FOD Control Checklist: Keep Foreign Objects Out of the Shop Floor
What is FOD?
Foreign Object Damage (FOD) is damage caused when tools, metal chips, packaging fragments or personal items enter a product or equipment, and it is a high-risk problem in aerospace manufacturing and maintenance. FOD prevention combines area management, tool control, clean working practices and personnel training to stop foreign objects from being left behind, contaminating or damaging products. Prevention should extend to supplier management and incoming inspection so objects do not enter the line inside packaging.
When to Use It
Use it in aircraft assembly, engine and component manufacturing, MRO (maintenance, repair and overhaul) shops and composite machining areas, as well as for customer or airworthiness FOD audits and new employee FOD training. High-risk operations such as grinding, drilling and cutting should be isolated in dedicated zones with more frequent patrols.
How to Use It (Step by Step)
Generate the checklist covering tool registration and counts, protection of exposed fasteners, chip isolation for cutting and grinding, packaging and unpacking control, timely waste removal, locker and pocket item rules, and patrol frequency with responsible owners. Walk the area at shift start, mid-shift and shift end, record findings with photos, and immediately stop the line to trace affected product if foreign objects are found.
Key Formulas / Example
An example control is a numbered tool shadow board with tethering and a full count before leaving the work area; a missing tool means stopping the line to search. Check frequencies commonly follow shift start, mid-shift and shift end, with additional special patrols in engine assembly and fuel tank areas per the company FOD procedure.