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Col CW Fox MA-HQ AF/SE

FOD - Risk Management. Col CW Fox MA-HQ AF/SE. Overview. FOD Mishap Statistics FOD Prevention Methods Challenges to FOD Prevention DEMIO Concept Questions. FOD Mishap Statistics. Data summary for FY95-04 800 total FOD mishaps Class A, B, & C

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Col CW Fox MA-HQ AF/SE

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

  2. Overview • FOD Mishap Statistics • FOD Prevention Methods • Challenges to FOD Prevention • DEMIO Concept • Questions

  3. 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

  4. FOD Mishap Statistics

  5. FOD Mishap Statistics L/G – Landing Gear “Other” includes metal fasteners, rocks, etc.

  6. FOD Mishap Statistics

  7. 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.

  8. Challenges to FOD Prevention • FOD considered small problem by many • Damage cost accounts for < 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

  9. DEMIO ConceptDedicated 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

  10. 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

  11. 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

  12. 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.”

  13. AFSC POCs • Major Jeff Taylor – Aircraft Maintenance • DSN 246-0609 Commercial 505-846-0609 • E-Mail Jeffrey.Taylor@kirtland.af.mil • Capt Brian McDonald – Propulsion Engineer • DSN 246-0991 Commercial 505-846-0991 • E-Mail Brian.McDonald@kirtland.af.mil • CMSgt Jeff Moening – Aircraft Maintenance • DSN 246-0972 Commercial 505-846-0972 • E-Mail Jeffery.Moening@kirtland.af.mil

  14. Questions The Goal is ZERO!

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