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FIRST ARTICLE INSPECTION

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FIRST ARTICLE INSPECTION AS IN AS9100C

FIRST ARTICLE INSPECTION AS IN AS9100C

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  • 1. Guide for successful completion of First Article Inspection ReportsCompany Confidential Rev. Jan 2012 1
  • 2. Introduction• This presentation is intended as supplemental information in support of the 9102 Standard for Aerospace First Article Inspection requirements.• This material should be used in conjunction with the standard. The requirements cited in the standard always take precedent. 2
  • 3. Requirements First Article Inspection Reports are to be recorded in English or in a language specified by the customer. AS/EN/SJAC9102 Revision A - Aerospace First Article Inspection Requirement 8.2.4.2 First Article Inspection: The organization’s system shall provide a process for the inspection, verification, and documentation of a representative item from the first production run of a new part, or following any subsequent change that invalidates the previous first article inspection result.  NOTE: USE (AS) (EN) (SJAC) 9102 with this tutorial for requirements 3
  • 4. Requirements Additional Customer requirements if applicable AS/EN/SJAC9102 Rev A forms are to be completed in accordance with the Appendix A guide of the standard Note: If alternate forms are used, they must contain all “Required” and “Conditionally Required” information and have the same field reference numbers as AS/EN/SJAC9102 Rev A 4
  • 5. DefinitionFIRST ARTICLE INSPECTION (FAI):A complete, independent, and documented physical andfunctional inspection process to verify that prescribedproduction methods have produced an acceptable itemas specified by engineering drawings, planning,purchase order, engineering specifications, and/orother applicable design documents.Ref 9102 Rev A 5
  • 6. PurposeProvides objective evidence: that all engineering, design and specification requirements, including process and manufacturing validation, are correctly  understood  accounted for  verified  and recorded. of a consistent documentation requirement for aerospace components. 6
  • 7. Evaluation Activities• The organization should conduct the following activities in support of FAI; – Review documentation for the manufacturing process (e.g., routing sheets, manufacturing/quality plans, manufacturing work instructions, etc.) to make sure all operations are complete as planned. – Review referenced exhibits supporting the FAI (e.g., inspection data, test data, Acceptance Test Procedures, etc.) for completeness. – Review nonconformance documentation (if any), for completeness. – Review material certifications for compliance, as applicable.
  • 8. Evaluation Activities – Verify that approved Special Process sources are used (as applicable), and that the manufacturing planning/routing document calls out the correct specification. – Verify that Key Characteristic requirements have been met, as applicable Verify part specific gages and/or tooling are qualified and traceable, as applicable. – Verify that every design characteristic requirement is accounted for, uniquely identified and has inspection results traceable to each unique identifier. – Note the company FAI procedure should address all evaluation activities
  • 9. When should FAI be performed? Full FAI  New part introduction  New supplier or new location of manufacture  Lapse in production for more than 2 years  When required by the customer Partial (Delta) FAI  Design change  A change in the method of manufacture (e.g. Tooling, Processes, Machine, Location, Numerical Control Program, Sequence of Manufacture). 9
  • 10. What does it apply to? All product defined by engineering drawings or model based definitions. Delete-issued by the Customer Assemblies- for those characteristics specified on the assembly level drawing only All levels of detail parts within assembly  including castings and forgings Modified Standard, Electronic or COTS Items as “make from” with unique engineer modifications on drawing Only the modifications 10
  • 11. What does it not apply to?Standard PartsElectronic ComponentsCommercial Off The Shelf (COTS) Items No FAI required 11
  • 12. What is included? Verification of all design characteristics Material and Special Process Certifications Manufacturing Process Verification Nonconformance resolution 12
  • 13. FormsThe Following Forms comprise a First Article InspectionReport (FAIR) full instructions in 9102 appendix A AS9102 A Form 1: Part Number Accountability shall be used to identify the part that is being first article inspected (FAI part) and associated sub-assemblies or detail parts. AS9102 A Form 2: Product Accountability – Raw Material, Specifications and Special Process(s), Functional Testing shall be used if any material, special processes or functional testing are defined as a design requirement. AS9102 A Form 3: Characteristic Accountability, Verification and Compatibility Evaluation shall be used to record an actual measurement or inspection/verification of the FAI part for every design characteristic on the drawing, including notes. 13
