• Share
  • Email
  • Embed
  • Like
  • Save
  • Private Content
1st Article Linked In
 

1st Article Linked In

on

  • 1,648 views

 

Statistics

Views

Total Views
1,648
Views on SlideShare
1,641
Embed Views
7

Actions

Likes
1
Downloads
44
Comments
0

3 Embeds 7

http://www.linkedin.com 5
http://www.slideshare.net 1
http://www.lmodules.com 1

Accessibility

Categories

Upload Details

Uploaded via as Microsoft PowerPoint

Usage Rights

© All Rights Reserved

Report content

Flagged as inappropriate Flag as inappropriate
Flag as inappropriate

Select your reason for flagging this presentation as inappropriate.

Cancel
  • Full Name Full Name Comment goes here.
    Are you sure you want to
    Your message goes here
    Processing…
Post Comment
Edit your comment

    1st Article Linked In 1st Article Linked In Presentation Transcript

    • AS9102 A Aerospace First Article Inspection Requirement Alan W. Spreadbury Property of AS9100 Solutions All rights reserved Unauthorized duplication prohibited
    • Why do First Articles and why do an “Aerospace” first article?  AS9100 rev B paragraph 8.2.4.2 First Article Inspection: – “The organization’s system shall provide for a process for the inspection, verification, and documentation of a representative item from the first production run of a new part, or following a subsequent change that invalidates the previous first article inspection result.”  AS9100 rev C paragraph 7.5.1.1 Production Process Verification – “The organization shall use a representative item from the first production run of a new part or assembly to verify that the production processes, production documentation and tooling are capable of producing parts and assemblies that meet requirements. This process shall be repeated when changes occur that invalidate the original results (e.g. engineering changes, manufacturing process changes, tooling changes).  AS9102 is widely accepted throughout the industry as the accepted first article guideline document/process. Property of AS9100 Solutions All rights reserved Unauthorized duplication prohibited
    • What a First Article is and what a First Article isn‟t.  A First Article is NOT just an inspection of a part to make sure that it meets the print. – In fact, in some circumstances, a part that does not meet the print (nonconforming) could be acceptable as a first article (we’ll cover that later). – You can’t complete a First Article if all you have is the part and the drawing.  A First Article is as much about the plan and the process used to produce the part as it is about the actual part itself (output of the process). – Its all about making sure the plan works and that the output of the plan (part) has all of the requirements completed, accounted for, and acceptable.  Make sure that the part is correct and complete using the plan, tools, etc that we intend to use to make all of the future parts. – Parts made in the prototype shop are not, typically, representative of the plan (unless that is where they intend to make them all). – During the development stage of a process a lot of things are going on that can invalidate the first article (fixtures changing, software changing, schedule demands, etc.). Its important to be cognizant of these changes and be assured that the changes are accounted for. Property of AS9100 Solutions All rights reserved Unauthorized duplication prohibited
    • Delta First Articles  Once invoked, the First Article requirement continues to apply even after initial compliance.  The whole idea is to make sure the plan works and produces complete and acceptable product, therefore it is implicit that any changes to the plan will require a new, or partial, first article.  First Article requirements may be satisfied by a partial First Article that addresses the differences between the current configuration and the approved configuration.  Only the affected portions of the documentation need to be completed for a partial First Article.  First Article requirements may also be satisfied by a previously approved First Article performed on identical characteristics of similar parts produced by similar means. Property of AS9100 Solutions All rights reserved Unauthorized duplication prohibited
