Ipc WP 116

IPC-WP-116
Guidance for the

Development and
Implementation of a
Foreign Object Debris
(FOD) Control Plan
Developed by the Wire Harness Design Task Group (7-31k)

and IPC-HDBK-620 Handbook Task Group (7-31h) of the
Product Assurance Committee (7-30) of IPC
Users of this publication are encouraged to participate in the

development of future revisions.
Contact:
IPC
December 2015 IPC-WP-116
Table of Contents
TECHNICAL BACKGROUND ........................................... 1 3.5 FOD Awareness and Prevention Training ............. 4
3.6 Measurement and Performance ............................. 5
1 GENERAL REQUIREMENTS ................................... 1
3.7 FOD Incident Investigation Reporting, and
1.1 Scope ...................................................................... 1 Corrective Action ................................................... 5
1.2 Purpose ................................................................... 1 3.8 Employee Awareness and Feedback ...................... 5
1.3 Applicability ........................................................... 1
4 ACRONYMS AND TERMS ....................................... 7
1.4 Commercial Off-The-Shelf (COTS) ...................... 1
4.1 Cleanliness Level ................................................... 7
1.5 Existing of Previously Approved Designs ............ 2
4.2 Commercial Off-The-Shelf (COTS) ...................... 7
1.6 Measurement Units and Tolerances ....................... 2
4.3 Complex Work ....................................................... 7
1.7 Terms and Definitions ............................................ 2 4.4 Contaminant ........................................................... 7
2 APPLICABLE DOCUMENTS .................................... 2 4.5 Critical Work .......................................................... 7
2.1 Government/Military Standards ............................. 2 4.6 Discrepancy Report (DR) ...................................... 7
2.2 Industrial Standards ................................................ 2 4.7 FOD Awareness Areas ........................................... 7
2.3 Reference Documents ............................................ 2 4.8 FOD Control Area .................................................. 7
4.9 FOD Focal Point .................................................... 7
3 FOREIGN OBJECT DEBRIS (FOD) PREVENTION
4.10 Foreign Object Debris ............................................ 7
PROGRAM ................................................................. 3
4.11 Foreign Object Debris (FOD) Damage ................. 7
3.1 FOD Focal Point .................................................... 3
4.12 Material Review Record ........................................ 7
3.2 Housekeeping – ‘‘Clean As You Go’’ ................... 3
3.3 Control of Personal Items, Tools, Hardware Figures
and Consumables ................................................... 4
Figure 1-1 Foreign Object Debris (FOD) Logo ................... 1
3.4 Control of Hazardous Material .............................. 4
vii
December 2015 IPC-WP-116
Guidance for the Development and Implementation of a

Foreign Object Debris (FOD) Control Plan
TECHNICAL BACKGROUND
Most Foreign Object Damage/Foreign Object Debris (FOD) issues can be attributed to poor housekeeping, facilities dete-
rioration, improper maintenance, careless assembly, or inadequate operational practices. An effective FOD Prevention Pro-
gram (Control Plan) identifies potential problems, corrects negative factors, promotes awareness, provides for effective
employee training, and uses ‘‘lessons learned’’ for continual improvement. The objective of any FOD Prevention Program
should always be zero FOD, to provide visibility to problem areas and trends, provide management and workers with
inspection results, incident/mishap reports, and feedback of progress.
1 GENERAL REQUIREMENTS (Figure 1-1)
1.1 Scope This document introduces design concepts, guidelines, pro-

cedures, practices, process attributes, and recommendations for the con-
trol and mitigation of performance and reliability risks associated with
the introduction of Foreign Object Debris (FOD) in electrical and elec-
tronic (E/E) assemblies, including optical and metallic cable and wiring
harness assemblies, and elements thereof.
1.2 Purpose The intent of this document is to provide guidance and a

template for the development and implementation of a Foreign Object
Debris (FOD) Control Plan.
For purposes of this document:
• The Designer is the design agent for the User.
IPC-wp-116-1-1
• The User is the individual, organization, company, contractually desig-
nated authority, or agency responsible for the procurement or design of Figure 1-1 Foreign Object Debris (FOD) Logo
electrical/electronic/electromechanical (EEE) hardware, and having the
authority to define the class of equipment and any variation or restrictions to the requirements of this document (i.e., the
originator/custodian of the contract detailing these requirements). The User is considered the Design Authority.
• The Supplier is considered the individual, organization or company which provides the Manufacturer (assembler) compo-
nents (electrical, electronic, electromechanical, mechanical, printed boards, etc.) and/or materials (solder, flux, cleaning
agents, etc.).
• The Manufacturer is considered the entity that provides a service or product to the User.
1.3 Applicability This document is targeted for control of Foreign Object Debris (FOD) in areas where both critical and
complex work is performed, and to operations involved with designing, developing, manufacturing, assembling, testing,
operating, repairing, modifying, refurbishing, and maintaining Class 3 (or higher) hardware to the User specified cleanliness
level.
a. The design concepts, guidelines, and procedures presented in this document are for guidance ONLY, and are not
requirements. As such, the use of the words ‘‘must,’’ ‘‘should’’ and ‘‘shall’’ (and derivations thereof) have no special
meaning in this document, and they do not indicate a binding criterion.
b. This document is not binding, unless separately and specifically included by the applicable contract, approved draw-
ing(s), or purchase order.
1.4 Commercial Off-The-Shelf (COTS) This document does not apply to Commercial-Off-The-Shelf (COTS) items.
Designers considering the use of COTS hardware for applications described above are responsible for identifying and
managing risks associated with hardware that was built without a control plan to control and/or reduce the introduction of
Foreign Object Debris (FOD) in electrical and electronic (E/E) assemblies, including optical and metallic cable and wiring
harness assemblies, and elements thereof.

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IPC-WP-116

Guidance for the

Developed by the Wire Harness Design Task Group (7-31k)

Users of this publication are encouraged to participate in the

Guidance for the Development and Implementation of a

1 GENERAL REQUIREMENTS (Figure 1-1)

1.1 Scope This document introduces design concepts, guidelines, pro-

1.2 Purpose The intent of this document is to provide guidance and a

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