as9102 fai guidelines

7/22/2019 AS9102 FAI Guidelines

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WELCOME

TELEPHONICS SUPPL IER

QUALITY MANAGEMENT

AS9102 FIRST ARTICLE

INSPECTION GUIDELINES



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BACKGROUND

Telephonics customer base is increasingly requiring by

contract that Telephonics provide full AS9102 First

Article documentation. In order to comply with this

requirement Telephonics must pass the same

requirement to our suppliers, to be certain of obtainingall required certifications, test reports and other

documentation to pass on to our customers. In the

same manner Telephonics suppliers must pass the

requirement to their suppliers to be certain of obtaining the needed documents for their AS9102 First

Article.



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WHY WE ARE HERE

The following presentation is an attempt to identify and

offer an explanation of the requirements of the AS9102specification. Often at first glance the requirements of

the specification look somewhat onerous and maybe a

little scary. It is hoped that this presentation will offer

clarification and a better understanding of how to

approach the First Article process.



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AS9102 First Article Inspection

Elements of this presentation

Quality Clause 2.5.1

Quality Clause 6.9

SOW requirements

Definitions

Evaluation Activities

Partial or re-accomplishment of the FAI

Forms

Form 1

Form 2

Form 3



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2.5.1 SAE AS9102, First Article Inspection (FAI) is required prior

to the first delivery of the product baseline configuration. FAI shall be

performed on the first unit/assembly produced and shall be

performed in accordance with all the requirements defined SAE

AS9102 (latest revision). Telephonics‟ Quality Assurance shall reviewthe FAI during the source inspection of the first Production unit(s).

Partial and/ or re-accomplishment of the FAI shall be required as per

specification. Telephonics will either review FAI activity, subsequent

to the accepted baseline FAI, during the applicable Source Inspection

or the FAI report will be sent to Telephonics for review. Telephonics

Quality Assurance reserves the right to perform some or all aspects

of the FAI activities at the supplier‟s or Telephonics‟ facilities.

Telephonics disclaims responsibility for material delivered prior to

first article approval. . (Note: QC Clause 2. and 6.9 are also invoked in

conjunction with this clause.)



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Clause includes Quality Clause 2 (Source Inspection)

and Quality Clause 6.9 (AS9102 Documentation).

Reference to QC 2 requires on-site inspection and acceptance

by Telephonics representative.

General requirement is for SQM personnel to conduct the

inspection.

First Article Inspection shall be identified on the Source Request.

QC 6.9 addresses documentation, requires AS9102

documentation to accompany the shipment.


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Quality Clause 6.9

Quality Clause 6.9

6.9 SAE AS9102, First Article Inspection (FAI) data is

required on this Purchase Order. A copy of the First Article

Inspection Report, associated drawings and all specialprocess and finish certifications of all lower level detail parts

must accompany the first shipment of unit/assemblies.

Telephonics preferred method of FAI report transmittal is by

way of electronic media.

Telephonics disclaims responsibility for material deliveredprior to first article approval.



Quality Clause 6.9

Requires AS9102 documentation to accompany the

shipment.

Does not require on-site inspection and acceptance.

Refers to the preference for documentation to be inelectronic format but does not make this a

requirement.

Documentation to include

Drawings

Special process certifications

Finish certifications

Addresses the requirement for lower level components



AS9102 as a SOW Requirement

AS9102 First Article Inspection may be called out in

the applicable Statement of Work.

Normally found in the Quality Assurance paragraphs.

Hardware Quality Engineering should identify this requirementand address it through the applicable Quality Clause.

Quality Clause 8, Statement of Work, makes this a requirement

even if QC 2.5.1 or QC6.9 are not referenced on the contract.

SOW may be called out in the block text of the contract making

this a contractual requirement.The SOW will identify the requirements, whether on-site or

documentation only.



AS9102 Revision A

Current revision is A, rumor exists that revision B is

coming.

Applies to the first production run parts.

Contains definitions applicable to completion of theforms.

Allows the use of other forms, however

“Forms other than those contained in the Appendix may be

used, however they must contain all „Required‟ and

„Conditionally Required‟ information and have the same field

reference n umbers ”.

Contains instructions for completion of the forms.

Contains the required form in the Appendix.



AS9102 Definitions

The following are included in paragraph 3 of AS9102

and are referred to here to address historic supplier

questions and discrepancies.

DRAWING REQUIREMENTS: Requirements of the drawing (including

parts lists), specification or purchasing document to which the articleis to be made. These include any notes, specifications and lower

level drawings invoked.

All notes must be addressed

All dimensions must be addressed

All lower level drawings must be addressed in the same manner

FIRST PRODUCTION RUN PARTS: “Prototype parts, or parts built using

methods different from those intended for the normal production process,

shall not be considered as part of the first production run”.



AS9201 Definitions

STANDARD CATALOG HARDWARE: A part or material that conforms

to an established industry or national authority published

specification, having all characteristics identified by text description,

National/Military Standard Drawing, or catalog item.

Certificate of Conformance required (Form 2, Field 10).

ATTRIBUTE DATA: A result from a characteristic or property that isappraised only as to whether it does or does not conform to a given

requirement (for example, go/no go, accept/reject, pass/fail etc.).