    • Documentation (Forms 1, 2, & 3)  AS9102 defines 3 separate forms to document the First Article – Other forms are permitted, but they must include the same required information and have the same reference numbers  Form 1: Part Number Accountability – Used to identify the part that is being First Article inspected and all associated subassemblies or detail part numbers. – Form 1 is like the Bill of Material and lists all of the details and their respective First Article status.  Form 2: Product Accountability-Raw Material, Specifications and Special Process(s), Functional Testing – Used if any material, special processes or functional testing are defined as a design requirement. – Form 2 is where we document: all special processes with specifications, sources, and certifications, all raw material that is listed by specification only (i.e. not a part number or standard catalog item), and any required functional testing.  Form 3: Characteristic Accountability, Verification and Compatibility Evaluation – Used to document every measurable design characteristic with a unique identifier, characteristic detail information, and measurement results. – Form 3 does a lot of the heavy lifting and is where all of the inspection results are documented.  Besides these forms, a complete First Article also needs all of the supporting and documentation evidence to support the manufacturing plan. Property of AS9100 Solutions All rights reserved Unauthorized duplication prohibited
    • Form 1 Example 1. Part Number 2. Part Name 3. Serial Number 4. FAI Report Number Your Part Number Your Part name Required if Serialized Optional 5. Part Revision Level 6. Drawing Number 7. Drawing revision level 8. Additional Changes Revision if applicable Drawing number if Drawing rev if applicable ECO‟s, ECN‟ or number for any different than part other change docs number 9. Manufacturing Process Reference 10. 11. Supplier Code 12. P.O. Number Organization Name Number, rev, or identifier of the current process Source name, Source code number Purchase order number address, etc. 13. Detail FAI 14. Full FAI Partial Baseline Part Number including revision level FAI Assembly FAI Reason for Partial FAI: a) if above part number is a detail part only, go to Field 19 b) if above part number is an assembly, go to the “INDEX” section below. INDEX of part numbers or sub-assembly numbers required to make the assembly noted above. 15. Part Number 16. Part Name 17. Part Serial Number 18. FAI Report Number Item 1 Part Number Item 1 Part Name Item 1 Serial Number Item 1 First Article report Number Item 2 Part Number Item 2 Part Name Item 2 Serial Number Item 2 First Article report Number Property of AS9100 Solutions All rights reserved Unauthorized duplication prohibited
    • Form 2 Example 1. Part Number 2 Part Name 3. Serial Number 4. FAI Report Number Your Part Number Your Part Name Required if Serialized Optional 5. Material or Process Name 6. Specification 7. Code 8. Special Process Supplier 9. Customer 10. Certificate of Number Code Approval Conformance Verification number (Yes/No/NA) Aluminum 6061-T6 Optional Northeast Aluminum N/A 121267 Hartford, CT 112113 Chem Film MIL-C-5541 Optional Southwest Coaters Yes 115116 Globe, AZ 131765 Property of AS9100 Solutions All rights reserved Unauthorized duplication prohibited
    • How can anyone possibly make sense of this!!!
    • Basic dimensions are not recordable dimensions and as such do not require numbering 2 1 5 6 Ø 0.750 .002 thru 0.750 + .005Ø m -A- -B- m -C- .002 1.500 3 .002 -C- .001 1.250 -B- 0.750 .002 4 2.000 Property of AS9100 Solutions -C- What about these two? All rights reserved Unauthorized duplication prohibited
    • Material specifications, be careful here. Stating “conforms‟ means that someone reviewed the certification and lab report against the material Form 3 Example specification and confirmed ALL of the requirements (chemical, physical, heat treat, hardness, etc.). Assume nothing, verify everything 1. Part Number 2. Part Name 3. Serial Number 4. FAI Report Your Part Number Your Part Name Required if Serialized Optional if used Characteristic Accountability Inspection / Test Results Optional Fields 5. Char 6. Reference 7. Characteristic 8. Requirement 9. Results 10. Designed 11. Non- 14.