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Improved Understanding of Human Factors FLIGHT SAFETY FOUNDATION Aviation Mechanics Bulletin JULY–AUGUST 2002 Improved Understanding Of Human Factors Could Reduce Foreign Object Damage FLIGHT SAFETY FOUNDATION Aviation Mechanics Bulletin Dedicated to the aviation mechanic whose knowledge, craftsmanship and integrity form the core of air safety. Robert A. Feeler, editorial coordinator July–August 2002 Vol. 50 No. 4 Improved Understanding of Human Factors Could Reduce Foreign Object Damage ........................................................1 Maintenance Alerts..................................................................................... 10 News & Tips ............................................................................................... 17 Cover photograph: © copyright 2002 PhotoDisc Inc. We Encourage Reprints Articles in this publication, in the interest of aviation safety, may be reprinted, in whole or in part, but may not be offered for sale, used commercially or distributed electronically on the Internet or on any other electronic media without the express written permission of Flight Safety Foundation’s director of publications. All uses must credit Flight Safety Foundation, Aviation Mechanics Bulletin, the specific article(s) and the author(s). Please send two copies of the reprinted material to the director of publications. These reprint restrictions apply to all Flight Safety Foundation publications. What’s Your Input? In keeping with FSF’s independent and nonpartisan mission to disseminate objective safety information, Foundation publications solicit credible contributions that foster thought-provoking discussion of aviation safety issues. If you have an article proposal, a completed manuscript or a technical paper that may be appropriate for Aviation Mechanics Bulletin, please contact the director of publications. Reasonable care will be taken in handling a manuscript, but Flight Safety Foundation assumes no responsibility for material submitted. The publications staff reserves the right to edit all published submissions. The Foundation buys all rights to manuscripts and payment is made to authors upon publication. Contact the Publications Department for more information. Aviation Mechanics Bulletin Copyright © 2002 Flight Safety Foundation Inc. All Rights Reserved. ISSN 0005-2140 Suggestions and opinions expressed in FSF publications belong to the author(s) and are not necessarily endorsed by Flight Safety Foundation. This information is not intended to supersede operators’/manufacturers’ policies, practices or requirements, or to supersede government regulations. Staff: Roger Rozelle, director of publications; Mark Lacagnina, senior editor; Wayne Rosenkrans, senior editor; Linda Werfelman, senior editor; Karen K. Ehrlich, web and print production coordinator; Ann L. Mullikin, production designer; Susan D. Reed, production specialist; and Patricia Setze, librarian, Jerry Lederer Aviation Safety Library. Subscriptions: One year subscription for six issues includes postage and handling: US$240. Include old and new addresses when requesting address change. • Attention: Ahlam Wahdan, membership services coordinator, Flight Safety Foundation, Suite 300, 601 Madison Street, Alexandria, VA 22314 U.S. • Telephone: +1 (703) 739-6700 • Fax: +1 (703) 739-6708 Improved Understanding Of Human Factors Could Reduce Foreign Object Damage A U.S. Federal Aviation Administration report provides guidelines for reducing maintenance-related foreign object damage through the application of human factors best practices. FSF Editorial Staff Foreign object damage (FOD) acci- organizational pressures, environ- dents/incidents have resulted in loss of mental pressures and work pressures. life and destruction of aircraft, as well as flight delays and additional work [FOD is defined as damage to any for aviation maintenance technicians part of an aircraft — frequently an and others. A U.S. Federal Aviation engine or a flight control mechanism Administration (FAA) report said that — that is caused by any extraneous one reason for maintenance-related material; the cost of FOD to the FOD occurrences is the complexity worldwide aerospace industry has of the aviation-maintenance envi- been estimated to be US$4 billion ronment, in which maintenance per- annually.]1 sonnel apply specialized knowledge and skills to conduct controlled pro- Maintenance personnel may not be cedures in surroundings that include able to anticipate many of the problems that result from the complexities of be used to eliminate and prevent the aviation-maintenance system. [FOD] in the aviation-maintenance environment,” the report said. “It is critical, therefore, to have an understanding of the human factors of The report said that a FOD- the system and to address