8 Operations Product related activities and servic

24、es through all stages of production, maintenance, and service execution (e.g., design and development, manufacturing, assembly, test, packaging, shipping). 3.9 Personal Items Items owned by individuals or distributed by the organization for personal use (e.g., badge, stamps, keys, cell phones, walle

25、ts, personal protective equipment, food, drink, tobacco products). 4. FOREIGN OBJECT DAMAGE PREVENTION PROGRAM REQUIREMENTS 4.1 Program Management 4.1.1 The organizations top management shall demonstrate leadership and commitment to the FOD Prevention Program. 4.1.2 The organization shall designate

26、a FOD Prevention Program management representative with the responsibility and authority for establishment, implementation, and maintenance of the program. 4.1.3 The organization shall establish, implement, and maintain documented information of a FOD Prevention Program commensurate with a FOD risk

27、assessment for product characteristics and operations. The FOD Prevention Program shall include consideration of the following elements for applicability: a. Operations (see 4.2). b. Area designation (see 4.3). c. Training and personnel access (see 4.4). d. Product protection (see 4.5). e. Housekeep

28、ing and clean-as-you-go (see 4.6). f. Consumables, hardware, personal items accountability, and control (see 4.7). g. Tool accountability and control (see 4.8). 4.1.4 The organization shall maintain documented information of FOD Prevention Program nonconformities and FOd/FOD product nonconformities

29、in accordance with its “control of nonconforming outputs” processes. 4.1.5 The organization shall report FOD Prevention Program nonconformities and FOd/FOD product nonconformities in accordance with its management review process. 4.1.6 The organization shall evaluate effectiveness of the FOD Prevent

30、ion Program based on internal, customer, statutory, and regulatory requirements. SAE INTERNATIONAL AS9146 Page 5 of 7 4.1.7 The organization shall communicate results and effectiveness of the FOD Prevention Program to relevant internal and external interested parties. 4.1.8 The organization shall ma

31、intain documented information of a FOD risk assessment for procured product and flow down FOD prevention requirements commensurate with that risk. 4.2 Operations 4.2.1 The organization shall establish, implement, and maintain FOd/FOD prevention processes for operations. 4.2.2 The processes shall est

32、ablish requirements for: a. Product design considerations for the prevention, inspection/detection, and removal of FOs. b. Selection, application, and control of protective devices/measures for products, processes, and personnel. c. Plan and sequence operations to reduce FO/FOd/FOD risk to product.

33、d. Identification of product/characteristics (e.g., openings, compartments, cavities) requiring protection from FO/FOd. e. Capabilities for cleaning and FO/FOd inspection/detection. f. Inspection/detection methods at appropriate steps or intervals to prevent contamination, damage, and deterioration.

34、 4.3 Area Designation 4.3.1 The organization shall determine area designation based on FOD risk assessment of product characteristics and operations. 4.3.2 For each area designation, the organization shall establish, implement, and maintain appropriate level of controls that include consideration of

35、 the following elements: a. Operations. b. Training and personnel access. c. Product protection. d. Housekeeping and clean-as-you-go. e. Consumables, hardware, personal items accountability, and control. f. Tool accountability and control. 4.3.3 The organization shall establish, implement, and maint

36、ain a process for visual management of each area designation (e.g., signage with specific colors, high visibility colored tape, high visibility floor decals). NOTE: Visual management means the area is physically identified and area designation is clearly visible. 4.3.4 The organization shall establi

37、sh, implement, and maintain a process to mitigate FOD risk when non-product related activities are performed in designated areas (e.g., infrastructure maintenance, equipment repairs, construction). 4.4 Training and Personnel Access 4.4.1 The organization shall establish, implement, and maintain a FO

38、D prevention training program commensurate with FOD risk assessment results. SAE INTERNATIONAL AS9146 Page 6 of 7 4.4.2 The training program shall: a. Determine the appropriate initial training content. b. Identify internal employees and external parties (e.g., visitors, contractors, customers) trai

39、ning requirements. c. Establish training methods (e.g., lecture, electronic). d. Establish recurring training criteria, content, and intervals. e. Evaluate training effectiveness (e.g., measuring employee competency, FOd/FOD nonconformities). f. Maintain documented information of training program co

40、mpliance. 4.4.3 The organization shall establish provisions to ensure anyone entering FOD prevention designated areas has received required FOD prevention training or is escorted by trained personnel. This includes personnel not typically assigned to the designated area (e.g., customer, visitors, co

41、ntractors, infrastructure maintenance). 4.5 Product Protection 4.5.1 The organization shall establish, implement, and maintain a process for product protection through all stages of operations. 4.5.2 The process shall establish requirements for: a. Protection against contamination by application and

42、 control of protective devices (e.g., bags, caps, covers, plugs). b. Storage, handling, and transportation of product (e.g., cleanliness of carts, containers, pallets). c. Protection against physical and functional damage from inadvertent contact with other objects that pose FO/FOd/FOD risk to produ

43、ct. d. Protection of product during infrastructure maintenance activities that pose FO/FOd/FOD risk to product. 4.6 Housekeeping and Clean-As-You-Go 4.6.1 The organization shall establish, implement, and maintain housekeeping and clean-as-you-go processes in all work areas and infrastructure. NOTE:

44、Infrastructure includes buildings, warehouse, workspace, associated utilities, and process/support equipment. 4.6.2 The process shall: a. Mitigate FO/FOd/FOD risks at appropriate intervals associated with accumulation of debris and waste in all work areas (commonly referred to as “housekeeping”). b.

45、 Mitigate FO/FOd/FOD risks in immediate work area of the product at appropriate intervals for production, maintenance, and service processes (commonly referred to as “clean-as-you-go”). NOTE: Examples of operations debris include application of adhesives, grease, or sealant in excess or in areas out

46、side of product requirements; machining chips; drill shavings; safety wire remnants; solder balls; coatings; tie wraps; grit blast; shot peen; tumbling media; and hardware remnants. 4.7 Consumables, Hardware, and Personal Items Accountability and Control 4.7.1 The organization shall establish, imple

47、ment, and maintain processes to account for and control consumables, hardware, and personal items to mitigate FOD risk to the product. SAE INTERNATIONAL AS9146 Page 7 of 7 4.7.2 The organization shall maintain documented information for a process of reporting lost consumables, hardware, and personal

48、 items to mitigate FOD risk to product. 4.8 Tool Accountability and Control 4.8.1 The organization shall establish, implement, and maintain a process to account for and control both company and personally owned tools to mitigate FOD risk. NOTE: For the purposes of this standard, a tool is a device w

49、hich is not part of the product hardware, consumables, personal items, or infrastructure. 4.8.2 Tool accountability and control shall include: a. Storage and preservation. b. Identification and inventory. c. Tool location and management (e.g., knowledge of tool locations at all times). d. Maintenance, serviceability, and condition (e.g., cleanliness, no broken pieces, missing pieces). e. Design considerations to avoid