[Insert columns, etc, as required by Organization or Customer] No. Location Designator Tooling Conformance Number Attribute results would be acceptable. It‟s not 1 Note 1 Material: Conforms feasible to measure variable data around every Aluminum 6061- edge of every surface accurately to report variable T6 results. But, „conforms‟ means that it was 2 Note 2 Remove all Conforms evaluated all over and not assumed. burrs and break all sharp edges Be sure to read the specification and determine if .010 max any measurable characteristics need to be 3 Note 3 Finish: Chem Conforms reported. Any measurable characteristics from the film per Mil-C specification must be numbered and accounted 5541 for. 4 Note 4 All diameters to See table This callout is a little different. The drawing has be true position several holes and only this one true position w/in .004 to requirement to tolerance the hole locations. This relative datums could be handle several ways: they could all be unless otherwise listed here, they could be listed later on with each specified of the diameter callouts, or as shown here included 5 Note 5 Tolerances Conforms in an attached table. In either case a location result apply after must be recorded for each diameter covered by plating this note. 6 Note 6 Depending on the thickness of the plating, the mfg plan may require some in-process dimensions to Property of AS9100 Solutions be modified to account for plating thickness. All rights reserved Unauthorized duplication prohibited
    • Form 3 Example 1. Part Number 2. Part Name 3. Serial Number 4. FAI Report Your Part Number Your Part Name Required if Serialized Optional if used Characteristic Accountability Inspection / Test Results Optional Fields 5. Char 6. Reference 7. Characteristic 8. Requirement 9. Results 10. Designed 11. Non- 14.[Insert columns, etc, as required by Organization or Customer] No. Location Designator Tooling Conformance Number 1 Note 1 Material: Conforms What about Block 14? What is supposed to go here? Aluminum 6061- T6 2 Note 2 Remove all Conforms The revision A version and break removed fields from burrs of AS9102 all sharp edges this area to permit some flexibility by the organization or .010 max customers to specify additional fields. Some additions 3 include: Note 3 Finish: Chem Conforms •Measurement Method (Final) film per Mil-C •Measurement Method (in-process) 5541 4 •Op Note 4 No. Generated diameters to See table All •Op No. Inspected true position be •Justification for <100% inspection w/in .004 to relative datums unless otherwise specified 5 Note 5 Tolerances Conforms apply after plating 6 Note 6 Property of AS9100 Solutions All rights reserved Unauthorized duplication prohibited
    • Form 3 Example (continued) 1. Part Number 2. Part Name 3. Serial Number 4. FAI Report Your Part Number Your Part Name Required if Serialized Optional Characteristic Accountability Inspection / Test Results Optional Fields 5. Char No. 6. Reference 7. Characteristic 8. Requirement 9. Results 10. Designed Tooling 11. Non-Conformance 14.[Insert columns, etc, as required by Organization or Customer] Location Designator Number 6A Ø .109 ± .005 .107 7A Ø .187 ± .005 .1875 8A .125 ± .005 Deep .127 This is an example of one way to delineate Note True Position w/in .0026 the data for each of several multiple 4(6A) .004 features (i.e. hole patterns, etc.). This 6B Ø .109 ± .005 .108 table lists variable results for each hole 7B Ø .187 ± .005 .187 for thru hole size, counterbore size, 8B .125 ± .005 Deep .128 counter bore depth and true position. As Note True Position w/in .0022 4(6B) .004 well as true position for each end of a slot. Not 4 True Position w/in .0015 (15A) .004 Not 4 True Position w/in .0017 (15B) .004 33A Ø .140 ± .005 .137 34A Ø .203 ± .005 .202 All variable data for all of 35A .050 ± .005 Deep .050 Not 4 True Position w/in .0033 the holes and slots. No (33A) .004 33B Ø .140 ± .005 .136 attribute results here. 34B Ø .203 ± .005 .202 35B .050 ± .005 Deep .049 Not 4 True Position w/in .0028 (33B) .004 Property of AS9100 Solutions All rights reserved Unauthorized duplication prohibited
    • Final Points  Assume nothing, verify everything  A proper AS9102 1st article requires painstaking detail.  Sometimes you’ll almost feel embarrassed to ask for some obscure bit of information, but don’t be.  You are just trying to verify every design characteristic and assuring that, at least once, everything was checked out and found acceptable.  Be firm and insist on variable data for each item if possible.  Take the time to carefully evaluate the whole package.  Making sure it is right the first time is what its all about. Property of AS9100 Solutions All rights reserved Unauthorized duplication prohibited
    • More Information/Additional Support  Supply Chain Management Handbook (www.IAQG.org) – An information tool offered by the International Aerospace Quality Group with lots of good information – The SCMH has valuable information concerning AS9102 first articles along with other aerospace quality information. Property of AS9100 Solutions All rights reserved Unauthorized duplication prohibited