First Article Inspection

Report
First Article
Inspection Report
“FAI”
1
First Article Inspection
Requirements
Industry
AS9102 Rev A - Aerospace First Article Inspection Requirement
Invoked by AS9100
The Marvin Group
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First Article Inspection
DEFINITION
FIRST ARTICLE INSPECTION (FAI):
A complete, independent, and documented physical and
functional inspection process to verify that prescribed
production methods have produced an acceptable item as
specified by engineering drawings, planning, purchase
order, engineering specifications, and/or other applicable
design documents.
Ref AS9102 Rev A
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First Article Inspection
Purpose
Provides objective evidence that:
All design and specification requirements are
• understood
• accounted for
• verified
• and documented
Validates “as designed” configuration when produced
• as planned
• as tooled
• as manufactured
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First Article Inspection
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 Customer
• Partial (Delta) FAI
• Design change
• Change in the method of manufacture (e.g. Tooling, Processes,
Special Process Sources, Location, Numerical Control Program).
• Following significant incident or trend of non-conformance
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First Article Inspection
What does it apply to?
• Assemblies
• Sub-assemblies
• All levels of detail “make to print” parts purchased directly
or within assemblies
• including castings and forging
• All castings and forgings
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First Article Inspection
What does it apply to? cont
NO FAI REQUIRED FOR:
Standard Parts
Product listed on Qualified Products List (QPL)
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First Article Inspection
What is included?
• Verification of all design characteristics
• Material and Special Process Certifications
• Manufacturing Process Verification
• Nonconformance resolution
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First Article Inspection
Forms
AS9102 Form 1: Part Number Accountability shall be used to identify the
part that is being first article inspected (FAI part) and associated subassemblies or detail parts.
AS9102 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 Form 3: Characteristic Accountability, Verification and
Compatibility Evaluation shall be used to record actual measurement
inspection of the FAI part for every design characteristic on the drawing,
including notes.
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AS9102 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
Reference
10. Organization Name
11. Supplier Code
12. P.O. Number
13. Detail FAI
14.
Baseline Part Number including revision level
Assembly FAI
a)
b)
Full FAI
Partial FAI
Reason for Partial FAI:
if above part number is a detail part only, go to Field 18
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.
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:
19. Signature By
FAI complete
FAI not Complete
20. Date
21. Reviewed By
22. Date
23. Customer Approval
24. Date
Form 1, 9102 Rev A, Date: Oct 24, 2003
AS9102 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
Reference
10. Organization Name
11. Supplier Code
12. P.O. Number
13. Detail FAI
14.
Baseline Part Number including revision level
Assembly FAI
a)
b)
Full FAI
Partial FAI
Reason for Partial FAI:
if above part number is a detail part only, go to Field 18
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
BLUE or DARK GREY fields – CONDITIONALLY
REQUIRED. These fields must be completed
when required.
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:
19. Signature By
FAI complete
FAI not Complete
20. Date
21. Reviewed By
22. Date
23. Customer Approval
24. Date
Form 1, 9102 Rev A, Date: Oct 24, 2003
AS9102 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
Reference
10. Organization Name
11. Supplier Code
12. P.O. Number
13. Detail FAI
14.
Baseline Part Number including revision level
Assembly FAI
a)
b)
Full FAI
Partial FAI
Reason for Partial FAI:
if above part number is a detail part only, go to Field 18
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
WHITE fields – OPTIONAL information required.
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:
19. Signature By
FAI complete
FAI not Complete
20. Date
21. Reviewed By
22. Date
23. Customer Approval
24. Date
Form 1, 9102 Rev A, Date: Oct 24, 2003
AS9102 Form 1 – Part Number Accountability
(Top of Form)
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
Reference
10. Organization Name
11. Supplier Code
12. P.O. Number
13. Detail FAI
Box14.1.FullPart
Number
theincluding
FAIrevision
part.
FAI
Baselineof
Part Number
level
Partial FAI
Assembly FAI
a)
b)
Reason for Partial FAI:
if above part number is a detail part only, go to Field 18
if above part number is an assembly, go to the “INDEX” section below.
Box 2. Name of the part as shown on
16. Part Name
17. Part Serial Number
18. FAI Report Number
the drawing.
INDEX of part numbers or sub-assembly numbers required to make the assembly noted above.
15. Part Number
Box 3. Serial number of the FAI part if
applicable.
Box 4. The Report No. is the Part.
