Insufficient Foreign Material Exclusion (FME) programs have been identified as a root cause for several significant claims. An effective FME program establishes protocols for preventing foreign objects from remaining inside critical systems and machinery following maintenance activities.
Foreign material can take many forms, including:
- Dirt, debris, and dust
- Fasteners (threaded and non-threaded)
- Tools and rags
- Machining tailing, slag, and grinding particles
- Personal items (such as badges, jewelry, pens, papers, etc.)
- Unapproved chemicals and lubricants
Foreign material can take many forms, including:
1. Administration and Structure
- Identify FME high-risk areas where critical equipment is open or exposed.
- Establish formal policies and procedures that include:
- Written guidelines for creating, accessing, working within, and closing out FME areas.
- Designated roles such as an FME coordinator, control point supervisor, and closeout inspector(s).
- Work packages that incorporate FME checklists, pre-work inspections, status reporting, and final closeout inspections.
2. Compliance and Control
- Establish clearly defined boundaries using appropriate signage and a single controlled access point.
- Restrict access to authorized personnel only.
- Maintain accountability logs that document:
- Personnel entry and exit, including name, date, and time.
- All tools, materials, and equipment entering and leaving an FME area.
3. Barriers and Protective Devices
- Use appropriate covers, caps, plugs, or custom-fabricated devices to protect and block openings.
- Employ high-visibility barriers and tools where applicable.
- Post signage, as necessary, to identify unguarded or exposed openings.
4. Training and Safety
- Document FME protocol and risk training for all personnel involved in applicable work activities.
- Address FME risks and controls in pre-job briefings.
5. Inspection and Recovery
- Conduct routine observations of FME areas by designated personnel.
- Document a final closeout inspection to verify that systems are free of foreign material.
- Implement a clear process for immediate reporting and recovery of any lost foreign material.
Effective implementation of an FME program can significantly reduce the risk of damage resulting from foreign material left in critical systems or machinery. Regardless of the service provider, adherence to these core elements helps support a safe, reliable, and trouble-free return to service.
If you have any questions, please reach out via email to Timothy Irwin, Senior Machinery Loss Control Professional.
About Quick Tips
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