Transcript AS9102 First Article Inspection Report TR-826 REV / - 01/21/2014 PAGE 1 First Article Inspection Requirements Industry AS9102 Rev A - Aerospace First Article Inspection Requirement The Marvin.

AS9102
First Article
Inspection Report
TR-826 REV / - 01/21/2014
PAGE 1
First Article Inspection
Requirements
Industry
AS9102 Rev A - Aerospace First Article Inspection Requirement
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 MEC or 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.
The Marvin Group
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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
BLUE or DARK
GREY fields
– CONDITIONALLY
information
required.
WHITE fieldsThese
– OPTIONAL
information
required.
REQUIRED.
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
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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
Box14.1.FullPart
Number
theincluding
FAIrevision
part.
FAI
Baselineof
Part Number
level
Partial FAI
Box 2. Name
of the part as shown on
Assembly FAI
Reason for Partial FAI:
Box 3. Serialthe
number
of the FAI part if
drawing.
a) if above part number is a detail part only, go to Field
18
b) if above part number Box
is an assembly,
to the “INDEX”
section below. No. is the Part.
4.goThe
Report
applicable.
INDEX of part numbers or sub-assembly numbers required to make the assembly noted above.
15. Part
Number latest part
16. Part Name
17. Part Serial
Number
Report Number
Box 5.
The
revision that
affects
the18. FAI
part
being first
Box 6. The drawing number associated with
articleBox
inspected.
Indicate
ifissue
there status
is no revision.
7. Reference
the
of the
the
First Article
Inspection
part.
Box 8. Reference
Design,
Engineering
Note: The
latest
revision
(Boxor
7)Manufacturing
does
engineering
drawing.
changes
affecting
the all
FAIparts
part,contained
not reflected
the current
not always
affect
on abydrawing.
drawing/ part revision level.
13. Detail FAI
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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 internalperforming
works order.
Box 10.
Name
of the organization
the FAI .
Box 11. Reference the supplier vendor code
Box 12. Reference the Customer Contract number.
Box
13. Check
as appropriate.
located
on applicable
P.O.
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.
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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
Box 15. Reference all lower level parts,
Box 16. Part
name asstandards
shown onorthe drawing/
including
Box 17. Reference
serial number of
partsthe
list.
next levelthe
sub-assembly
Part Number.
part
if
applicable.
Box 18. A reference number that
identifies the FAI package of the detail.
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AS9102 Form 1 – Part Number Accountability
(Bottom of Form)
Box20.
19.Date
The name
signature
of the
Box
when and
the FAI
was prepared.
Box 21. The name of the person who
person who prepared the FAI.
reviewed or approved the FAI package.
Box 22. Date when the FAI was reviewed.
Box 23. Customer Approval.
Box 24. Date ofFAICustomer
approval.
2) Also indicate if the FAI is complete per Section 5.4:
complete
FAI not Complete
1) Signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for
disposition.
19. Signature By
20. Date
21. Reviewed By
22. Date
23. Customer Approval
24. Date
Form 1, 9102 Rev A, Date: Oct 24, 2003
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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
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15. Date
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AS9102 Form 2 – Product Accountability
(Top of Form)
1 . P a rt N u m b e r
2 P a rt N a m e
5 . M a te ria l o r P ro c e s s
N am e
6 . S p e c ific a tio n
Num ber
3 . S e ria l N u m b e r
7. Code
8 . S p e c ia l P ro c e s s
S u p p lie r C o d e
4 . F A I R e p o rt
N um ber
9 . C u s to m e r
A p p ro v a l
V e rific a tio n
(Y e s /N o /N A )
1 0 . C e rtific a te o f
C o n form a n c e
n um ber
Box 5. Enter the name of the material or process
Boxi.e.
6. Enter the material
or process
specification
Alloy,
Plate
etc.
Box Aluminium
7. Reference
any Cadmium
material code
specified.
Box 8.class
Approved
Sources
Code
Listed ‘make
on ASL.
number,
and material
form
(Include
from’
Box 9. Indicate if technical approval is required by the customer.
Box
10. Reference
any Certificate
of Conformance
number(s)
materials,
weld/ braze
filler materials,
standard catalogue
e.g. Special Processhardware
certification,
etc).Raw material & Mill
certification, Laboratory Reports etc.
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AS9102 Form 2 – Product Accountability
(Bottom of Form)
1 1 . F u n c tio n a l T e s t
P ro c e d u re N u m b e r
1 2 . A c c e p ta n c e re p o rt n u m b e r, if a p p lic a b le
Box 11. Reference the Functional Test procedure
Box 12. Reference the Functional Test report.
as stated on the drawing.
1 3 . C o m m e n ts
1 4 . P re p a re d B y
1 5 . D a te
Box 13. Comments – As applicable.
Box 14. The name of the person who prepared this form.
Box 15. Date when this form was completed.
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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
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
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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 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).
Characteristics,
Safety Critical
etc.
These
are to be traceable
to each Characteristic,
drawing requirement.
The signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition.
12. Prepared By
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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 9.
Box
10. Record
the tool
identification
number
of specially
Indicate
measurements
obtained
for
each
design
characteristic.
Box
8. Indicate
the specified
requirement
for the design
designed
tooling
used
as
a
media
of
inspection.
Multiple
characteristics
shall be listed as
individual reference
values or list
once with
the
Box 11.
Record non-conformance
document
number
if any
characteristic
i.e.
Dimensional
features
with
minimum
and
Box
Record
any addition
information
required.
min. & max.
of 14.
measured
values.
If afound
characteristic
is found
to be nondesign
characteristic
is
non-conforming.
maximum
value
of
tolerance,
Drawing
notes,
Specification
conforming then the characteristic must be listed separately with the measured
requirements
value noted. etc.
All drawing notes must be accounted for.
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
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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
14.
Measurement Equipment (FAI)
11.
Non-Conformance
Number
10.
Designed Tooling
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
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PAGE 21
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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