those hu- prevention program should include man factors through both proactive precise policies and procedures that [measures], as well as reactive discuss the following items: measures,” the report said. “Through • The importance of FOD preven- a grounded understanding of the tion and how FOD prevention human factors involved in FOD, the affects safety, quality, costs and industry can provide the best customer satisfaction; guidance to eliminate existing FOD problems and prevent future • The goals of the FOD-prevention FOD occurrences.” program and the time required to achieve those goals; Many FOD-prevention programs • The standards that will be used emphasize technical procedures but to assess the progress of the do not consider human factors relat- FOD-prevention program and to ed to those procedures. Therefore, the compare it with similar programs FAA Office of Aerospace Medicine in other organizations; conducted a study to identify meth- ods of reducing maintenance-related • The organization of the FOD- FOD occurrences by applying human prevention program, including factors best practices.2 how the program will be man- aged and what support will be The report discussed the four causes available; of most FOD in the maintenance en- • The FOD-prevention program’s vironment — poor housekeeping, policies and procedures, includ- deterioration of facilities, improper ing how those procedures will be maintenance and inadequate opera- disseminated and how improve- tional practices. The report also dis- ments in the process will be cussed interaction and support of achieved; FOD-prevention efforts by manage- ment and employees, FOD aware- • The methods of communicating ness, FOD training, FOD audits and the successes or failures of the FOD inspections. FOD-prevention program to avi- ation maintenance technicians “These factors, taken together, make and aviation maintenance man- up the proactive measures that can agers; and, 2 FLIGHT SAFETY FOUNDATION • AVIATION MECHANICS BULLETIN • JULY–AUGUST 2002 • The methods of investigating The report said that all maintenance FOD incidents and FOD acci- personnel should receive training in dents, including how the occur- how to prevent FOD, including infor- rences will be reported, what data mation about the organization’s FOD- will be collected and how the data prevention procedures; causes and will be stored and analyzed. effects of FOD; safe working practices and individual responsibilities; correct The report described management storage, shipping and handling of support as essential to the success of material, components, equipment, a FOD-prevention program and said personal items and tools; accountabil- that management support should in- ity and control of tools, materials and clude adequate funding, appointment hardware; vigilance for potential of an individual or group with sources of FOD; clean-up techniques; authority to implement the program, and reporting of FOD incidents. support for work to eliminate FOD throughout the aerospace industry “In addition to the general FOD train- and support of a “FOD-prevention ing required for all employees, con- culture” throughout the organization. tractors and subcontractors, the maintenance technician should re- “The culture of an organization is the ceive additional training focused on collection of beliefs, norms, attitudes, the technical aspects of FOD preven- roles, as well as social [practices] and tion,” the report said. The additional technical practices, that are shared by training may discuss correct methods individuals within an organization,” of cleaning and maintaining fuel fil- the report said. “A good safety cul- ters and disposing of small pieces of ture focuses on minimizing danger- maintenance-related material, such as ous and injurious conditions that may pieces of safety wire. affect not only the employees of the organization. A more important result FOD-prevention training should be of a good safety culture is improved required before maintenance person- safety for the public at large. … nel work on an aircraft on or aircraft subassemblies. Recurrent training “The aircraft maintenance techni- also should be required, the report cian’s attitudes toward FOD will be said. a reflection of the values and beliefs that management places on FOD pre- To ensure that all employees develop vention or elimination. … Thus, it is an awareness of FOD occurrences incumbent on management to estab- and the FOD-prevention program, lish and maintain a FOD-prevention FOD announcements and discussions culture within the organization.” should be included in meetings, FLIGHT SAFETY FOUNDATION • AVIATION MECHANICS BULLETIN • JULY–AUGUST 2002 3 incentive programs should be estab- walk over it; pick it up and dis- lished to reward individuals or depart-
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