supplier quality engineering/receiving and inspection first ......p-389, rev. 03 – page 1 of 9 l3...

P-389, Rev. 03 – of 9 L3 Proprietary. Printed versions of this document are considered obsolete.

Supplier Quality Engineering/Receiving and Inspection – First Article Verification

Procedure – Level II Document Number: P-389

Revision: 03 Effective Date: 10/21/2019

Point of Contact: Dan Anderson Title: Manager, Supplier Quality Engineering

Requirements: AS9100 : 8.5.1.3; AS9102

TABLE OF CONTENTS

PURPOSE & SCOPE ............................................................................................................................................................................ 1

ACRONYMS, TERMS, & DEFINITIONS ................................................................................................................................................ 1

PROCEDURE ...................................................................................................................................................................................... 2

1. FIRST ARTICLE INSPECTION REPORT REQUIREMENTS .............................................................................................................. 2

2. FIRST ARTICLE INSPECTION REPORT VERIFICATION ON-SITE AT SUPPLIER .............................................................................. 3

3. FIRST ARTICLE INSPECTION REPORT VERIFICATION AT CSW .................................................................................................... 4

4. FIRST ARTICLE INSPECTION REPORT VERIFICATION STEPS ....................................................................................................... 4

RECORDS ........................................................................................................................................................................................... 8

DOCUMENT INFORMATION .............................................................................................................................................................. 9

PURPOSE & SCOPE

A First Article Inspection (FAI) will be completed by L3 Communication Systems – West (CSW) Suppliers on supplied production hardware when required according to AS9102. The following steps outline the proper process for verifying that a First Article Inspection Report (FAIR) completed by Suppliers is compliant to FAI requirements. This document is intended for BCS Receiving Inspector, Inspection Technicians and Supplier Quality Engineering (SQE) personnel who participate in First Article verifications and reviews.

ACRONYMS, TERMS, & DEFINITIONS

ATS – Authorization to Ship

BOM – Bill of Material

C of C – Certificate of Conformance

Conditionally Required – Information that shall be completed in AS9102 forms when applicable to product or when required by the Customer

COTS – Commercial Off The Shelf

Design Characteristics – Those dimensional, visual, functional, mechanical, and material features or properties, which describe and constitute the design of the article as specified by drawing requirements

EC – Enterprise Change

FAI – First Article Inspection

FAIR – First Article Inspection Report

Initial First Article Inspection – The initial First Article Inspection that is performed on a part

Inspection Point – A buyoff, data collect, or operation that is associated with drawing characteristics to be inspected to complete First Article requirements

MOTS – Modified Off The Shelf

Optional – Information that can be included by Suppliers in AS9102 forms for clarification or convenience, but is not explicitly required by CSW


Partial First Article Inspection – A First Article Inspection completed after the initial First Article that addresses differences between the current configuration and prior approved configurations. Partial FAIRs are also used when parts lists are updated, manufacturing processes have been modified, manufacturing location has been moved, or the addition of alternative part numbers. Also known as a “delta” FAI.

PO – Purchase Order

PCD – Procurement Control Drawing

Required – Mandatory information that shall be included in First Article Documentation (Forms 1, 2, and 3)

SCD – Source Control Drawing

VICD – Vendor Item Control Drawing

PROCEDURE

1. FIRST ARTICLE INSPECTION REPORT REQUIREMENTS

1.1 The requirement for a Supplier to perform an FAI on a product will be communicated via the Purchase Order (PO) in the form of a Quality Clause.

On-site FAI Verification at the Supplier: For this requirement, the CSW SQE travels to the Supplier’s facility and validates the Supplier’s FAIR on-site. Based on the cost of the product, the Supplier’s performance rating, and other factors, the SQE (or authorized individual) may waive the on-site FAI and have the Supplier ship the FAIR with the product for verification at CSW. Only the SQE (or authorized individual) has the authority to waive the on-site FAI.

FAI Verification at CSW: For this requirement, the Supplier performs an FAI and ships the FAIR with the product for verification at CSW.

1.2 First Article Inspection by drawing type

1.2.1 Commercial Off The Shelf (COTS) items are identified with a Vendor Item Control Drawing (VICD) type and do not require an FAI.

1.2.2 Modified Off The Shelf (MOTS) items are identified with a Procurement Control Drawing (PCD) type and shall be evaluated by the appropriate SQE to determine if an FAI is required.

PCD type parts require an FAI if the drawing includes the word “modified” at the bottom of the title block as shown in Figure 1. The inclusion of the word “modified” in that location signifies that Note 3 exists within the drawing notes section and a corresponding superscript 3 is called out on a feature, item, or table in the drawing. If the word “modified” is not shown at the bottom of the title block, then no FAI is required.

Figure 1 – “Modified” notation example

1.2.3 Source Control Drawing (SCD) types always require an FAI.

1.3 Figure 2 illustrates the decision steps to determine if a specific PO requires an FAI.


Figure 2 – FAI Decision Process Flow

2. FIRST ARTICLE INSPECTION REPORT VERIFICATION ON-SITE AT SUPPLIER

2.1. FAIR verification on-site at a Supplier shall only be completed by an SQE (or authorized individual) who has been trained to the requirements of AS9102 as well as to this procedure.

2.2. Upon successful completion of the FAIR verification, the SQE (or authorized individual) shall sign the AS9102 Form 1, Block 23 and date Block 24 to certify their acceptance of the FAIR.

