With the arrival of the New Year, many of us look for changes, eager and open to trying new things, and questioning old habits, both in life and at work.
TheCanKey was built on the mindset of embracing change and confronting challenges head-on. As an aircraft mechanic, I dealt with Foreign Object Damage (FOD) in aircraft engines for years, including on my own aircraft—the GAF Nomad.
My Nomad frequently triggered chip alert signals—metal debris appeared to be in the engine, causing wear. I couldn’t understand where this debris was coming from. “Use a screwdriver when opening the metal oil can,” I was often told. “What’s wrong with using a Leatherman key to open the can?” I followed the industry’s established habits like so many mechanics did. I was young and didn’t question the norms. Eventually, I began to wonder: Could those chip alerts be linked to metal debris in the oil caused by the way I had been opening the cans? And indeed, that was the case! That’s when TheCanKey story began.
The issue of FOD damage is real. Even tiny particles in the oil can lead to long-term damage, repairs, faulty oil samples, increased costs, and safety risks. Every day, aircraft engineers worldwide open thousands of turbine oil cans using screwdrivers, flat-nosed pliers, Leatherman tools, or even a “church key.” Sharp metal tools almost always deposit tool debris and can material into the oil. This contaminated oil is then poured into the aircraft turbine engine or hydraulic system. As the debris enters the system, it wears down the internal moving parts of the engine or hydraulic system by reducing the clearance.
The presence of solid particles in oil reduces its lubricating properties, leading to wear. Contamination by particles as small as 5 µm can affect the reliability and safety of the lubrication system. Larger particles? Even worse.
Read more and watch the test video demonstrating the effect of metal debris in the oil from can openings with metal tools: Why-fod-shortens-turbine-engine-bearing-life
Do you want to take that risk?
Why do old habits die so hard? We are creatures of habit and changing our routine takes an open mind, there will obviously be some who remain fixed to their old habits.
Embrace the new ways of doing things. Try to implement those relatively simple steps to implement change in your own and your team´s work routine:
- Create consideration and understanding of the risks of FOD. Start conversations about the problem and establish knowledge about it. At TheCanKey we focus on building knowledge, led by our 30+ years’ experience as aircraft engineers. Review our series of newsletters and recommendations for input and inspiration.
- Once awareness is built, create an action plan to ensure a smooth transition for the organization. This should include securing new tools, like TheCanKey, that facilitate safer practices. Establish clear goals for the implementation of these new tools and processes.
- To ensure that your team adopts the new practices, make the tools readily available—near the aircraft, in every toolbox, in the tool store, or even next to oil cans. The easier it is to access these tools, the more likely they will become a standard part of your routine.
- Set clear and consistent procedures that require the implementation of the new habit. Establish routines of checking how the implementation goes. Offer support and accountability procedures e.g. use your employee ‘early adopters’ as ambassadors of change, coach and support the wider group.
- It takes weeks for a new routine to become a habit. Don’t abandon the change after the first attempt. Be patient, and persistent, and celebrate the small successes along the way. Persistence will pay off as you see fewer engine issues and less maintenance downtime.
6. For change to truly become ingrained, keep the topic of FOD prevention alive in your team’s daily routine. Encourage open discussions, monitor the process, and always be willing to improve.
Success Stories
Real-life success stories show how these changes lead to real benefits. For instance, Norwegian Air Ambulance embraced FOD risk prevention and saved both time and money by improving engine reliability and reducing costly repairs – read more here. Likewise, a seaplane operator avoided environmental fines and maintenance costs by implementing tools like FunnelCaps, a simple yet effective solution to prevent contamination during fuel and oil can openings – read more here.
Keep Moving Forward
The transition to new habits won’t be easy, but it’s a necessary step toward ensuring the safety, longevity, and cost-efficiency of your equipment. With persistence and the right tools, FOD risk prevention can become second nature. TheCanKey is here to help make this change simple, effective, and beneficial for all.
Learn more about how TheCanKey can help you avoid costly repairs and extend the life of your aircraft engines.
