Col CW Fox

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FOD - Risk Management
Col CW Fox MA-HQ AF/SE
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Overview

• FOD Mishap Statistics
• FOD Prevention Methods
• Challenges to FOD Prevention
• DEMIO Concept
• Questions

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FOD Mishap Statistics

• Data summary for FY95-04
• 800 total FOD mishaps
• Class A, B, C
• A reported AF FOD mishap occurs every 4.5 days
• Total cost 240M
• Approx. 4 of total USAF mishap cost
• Average cost per FOD mishap 300K
• Median cost per FOD mishap 118K
• Three destroyed aircraft from FOD 66M

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FOD Mishap Statistics
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FOD Mishap Statistics
L/G Landing Gear Other includes metal
fasteners, rocks, etc.
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FOD Mishap Statistics
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FOD Prevention Methods

• 1 Priority Attack the source!
• Continued vigilance in traditional methods
• FOD education, sweeps/walks, tool control, etc.
• Look for new ways to prevent an old problem
• Innovative programs at grassroots level
• Utilize/Apply Risk Management principles to
  reduce your mishap potential
• If we miss the FO, prevent the D
• Increased durability of engine blades
• Design improvements and surface treatments
• System approach at aircraft design stage
• Inlet location and shape, inlet screens, etc.

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Challenges to FOD Prevention

• FOD considered small problem by many
• Damage cost accounts for lt 4 mishaps
• Prevention methods cost time and money
• Must show return on investment
• Benchmark off successful units / organizations to
  learn how they reduced their FOD incidents

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DEMIO Concept Dedicated Engine Mishap
Investigation Office

• Collocated with teardown facility at Tinker AFB,
  OK
• Office owned by field MAJCOM, not AFMC
• Direct control to influence office performance
• ACC pursued as top submitter of engines, AETC
  runner-up
• Not saddled with existing perceptions of depot
• Personnel
• Est. 3 investigators needed to handle workload
• Based on 3-year average of OC-ALC engine
  teardowns
• GS-13 or O-4 runs office serves as investigator
• Two senior enlisted or contractors as worker bees
• Approx. 350K annual budget

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DEMIO Concept

• Solution to MAJCOM criticisms of current process
• Engine-related mishaps take SIB members away from
  primary duties for too long
• From 04 AFOSC 4-star Survey The most recent
  AFMAN 91-223 change to require a formal board for
  every Flight Class B (with few exceptions) is
  causing unnecessary workload on our mishap wings,
  particularly with regards to engine mishaps.
• Depots take too long to complete engine teardowns
• 73 days was median time to process (open to
  close) engine-related deficiency reports from
  FY02-FY04
• Investigating known failure modes is a waste of
  resources

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DEMIO Concept

• Solution to AFSC criticisms of current process
• SIBs do not attend teardowns, lose touch with
  investigation, get frustrated, write marginal
  reports
• SIBs lack depth of technical knowledge needed to
  fully understand failure modes corrective
  actions
• From 04 AFOSC 4-star Survey Let unit Chiefs
  of Safety concentrate on human factors issues and
  not waste their time investigating complex engine
  failures they are not trained to do.
• Mishap engines are not properly labeled,
  resulting in major delays or even complete loss
  of item
• Complete loss occurred as recently as 2003

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DEMIO Concept

• Relieve some investigative burden from field,
  while improving engine-related mishap
  investigations
• Free-up safety resources for local mishap
  prevention
• Improved investigation better understanding of
  mishap drivers better recommendations
• Decreased potential for future mishaps
• Apply resources to drive down the 1 most
  frequent cause of Air Force aviation mishaps
  (Powerplant)
• You can't expect different results when
• you keep doing things the same way.

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AFSC POCs

• Major Jeff Taylor Aircraft Maintenance
• DSN 246-0609 Commercial 505-846-0609
• E-Mail Jeffrey.Taylor_at_kirtland.af.mil
• Capt Brian McDonald Propulsion Engineer
• DSN 246-0991 Commercial 505-846-0991
• E-Mail Brian.McDonald_at_kirtland.af.mil
• CMSgt Jeff Moening Aircraft Maintenance
• DSN 246-0972 Commercial 505-846-0972
• E-Mail Jeffery.Moening_at_kirtland.af.mil

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Questions
The Goal is ZERO!