VARIABLES DATA: Quantitative measurements taken on a

continuous scale. For example the diameter of a cylinder or the gap

between mating parts.




The organization should conduct the following

activities in support of the FAI.

1. Review documentation for the manufacturing process to ensure all

operations are complete as planned.

Routing sheets, quality plans, work instructions etc.

2. Review reference exhibits supporting the FAI for compliance.

Inspection data, test data, Acceptance Test Procedures etc.

3. Review nonconformance documentation (if any) for completeness.AS9131 may be used as a guidance.

4. Review material certifications for compliance.




5. Verify that approved Special Process sources are used and that the

manufacturing/routing document calls out the correct specification.

6. Verify that Key Characteristic requirements have been met.

See AS9103 for guidance.

7. Verify part specific gages and/or tooling are qualified and traceable

as applicable.

8. Verify that every design characteristic requirement is accounted for,

uniquely identified and has inspection results traceable to eachunique identifier.



Partial or Re-Accomplishment of FAI

The FAI requirement, once invoked, shall continue to

apply even after initial compliance. The organization

shall perform a full or partial FAI when there is-1. A change in design affecting form, fit or function.

2. A change in manufacturing source, process, inspection method, location of manufacture tooling or materials.

3. A change in numerical control program or translation to another media.

4. A natural or man-made event which may adversely affect the manufacturing

process.

5. A lapse in production for two years or as specified by the customer.

The FAI is not complete until the organization closes all

non-conformances affecting the part and implements the

corrective actions. The organization shall re-do the FAI for

those affected characteristics.



AS 9102 Forms

The Appendix of the Standard contains the forms that comply

with the documentation requirements.

Each field of the forms is designated with a unique reference

number.

Each field is also identified as:(R) Required, mandatory information

(CR) Conditionally Required, must be completed when there exists a

customer requirement.

(O) Optional, this field is provided for convenience.

Forms other than those contained in the Appendix may be used,

however they must contain all “Required” and “Conditionally Required”

information and have the same field numbers.



AS9102 Forms

The organization shall verify every Design Characteristic during

FAI and record the results. Every Design Characteristic shall

have its own unique identifier.

Reference characteristics may be omitted from the FAI.

Characteristics not measurable in the final product shall be

verified during the manufacturing process (as long as they are

not affected by subsequent operations) or by destructive means.

Characteristics verified at the detail level may be referenced in

the assembly level FAIR.



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AS9102 Form 1



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AS9102 Form 1

Form 1: Part Number Accountability

This form is used to identify the part that is being first-article

inspected and associated subassemblies or detail parts.

Fields 1-4 (repeated on all forms) identify the part number and name,

serial number (CR) and FAI report number (O).

Fields 5-8 (CR) identify drawings, revisions, and any changes from

the drawing (i.e. SVRs).

Field 9 (R) provides traceability to the manufacturing record (router

number, manufacturing plan number, etc.).

Fields 10-12 provide identification of the organization.

Field 13 (R) identify if a detail part or assembly FAI.

Field 14 (R) Identify either a Full or Partial FAI

Fields 15-18 apply if the part number in Field 1 is an assembly

requireing lower level parts to be installed in the assembly.



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AS9102 Form 2



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AS9102 Form2

Form 2: Product Accountability

This form is used if any material, special processes or funtional

testing are defines as a Design Requirement.

Field 5 (CR) The name of the material or the process

Field 6 (CR) Material or process specificationInclude all “Make From” materials

Include all Raw Materials incorporated

Include Standard Catalog Hardware

Fields 8-9 (CR) Apply if Special Processes are required to be

approved by the customer

Field 10 (CR) Certificate of Conformance number

Special Process completion certification

Raw Material test report

Standard Catalog hardware compliance number

Traceability number



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AS9102 Form 2

Form 2 Continued

Field 11 (CR) Functional Test Procedure Number

When Functional Test (ATP) is a Design Requirement

Field 12 (CR) Acceptance Report Number

Certification indicating that test requirements have been met.

ATP results

Outside testing results certifications



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AS9102 Form 3



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AS9102 Form3

Form 3: Characteristic Accountability, Verification and

Compatibility Evaluation

Field 5 (R) Unique characteristic number for each Design

Characteristic

Field 6 (CR) Reference Location i.e. drawing zone, page number andsection, specification etc.

Field 7 (CR) Characteristic Designator i.e. key, critical, flight safety,

major etc.

Field 8 (R) Requirement i.e. dimensional characteristics with

tolerances, drawing notes, specification requirements etc.

Field 9 (R) Results

Multiple Characteristics list each characteristic as an individual value

Or list once with the minimum and maximum values noted

If a characteristic is found to be non-conforming then that characteristic

must be listed separately with the measured value noted.



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AS9102 Form 3

Form 3 Continued

Field 9 Continued

If a Design Requirement requires verification testing actual values will be

recorded on the form.

An attached laboratory report listing specific values may be referenced in this

field.

For metallurgical characteristics with a visual verification

requirement list the photo number of the closest comparison.

A C of C is acceptable, record the reference number in this field.

For processes that require verification per Design Characteristic

include a statement of compliance.For part marking ensure marking is legible, correct and properly

located.

Attach photo if possible.



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AS9102 Form 3



AS9102

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