  • 14. AS9102 A Form 1 – Part Number Accountability 1. Part Number 2. Part Name 3. Serial Number 4. FAI Report Number 5. Part Revision Level 6. Drawing Number 7. Drawing revision level 8. Additional Changes 9. Manufacturing Process 10. Organization Name 11. Supplier Code 12. P.O. Number Reference 13. Detail FAI 14. Full FAI Baseline Part Number including revision level Partial 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 YELLOW or LIGHT GREY fields – MANDATORY information required. BLUE or DARK GREY fields – CONDITIONALLY REQUIRED. These fields must be completed when information is available. WHITE fields – OPTIONAL information required when available. 1) Signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition. 2) Also indicate if the FAI is complete per Section 5.4: FAI complete FAI not Complete 19. Signature By 20. Date 21. Reviewed By 22. Date 23. Customer Approval 24. Date Form 1, 9102 Rev A, Date: Oct 24, 2003 14
  • 15. AS/EN/SJAC9102 Rev A First Article Inspection AS9102 A Form 1 – Part Number Accountability Sheet 1 of _ Form 1: Part Number Accountability 1. Part Number 2. Part Name 3. Serial Number 4. FAI Report Number 5. Part Revision Level 6. Drawing Number 7. Drawing revision level 8. Additional Changes Box 1. Part Number of the FAI part. Box 2. Name of the part as shown on the drawing. 9. Manufacturing Process 10. Organization Name 11. Supplier Code 12. P.O. Number Reference Box 3. Serial number of the FAI part. Box 4. The Report No. 13. Detail FAI 14. Full FAI Baseline Part Number including revision level Box 5. The revision of the part Partial FAI being first article inspected. Indicate if Assembly FAI therePartial FAI: revision. Reason for is noNote: The latest revision (Box 7) does not always affect all parts contained on a drawing. a) if above part number is a detail part only, go to Field 19 Box 6. ifThe drawing numbersection below. b) above part number is an assembly, go to the “INDEX” associated with the FAI part. (if different from numbers or sub-assembly numbers required to make the assembly noted above. INDEX of part part number) 15. Part Number 16. Part Name 17. Part Serial Number 18. FAI Report Number Box 7. Reference the revision engineering drawing. (if drawing number is different from part number) Box 8. Reference Design, Engineering or Manufacturing changes affecting the FAI part, not reflected by the current part/drawing15 revision level. 15
  • 16. AS9102 A Form 1 – Part Number Accountability 1. Part Number 2. Part Name 3. Serial Number 4. FAI Report Number 5. Part Revision Level 6. Drawing Number 7. Drawing revision level 8. Additional Changes 9. Manufacturing Process 10. Organization Name 11. Supplier Code 12. P.O. Number Reference Box 9. Reference the internal works order. 13. Detail FAI 14. Full FAI Baseline Part Number including revision level Box 10. Name of the organization performing the FAI . Partial FAI Assembly FAI 11. Reference the supplier vendor code. Box Reason for Partial FAI: Box if12.part number is a detail part only, go to Field 19 a) above Reference the customer Purchase Order number. b) if above part number is an assembly, go to the “INDEX” section below. Box 13. Check as appropriate. INDEX of part numbers or sub-assembly numbers required to make the assembly noted above. BoxPart Number 15. 14. Check asPart Name 16. appropriate. Part Serial Partial FAI Report Number 17. For Number 18. FAI provide the baseline drawing number, including issue status and the reason. i.e Change of manufacturing location, Non-Conformance, Process change, Design change etc. 16
  • 17. AS9102 A Form 1 – Part Number Accountability 1. Part Number 2. Part Name 3. Serial Number 4. FAI Report Number 5. Part Revision Level 6. Drawing Number 7. Drawing revision level 8. Additional Changes Boxes 15, 16, 17 and 18 – this section is only required if the Part Number in Box 1. is an Assembly with lower level parts.P.O. Number 9. Manufacturing Process 10. Organization Name 11. Supplier Code 12. Reference Box 15. Reference all lower level parts or next level sub-assembly Part Number. 13. Detail FAI 14. Full FAI Baseline Part Number including revision level Box 16. Part namePartial FAI as shown on the drawing/ parts list. 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 Box 17. Reference the serial number of the part. Box 18. A reference number that identifies the FAI package. 17
  • 18. AS9102 A Form 1 – Part Number Accountability Box 19. The name and signature of the person who prepared the FAI. Box 20. Date when the FAI was prepared. Box 21. The name of the person who reviewed or approved the FAI package. Box 22. Date when the FAI was reviewed. 1) Signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition. 2) Also indicate if the FAI is complete per Section 5.4: FAI complete FAI not Complete 19. Signature By 20. Date 21. Reviewed By 22. Date 23. Customer Approval 24. Date Form 1, 9102 Rev A, Date: Oct 24, 2003 Box 23. Customer Approval. Box 24. Date of Customer approval. 18
  • 19. AS9102 A Form 2 – Product Accountability 1. Part Number 2 Part Name 3. Serial Number 4. FAI Report Number 5. Material or Process 6. Specification 7. Code 8. Special Process 9. Customer 10. Certificate of Name Number Supplier Code Approval Conformance Verification number (Yes/No/NA) Boxes 1 - 4 are repeated on all forms for convenience and traceability. 11. Functional Test 12. Acceptance report number, if applicable Procedure Number 13. Comments 14. Prepared By 15. Date 19
