FOD is Public Enemy No. 1 Published June 13, 2006 By Damian Housman Warner Robins Air Logistics Center Public Affairs ROBINS AIR FORCE BASE, Ga. (AFPN) -- Tiny objects make big trouble for jet engines -- something smaller than a fingernail can destroy an engine worth hundreds of thousands, even millions, of dollars. Foreign object damage, or FOD, typically occurs when small objects such as hardware fragments from aircraft are ingested into the aircraft’s engines when they are started.The Air Force has concentrated efforts to keep its aircraft free of FOD, and a program to reduce FOD incidents is meeting with success. In fiscal 2005, Warner Robins Air Logistics Center recorded 44 incidents of FOD, according to Senior Master Sgt. Joe German, who runs the center’s FOD office. Fiscal 2006, which ends Sept. 30, has seen 17 incidents. Of those, only two were chargeable to the center. “The greatest number in the current fiscal year -- nine -- were F-15 (Eagle) engines,” Sergeant German said. “There were also six C-5 (Galaxy) engines and two C-130 (Hercules) engines damaged.”For an idea of what can happen to an F-15, a recent incident of FOD ingestion in an F-100-series engine caused nearly $1 million damage. Another incident with an F-22 Raptor resulted in repairs estimated at several million dollars. Damage isn’t limited to engines. If an object disintegrates an engine, engine parts can be propelled throughout the engine compartment and beyond, endangering fuel and hydraulic lines, controls and aircrew. If the aircraft is in the air when the incident happens, the plane may be destroyed. Sergeant German calls it a “multiplier effect.” Everything touched by the original object can become another missile, doing more damage.“In the F-15, rivets get drilled out during the depot process,” he said. “Occasionally these result in leaving bits of fragments and residue (that) can present opportunities for FOD.” Another concern is loose objects in the cockpit. A loose object in a negative-G situation in an F-15 can become lodged behind a throttle. Suddenly the throttles can’t be moved, which is an in-flight emergency. “It would be bad enough if it were just a waste of taxpayer dollars,” Sergeant German said. “But if we damage an aircraft, it stays here for as long as it takes to fix it. That’s not doing our warfighters any good.” Sergeant German keeps busy in his quest to spread the word about FOD prevention. “Quality assurance inspections have been increased for each cell where aircraft go through the (programmed depot maintenance) process,” he said. “More barriers have been introduced to prevent migration of articles that can become FOD. We are also working with technicians to make sure they clean as they go along.” X-raying components is effective since the introduction of X-ray templates for correct positioning. The biggest effort in FOD reduction is with worker awareness.“We concentrate on keeping the technicians aware of how they can keep FOD away,” Sergeant German said. “We also conduct supervisor briefings."There are also monthly FOD working groups and quarterly meetings. “The first line of defense against FOD is the mechanic or technician. If the mechanic doesn’t buy into the program, it won’t work,” Sergeant German said. “The second line is supervisors. That’s why we make sure they have the training, materials and understanding of the problem.” Workers are rewarded for finding FOD. For example, a D-ring on a checklist binder recently fell off, but was located by an alert mechanic. Something like that can earn the mechanic an Eagle Eye award. The FOD office staff also places objects where an alert individual can find it, earning a Golden Bolt award. All units have regular FOD walks to clear the area of objects. Awareness and vigilance are the two best tools for fighting the FOD danger, Sergeant German said. “That’s how we’ll keep our incident numbers improving,” he said.