AS9102 Form 1 – Part Number Accountability
(Top of Form)
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
Reference
10. Organization Name
11. Supplier Code
12. P.O. Number
Box 6. The
number
associated
14. Fulldrawing
FAI
Baseline Part Number
including revision level with
Partial FAI
the First
Article
Inspection part.
Assembly FAI
Reason for Partial
FAI:
13. Detail FAI
a)
b)
if above part number is a detail part only, go to Field 18
if above part number is an assembly, go to the “INDEX” section below.
Box 7.16.Reference
the
issue status18. FAI
ofReport
the
Part Name
17. Part Serial Number
Number
engineering drawing.
INDEX of part numbers or sub-assembly numbers required to make the assembly noted above.
15. Part Number
Box 5. The latest part revision that affects the part being first
article inspected. Indicate if there is no revision.
Note: The latest revision (Box 7) does
not always affect all parts contained on a drawing.
Box 8. Reference Design, Engineering or Manufacturing
changes affecting the FAI part, not reflected by the current
drawing/ part revision level.
AS9102 Form 1 – Part Number Accountability
(Top of Form)
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
Reference
10. Organization Name
11. Supplier Code
12. P.O. Number
13. Detail FAI
14.
Baseline Part Number including revision level
Assembly FAI
a)
b)
Full FAI
Partial FAI
Reason for Partial FAI:
if above part number is a detail part only, go to Field 18
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 9. Reference the internal works order.
Box 10. Name of the organization performing the FAI .
Box 11. Reference the supplier vendor code
located on applicable P.O.
AS9102 Form 1 – Part Number Accountability
(Top of Form)
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
Reference
10. Organization Name
11. Supplier Code
12. P.O. Number
13. Detail FAI
14.
Baseline Part Number including revision level
Assembly FAI
a)
b)
Full FAI
Partial FAI
Reason for Partial FAI:
if above part number is a detail part only, go to Field 18
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 12. Reference the Customer Contract number.
Box 13. Check as appropriate.
Box 14. Check as appropriate. For Partial 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.
AS9102 Form 1 – Part Number Accountability
(Top of Form)
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 15,10.16,
17 and 1811. Supplier
– this
section
is only
Organization Name
Code
12. P.O. Number
required if the Part Number in Box 1. is an
Assembly
with lower
level parts.
13. Detail FAI
14. Full FAI
Baseline Part Number including revision level
9. Manufacturing Process
Reference
Partial FAI
Assembly FAI
a)
b)
Reason for Partial FAI:
if above part number is a detail part only, go to Field 18
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
AS9102 Form 1 – Part Number Accountability
(Top of Form)
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 15. Reference all lower level parts,
10.including
Organization Name
9. Manufacturing Process
11. Supplier Code
standards
or 12. P.O. Number
Reference
next level sub-assembly Part Number.
13. Detail FAI
14.
Full FAI
Partial FAI
Baseline Part Number including revision level
Box
name as shown on the
Reason for16.
Partial Part
FAI:
if above part number is a detail part only, go to Field 18 drawing/ parts list.
if above part number is an assembly, go to the “INDEX” section below.
Assembly FAI
a)
b)
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 if applicable.
Box 18. A reference number that
identifies the FAI package of the detail.
15. Part Number
16. Part Name
17. Part Serial Number
18. FAI Report Number
AS9102 Form 1 – Part Number Accountability
(Bottom of Form)
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:
19. Signature By
FAI complete
FAI not Complete
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.
AS9102 Form 2 – Product Accountability
1. Part Number
2 Part Name
5. Material or Process
Name
6. Specification
Number
3. Serial Number
7. Code
8. Special Process
Supplier Code
4. FAI Report
Number
9. Customer
Approval
Verification
(Yes/No/NA)
10. Certificate of
Conformance
number
Boxes 1 - 4 are repeated on all forms for
convenience and traceability.
11. Functional Test
Procedure Number
12. Acceptance report number, if applicable
13. Comments
14. Prepared By
15. Date
AS9102 Form 2 – Product Accountability
(Top of Form)
1. Part Number
2 Part Name
5. Material or Process
Name
6. Specification
Number
3. Serial Number
7. Code
8. Special Process
Supplier Code
4. FAI Report
Number
9. Customer
Approval
Verification
(Yes/No/NA)
10. Certificate of
Conformance
number
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 and material form (Include ‘make from’
materials, weld/ braze filler materials, standard catalogue
hardware etc).
Box 7. Reference any material code specified.
