Resource Library/Product Integrity and Aerospace Requirements/FOD Inspection Checklist
FOD Inspection Checklist
Find foreign objects before your customer does: a monthly area audit with thirty checks, a five-minute daily walk log, and a lost item log that holds the product first and searches second.
- Excel
- fillable PDF
- Worked example
- Your logo on it
- Aegis Insights
Page 1 of the PDF. Every resource includes a fully worked example.
The problem it solves
Foreign object damage rarely starts with carelessness. It starts with a chip left in a blind hole, a test plug that went missing at the wash, a broken drill tip nobody accounted for, or a parts cart with rivets rolling around in the bottom. Most shops have a FOD poster and a clean floor for audits; fewer walk their areas with a checklist, count caps and plugs, or treat a lost tool as a reason to hold product. This workbook gives you the three tools that do: a monthly area audit, a daily walk log and a lost item log, with a summary that shows where FOD is coming from. The IA9100 FOD and Planning Check (AQL-D14) asks whether FOD is in your PFMEA and control plan; this is the walk on the floor.
Who uses it
Production supervisors and area leads who walk their areas, inspectors, and the quality engineer who audits each area monthly.
When
A daily walk per area, a monthly audit per area, and a lost item line the moment anything cannot be accounted for.
Free to use, change and copy, in your own organization or with your clients; add your own logo, keep the Aegis credit. Clause references: 8.5.1 (with 7.2, 7.3, 8.5.4, 8.7.1) (numbers only; use your own licensed copy of the standard).
A management aid, not certification or a registrar audit. Using it does not by itself show conformity to AS9100D or any other standard.
How to put it to work
Chapters of our free guides that use this tool.
Related resources
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Worksheet
IA9100 FOD and Planning Check
Foreign objects in the PFMEA and control plan, phased planning with gates, measurement behind your capability, and process verification beyond the first part.
Excel · PDFFree by email -
Workbook
Product Safety Risk Assessment
List the parts that carry product safety, assess what in your own processes could defeat each safety-relevant characteristic with a plain severity and likelihood rating you control, and record the controls, the actions and who accepted any risk that remains High.
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Workbook
Product Safety Reporting and Escalation Matrix
Decide before the event: for each kind of product safety event, what to stop and hold, who inside is told and by when, who decides, when the customer hears and what goes outside. Then log every real event against those times.
Excel · PDFFree download -
Checklist
Nonconforming Product Segregation Checklist
Walk the floor and the hold area with five short checklists and a reconciliation sheet: every nonconforming and suspect part identified where it was found, held where it cannot be used, matched to its record, scrapped beyond recovery, and released only on a signed disposition.
Word · PDFFree download -
Workbook
MRB Disposition Record and Log
One record per material review board case, from the evaluation to the signatures to the product action, and one log that ages every open case, tracks every customer authorization and flags any use-as-is or repair released without the approvals it needs.
Excel · PDFFree by email
Need more than one resource, or not sure where to start? Book a complimentary 30-minute Aegis Quality Guidance Call. We'll find the tools that fit your situation and a sensible place to start. No sales pressure, no obligation.
These tools help you run the work by hand. When you want the whole picture of your quality system from the records you already keep, that's what the AeroAssure Audit Defense Pack and the IA9100 Transition Gap Analysis do.