  • 20. AS9102 A Form 2 – Product Accountability 1. Part Number 2 Part Name 3. Serial Number 4. FAI Report Number 5. Material or Process 6. Specification 7. Code 8. Special Process 9. Customer 10. Certificate of Name Number Supplier Code Approval Conformance Verification number (Yes/No/NA) Box 5. Enter the name of the material or process i.e. Aluminium Alloy, Cadmium Plate etc.Box 6. Enter the material or process specification number, class andmaterial form i.e. AMS4928 Bar (Include ‘make from’ materials, weld/ braze filler materials, standard catalogue hardware etc). Box 7. Reference any material code specified. Box 8. Reference Special Process Supplier Vendor code, name & address. Box 9. Indicate if technical approval is required by the customer.Box 10. Reference Certificate of Conformance number(s) e.g. SpecialProcess, Raw material & Mill certifications, Laboratory Reports etc. 20
  • 21. AS9102 A Form 2 – Product Accountability11. Functional Test 12. Acceptance report number, if applicableProcedure Number Box 11. Reference the Functional Test procedure as stated on the drawing. Box 12. Reference the Functional Test report.13. Comments14. Prepared By 15. Date Box 13. Comments – As applicable. Box 14. The name of the person who prepared this form. Box 15. Date when this form was completed. 21
  • 22. Ballooned Drawings A ballooned drawing is optional and considered an industry best practice to support Box 5 of Form 3 Identify 100% of characteristics Balloon and number all dimensions Balloon and number all surface finish callouts  Including exclusion and inclusion area callouts Balloon and number all material and hardness callouts  Don’t forget the requirements identified in the title boxes at the bottom of the drawings. 22
  • 23. BALLOONED Note 2DRAWINGS 1 2 3 8 4 7 5 6Note: In this example not all characteristics ballooned 23
  • 24. AS9102 A Form 3 – Characteristic Accountability, Verification and Compatibility Evaluation1. Part Number 2. Part Name 3. Serial Number 4. FAI Report Characteristic Accountability Inspection / Test Results Optional5. 6. 7. Characteristic 8. 9. 10. 11. 14.Char Reference Designator Requirement Results Designed Non- [Insert columns, etc., as required byNo. Location Tooling Conformance Organization or Customer} Number Boxes 1 - 4 are repeated on all forms for convenience and traceability.The signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition.12. Prepared By 13. Date 24
  • 25. AS9102 A Form 3 – Characteristic Accountability, Verification and Compatibility Evaluation1. Part Number 2. Part Name 3. Serial Number 4. FAI Report Characteristic Accountability Inspection / Test Results Optio5. 6. 7. Characteristic 8. 9. 10. 11. 14.Char Reference Designator Requirement Results Designed Non- {Insert columns, etc. as required by OrganizationNo. Location Tooling Conformance or Customer} Number Box 5. Assign a unique number for each design Box 6. Reference the drawing zone Box 7. Reference any zoned characteristics i.e. Key characteristic. (include Sheet No. and Zone). These are to be traceable Critical Characteristic, etc. Characteristics, Safety to each drawing requirement.The signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition.12. Prepared By 13. Date 25
  • 26. AS9102 A Form 3 – Characteristic Accountability, Verification and Compatibility Evaluation1. Part Number 2. Part Name 3. Serial Number 4. FAI Report Characteristic Accountability Inspection / Test Results Opt5. 6. 7. Characteristic 8. 9. 10. 11. 14.Char Reference Designator Requirement Results Designed Non- {Insert columns, etc. as required by OrganizationNo. Location Tooling Conformance or Customer} Number Box 9. Indicate measurements specified for each designof specially Box 10. Record the tool identification number characteristic. Box 8. Indicate the obtained a media of inspection. designed tooling used as requirement for thenumber if any design Box 11. Record non-conformance be features reference values. Multiple characteristics shall document with minimum and i.e. Dimensional listed as individual characteristicRecord any addition information required. Box 14. maximum value of tolerance, foundaccountedSpecification design characteristicmust be non-conforming. All drawing notes is Drawing notes, for. requirements etc. Processes that require design verification must have statement of compliance recorded on the form i.e. Certification of Compliance – state ‘Accept’. Laboratory reports or Certificate of test must show specific values for requirements and actual results.The signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition.12. Prepared By 13. Date 26
  • 27. AS9102 A Form 3 – Characteristic Accountability, Verification and Compatibility Evaluation1. Part Number 2. Part Name 3. Serial Number 4. FAI Report Characteristic Accountability Inspection / Test Results Optio5. 6. 7. Characteristic 8. 9. 10. 11. 14.Char Reference Designator Requirement Results Designed Non- [Insert columns, etc., as required by OrganizationNo. Location Tooling Conformance or Customer] Number Box 12. Name of the person who prepared this form. Box 13. Date when this form was completed.The signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition.12. Prepared By 13. Date 27
  • 28. Forms LinkAS9102 A forms can be downloaded at: www.sae.org/aaqg/publications/as9102a-faq.htm9102 FAQ Link www.sae.org/iaqg/publications/faq9102.htm 28
  • 29. Most Common Reasons for FAI Rejection C of Cs do not accompany the FAI Report. Missing FAI Reports or Test Reports for sub-assemblies and/or fabricated detail parts. Variable data requirements from the engineering drawing are not provided with numerical results. Missing or wrong information provided. Missing special processor full address on AS9102 A Form 2, box 8. Missing tolerances on AS9102 A Form 3, box 8. Customer flow down requirements not met. 29

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