In aviation maintenance, even the smallest particles can have enormous consequences. Every day, engineers open thousands of turbine oil cans. Screwdrivers, pliers, Leathermans, even “church keys”—all of these tools can shave small metal fragments into the oil. That tiny debris may seem harmless, but once it enters an engine oil- or hydraulic system, it becomes Foreign Object Debris (FOD)—a silent but potent threat. It can accelerate wear, clog oil nozzles, cause overheating, and, in the worst cases, trigger catastrophic engine failure.
“Metal you didn’t want can enter your engines before you even realise it.”
I’ve seen this risk repeatedly throughout my career. Holding EASA PART-66 and FAA A&P-I licences, I’ve worked on everything from sports planes to small airliners, led quality audits, and managed line and base operations. One issue consistently stood out: the tools we use to open oil cans weren’t designed to protect against FOD. It’s a blind spot in maintenance that’s easy to overlook—but its consequences are very real.
A Silent Threat in Routine Maintenance
At first glance, it may seem trivial. A tiny shaving, almost invisible to the naked eye—what harm could it do? But I’ve seen the consequences firsthand. Those near-invisible particles can accelerate wear patterns, clog oil nozzles, and lead to overheating. In the worst cases, they can even cause complete engine failure. FOD contamination is a silent threat, and it doesn’t announce itself until it’s too late.
“Even highly qualified engineers can unknowingly introduce FOD during routine maintenance.”
Why This Issue Persists
Even highly qualified engineers, myself included, can inadvertently introduce this risk. Over my career, one persistent issue kept appearing: the tools used to open oil cans were never designed with FOD prevention in mind. Oil handling was a blind spot. It’s easy to underestimate the problem because the debris is nearly invisible and the process seems mundane. But in aviation, the seemingly small things often have the largest impact.
“A personal approach to solving the problem.”
Recognising this gap led me to focus on practical solutions that eliminate debris at the source. It’s not just about reducing risk—it’s about taking responsibility as engineers for the safety and longevity of the machines we maintain. What I’ve learned is simple: meticulous handling matters. Every action, no matter how small, contributes to the overall safety and performance of an aircraft. Tools should support that, not undermine it.
A Practical Solution: TheCanKey
This challenge inspired the development of TheCanKey—a certified, FOD-free turbine oil can opener designed specifically for professional aircraft engineers. Made from reinforced, high-quality plastic and ergonomically shaped for comfort and ease of use, TheCanKey ensures that no metal shavings or debris enter the oil. Saybolt-certified and pocket-sized, it fits on a key ring and passes airport security checks, making it easy to integrate into daily maintenance routines.
By replacing screwdrivers and other inappropriate tools with TheCanKey, engineers can eliminate debris at its source, protecting engines, extending machinery’s lifespan, and reducing operational risks—all without changing established workflows.
The Bigger Picture
The takeaway is simple: small debris = massive risk. FOD prevention isn’t just about reducing costs—it’s about maintaining the safety and integrity of turbine engines. From airlines and helicopter operators to air forces and private aviation, the lesson is universal: every detail matters, and every tool choice counts.
Throughout my career, I’ve learned that meticulous handling, awareness, and the use of the right tools are what separate good maintenance from great maintenance. With certified solutions like TheCanKey, engineers can take a proactive step toward safer, cleaner, and more efficient operations—preventing the “metal you didn’t want” before it ever becomes a problem.
