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The difference in our shop's FOD logs from last year to now is crazy

We used to average maybe 2 or 3 stray tool reports a month, mostly small stuff like a missing 1/4 inch socket. Over the last six months, that number jumped to 8 or 9 a month, and last week we had a 10mm wrench left in an engine bay. The big change was when management brought in a bunch of new hires from that quick-cert program and rushed them onto the floor with minimal shadow time. Now I'm spending half my shift double-checking other people's work areas. How do you guys handle FOD control with a mixed-experience crew?

3 comments

3 Comments

wells.alice3mo ago

Honestly that quick-cert pipeline is a known problem. They get the paper but miss the shop floor habits that take years to build. Maybe push for a mandatory buddy-tool check system before any job wraps up.

ivan2302mo ago

Feel that in my bones. Saw a new guy last week sign off on a wiring job he was sure about, but he'd left a whole set of test leads inside the panel. Years of muscle memory just aren't in a textbook. A buddy system isn't about babysitting, it's about building that second-nature habit from day one. That piece of paper really doesn't teach you how to actually look at a finished job.

the_barbara3mo ago

Ever notice how this happens with everything from cooking to home repair? You can watch all the videos but still burn the sauce or flood the bathroom. That buddy check is like having someone read the recipe back to you, it catches the simple stuff experience teaches you to never forget.