AS9102 Form 2 – Product Accountability
(Top of Form)
1. Part Number
2 Part Name
5. Material or Process
Name
6. Specification
Number
3. Serial Number
7. Code
8. Special Process
Supplier Code
4. FAI Report
Number
9. Customer
Approval
Verification
(Yes/No/NA)
10. Certificate of
Conformance
number
Box 8. Approved Sources Code Listed on ASL.
Box 9. Indicate if technical approval is required by the customer.
Box 10. Reference any Certificate of Conformance number(s)
e.g. Special Process certification, Raw material & Mill
certification, Laboratory Reports etc.
AS9102 Form 2 – Product Accountability
(Bottom of Form)
11. Functional Test
Procedure Number
12. Acceptance report number, if applicable
Box 11. Reference the Functional Test procedure
as stated on the drawing.
Box 12. Reference the Functional Test report.
13. Comments
14. 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.
AS9102 Form 3 – Characteristic Accountability, Verification and
Compatibility Evaluation
1. Part Number
2. Part Name
Characteristic Accountability
5.
6.
7. Characteristic 8.
Char Reference Designator
Requirement
No.
Location
3. Serial
Number
Inspection / Test Results
9.
Results
10.
Designed Tooling
11.
Non-Conformance
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
4. FAI
Report
13. Date
14.
As required
AS9102 Form 3 – Characteristic Accountability, Verification and
Compatibility Evaluation
1. Part Number
2. Part Name
Characteristic Accountability
5.
6.
7. Characteristic 8.
Char Reference Designator
Requirement
No.
Location
3. Serial
Number
Inspection / Test Results
9.
Results
10.
Designed Tooling
11.
Non-Conformance
Number
Box 5. Assign a unique number for each design
characteristic.
These are to be traceable to each drawing requirement.
Box 6. Reference the drawing zone
(include Sheet No. and Zone).
Box 7. Reference any zoned characteristics i.e. Key
Characteristics, Safety Critical Characteristic, etc.
The signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition.
12. Prepared By
4. FAI
Report
13. Date
14.
As Required
AS9102 Form 3 – Characteristic Accountability, Verification and
Compatibility Evaluation
1. Part Number
2. Part Name
Characteristic Accountability
5.
6.
7. Characteristic 8.
Char Reference Designator
Requirement
No.
Location
3. Serial
Number
4. FAI
Report
Inspection / Test Results
9.
Results
10.
Designed Tooling
11.
Non-Conformance
Number
14.
As Required
Box 8.
Indicate the specified requirement for the design characteristic i.e. Dimensional
features with minimum and maximum value of tolerance, Drawing notes,
Specification requirements etc.
Box 9.
Indicate measurements obtained for each design characteristic.
Multiple characteristics shall be listed as individual values or list once with the
minimum and maximum of measured values attained. If a characteristic is found
to e non-conforming then the characteristic must be listed separately with the
measured value noted.
All drawing notes must be accounted for.
Processes that require design verification must have statement of compliance
recorded
the form
i.e. for;
Certification
of Compliance
– state
‘Accept’.
The signature
indicates that all on
characteristics
are accounted
meet drawing requirements
or are properly documented
for disposition.
12. Prepared By
13. Date
Laboratory reports or Certificate of test must show specific values for
requirements and actual results.
AS9102 Form 3 – Characteristic Accountability, Verification and
Compatibility Evaluation
1. Part Number
2. Part Name
Characteristic Accountability
5.
6.
7. Characteristic 8.
Char Reference Designator
Requirement
No.
Location
3. Serial
Number
4. FAI
Report
Inspection / Test Results
9.
Results
10.
Designed Tooling
11.
Non-Conformance
Number
14.
As Required
Box 10. Record the tool identification number of specially
designed tooling used as a media of inspection.
Box 11. Record non-conformance document reference number if any
design characteristic is found non-conforming.
Box 14. Record any addition information required.
The signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition.
12. Prepared By
13. Date
AS9102 Form 3 – Characteristic Accountability, Verification and
Compatibility Evaluation
1. Part Number
2. Part Name
Characteristic Accountability
5.
6.
7. Characteristic 8.
Char Reference Designator
Requirement
No.
Location
3. Serial
Number
Inspection / Test Results
9.
Results
10.
Designated Tooling
11.
Non-Conformance
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
4. FAI
Report
13. Date
14.
As Required
First Article Inspection
FAI Completion & Verification
• Results compiled by person independent to process
• Results reviewed independently and signed
• Customer acceptance
The Marvin Group
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