Daniel Caban Background
As an F-15 and F-22 Crew Chief with 12 years maintenance experience, I understand the daily challenges maintainers face. This operational expertise drives my design philosophy: create tools that make the maintainer's job easier, faster, and safer.
U.S. Patent #11,772,812 B1
for Portable Magnetic Aircraft Covers (PMAC)
Air Force Spark Tank finalist
(2020)
PMAC Adoption
Adopted fleet-wide on F-22, F-35, and upcoming B-21 platforms
Successfully led
SBIR Phases I, II, and III programs
Every solution is built from the ground up with maintainer feedback and real-world operational constraints in mind.
The Problem
Current masking methods are slow and lack accountability, creating a critical gap in FOD prevention.
A single, overlooked piece of masking tape after routine washing triggered a catastrophic Foreign Object Damage (FOD) incident for an F-22, resulting in $201 million loss. Fortunately, the pilot ejected safely and sustained only minor injuries.
Prolonged Wash Cycles
Wash cycle masking process exceeds 1.7 hours
Untracked Tape/Consumables
Zero tracking of consumables leads to unquantified and potentially catastrophic FOD risks.
SMART-FOD F-16 WASH KIT
System for Maintenance & Accountability to Reduce Threats of Foreign Object Damage
SMART-FOD is a task-specific, consumable kit of protective covers with built-in tracking and accountability to prevent FOD.
Speeds up aircraft washes by replacing hand-cut tape with precision-cut covers with printed orientation that are pre-matched to T.O. locations
SMART-FOD Kit:
Key Features
Precision-Cut Components
Aviation-grade 3M 481, cut to exact fit with visual placement instructions printed on each cover
Shadowed locations
Covers are serialized and have locations on the shadow backing— missing pieces are immediately visible, just like a CTK
Simple Integration
Full integration with existing tool control software including TCMax
One fool proof kit. Zero guesswork. 100% accountability.
1st SMART FOD F-16 Wash Kit Tested at Holloman, AFB
Holloman AFB Time Study Results
849 AMXS | January 30, 2026
Two teams of three performed the same masking task— one using traditional hand-cut methods with experienced personnel, the other using a SMART-FOD Kit with a crew that had zero prior experience.
Traditional (Experienced)
72 min Install + 30 min Removal
102 min Total Cycle
Multiple areas missed per T.O. Compliance
Traditional masking tape often fails to adhere to oily surfaces
SMART-FOD (Zero Experience)
28 min Install + 17 min Removal
45 min Total Cycle
100% T.O. Compliance & 100% FOD Accountability
481 tape adheres to oily engine bay doors.
2.3x
Faster
57 min
Saved Per Wash
100%
Compliant & Accountability
SMART-FOD Kit: Man-Hours Returned to the Flight Line (F-16 Fleet)
USAF + ANG F-16 Fleet — One-Year Impact
838
F-16 Aircraft in Fleet
6.08
Washes per Aircraft per Year
2.85
Man-Hours Saved per Wash
5,098
Total Washes per Year
14,529 hours
Total Man-Hours Returned Annually
4,843 hours
Hours Freed for MC Rate Improvement
These freed Man-hours directly support Mission Capable Rate recovery, ensuring optimal fleet readiness and operational efficiency.
Cost Comparison
Once labor burden, FOD exposure, and accountability gaps enter the picture. SMART-FOD shifts the equation — trading a higher material cost for dramatically lower total cost of ownership and measurably managed risk.
SMART-FOD F-16 WASH KIT
System for Maintenance & Accountability to Reduce Threats of Foreign Object Damage
Faster & Accountable
The SMART-FOD Kit cuts wash time by 2.3x, ensuring 100% accountability.
Precision-Cut Components
Aviation-grade 3M 481 tape, precision-cut with direct visual placement instructions.
Shadowed Locations
All covers are shadowed, making missing pieces immediately visible—just like a CTK.
Nu MAYA LLC.
Phone: 863-409-9991 or 281-785-6184
Email: daniel@nu-maya.com or brett@nu-maya.com