Aerospace Supplier Eliminates FOD Risk with Precision Die-Cut Foam Kitting
Summary
Discover how an aerospace components supplier transformed their tool and parts organization with custom die-cut foam solutions, achieving FOD compliance and efficiency gains.
Our Role
- Tool and parts inventory analysis
- Custom foam kitting design
- Shadow board creation
- FOD prevention program implementation
- Ongoing foam replacement program
Client Profile
The Challenge
Pain Points
- FOD (Foreign Object Debris) risk: Loose tools posed contamination threats
- Tool accountability: Missing tools triggered production holds
- Search time waste: Workers spent excessive time locating tools
- Audit findings: Recurring observations on tool control
- Inventory losses: Tools disappeared, requiring costly replacements
The Solution
Phase 1: Tool Documentation
We created detailed specifications for every tool, cataloging 4,247 individual tools with 312 unique tool profiles and 47 workstation kits designed.
Phase 2: Foam Material Selection
Workstation Drawer Inserts- Cross-linked polyethylene foam
- High-visibility yellow base with shadow contrast in black or red
- Chemical resistant for aerospace fluids
- Closed-cell polyethylene, anti-static formulation for ESD areas
- Low-particulate polyethylene, validated for cleanroom compatibility
Phase 3: Shadow Board Design
- High-contrast shadow outlines
- Tool silhouettes for instant identification
- Red "missing" indicators in shadow areas
Results
FOD Compliance
| Metric | Before | After | Improvement |
|---|---|---|---|
| Missing tool incidents | 8/year | 0 | 100% elimination |
| Production holds | 3/year | 0 | 100% elimination |
| FOD audit findings | 2/year | 0 | Zero findings |
| Tool search time | 8.5 min avg | <1 min | 88% reduction |
Cost Savings
- Production hold elimination: $135,000/year
- Tool replacement reduction: $28,000/year
- Labor efficiency: $67,000/year
- Total: $230,000/year
Explore Our Die-Cut Foam Solutions
Ready to implement precision foam kitting? Learn more about our offerings:
- Die-Cut Foams - Custom shadow boards, tool trays, and equipment protection
- Protective Packaging - Engineered foam solutions for parts protection
- Material Handling - Industrial workstations and storage systems
Conclusion
Die-cut foam kitting is essential for aerospace operations where tool control is non-negotiable. By implementing a comprehensive shadow board system, this manufacturer eliminated FOD risk, achieved audit excellence, and improved operational efficiency.
Contact Country Innovation & Supply for custom die-cut foam solutions.
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