2.3. The SQE (or authorized individual) completes the Authorization to Ship (ATS) form and provides it to the Supplier.

2.4. The Supplier shall include the signed FAIR with the shipment of the product to CSW.

2.5. Upon receipt of the FAIR at CSW, the Inspector shall verify that Blocks 23 and 24 of AS9102 Form 1 are signed and dated by an SQE (or authorized individual).

2.6. The Inspector shall record the FAIR in the FAI log.

2.7. The Inspector shall place the FAIR in the Quality Records basket for electronic storage via scanning.

FAI Process: FAIR Verification On-site at Supplier

SQE

Sup

plie

rR

I

StartNotifies Buyer/SQE FAI is ready

End

SQE schedules on site FAI

SQE completes review of FAI at

Supplier

FAI Acceptance

No

Yes

Signs Form 1 Block 23 & 24, Completes ATS

Form

Corrects FAIShips Parts to BCS

with the signed FAIR

Verify Form 1 Block 23 & 24 are signed and dated

Record FAIR in FAI Log, put FAIR in basket for QA

Records

Figure 3 - FAI Process: FAIR Verification On-site at Supplier


3. FIRST ARTICLE INSPECTION REPORT VERIFICATION AT CSW

3.1. FAIR verification shall only be completed by an Inspector, Technician, or SQE who has been trained to the requirements of AS9102 as well as to this procedure.

3.2. Inspectors and Technicians shall verify all FAIR attributes that are within the scope of their personal knowledge base. Inspectors and Technicians shall contact the appropriate SQE if the FAIR contains attributes outside their current knowledge level. The applicable SQE shall work directly with the Inspector or Technician to verify material compliance to the drawing and Bill of Material (BOM).

3.3. Upon successful completion of the FAIR verification, the Inspector, Technician, or SQE shall sign the AS9102 Form 1, Blocks 23 and date Block 24 to certify their acceptance of the FAIR.

3.4. The Inspector, Technician, or SQE shall record the FAIR in the FAI log.

3.5. The Inspector, Technician, or SQE shall place the FAIR in the Quality Records basket for electronic storage via scanning.

FAI Process: FAIR Verification at CSW

SQE

Sup

plie

rA

S91

02

Cer

tifi

ed R

I

Start

End

Ships Parts to CSW with the

FAIR

Verify FAIR content


Records

FAI within scope of

knowledge base

Complete FAIR verification

Yes

Complete FAIR verification

No


Records

FAI Acceptance

FAI AcceptanceSign Form 1 Block

23 & 24

Sign Form 1 Block 23 & date Block

24

Yes

No Corrects FAI

No

Yes

Figure 4 - FAI Process: FAIR Verification at CSW

4. FIRST ARTICLE INSPECTION REPORT VERIFICATION STEPS

The following are detailed instructions on how to thoroughly review and verify a FAIR for completeness and accuracy. A physical part must be used to perform a valid FAIR verification.

4.1. General

4.1.1. Verify that all required sections of the FAIR are complete, in English.

4.1.2. Verify the material number and revision on the FAIR match the material number and revision of the physical part as well as the material number and revision of the PO.

4.1.3. Verify all design characteristics (dimensions, finish, etc.), notes, and BOM items are accounted for in the FAIR and are within specification. Compliant FAI documentation should contain actual data to verify conformance to the print characteristic and note requirement. It is not required, but highly recommended that the Supplier include a design characteristic accountability sheet (ballooned drawing) in conjunction with AS9102 Form 3 in the FAIR for location and print requirement information. Print characteristics labeled as “Reference” or “Reference Designators” are intended for informational purposes only and are not required to be ballooned or entered on FAIR.

4.1.4. Items that cannot be verified due to the product already being assembled are considered acceptable based on the Supplier’s Certificate of Conformance (C of C).

4.2. AS9102 Forms

4.2.1. Form 1, Part Number Accountability


Note: FAI form blocks (except blocks 23 & 24) will be filled by the Supplier designee with detailed information. One entry may be made for each column/row. Optional or Conditionally Required blocks may be left blank or filled with “N/A.”

Table 1 - Fields Required for AS9102 Form 1

Form Location Inspection Action Form Definition Example

Block 1 Required Part Number/ Material Number ex. 1000382717

Block 2 Required Part Name ex. SUPPORT, BLANK SIDE, NBA GND

Block 3 Conditionally required Serial Number ex. 325

Block 4 Conditionally required FAI Report Number ex. FA 08753

Block 5 Conditionally required Part Revision Level ex. REV. A

Block 6 Conditionally required Drawing Number ex. 1000382717

Block 7 Conditionally required Drawing Revision Level ex. REV. A

Block 8 Conditionally required Additional Changes ex. 15789

Block 9 Required Manufacturing Process Reference ex. 10267814

Block 10 Required Organization name ex. CSW

Block 11 Optional Supplier Cage Code, or Supplier Identification Number

ex. 06401

Block 12 Optional Purchase Order Number ex. 4500011100

Block 13 Required Detail FAI, Assembly FAI checkboxes ex. Check in applicable box (see section 2.2.1.1, 2.2.1.2)

Block 14 Required Full FAI, Partial FAI checkboxes ex. Check in applicable box (see section 2.2.1)

Block 15 Conditionally required (Required when block 13 Assembly FAI is checked)

Part Number ex. 60055828-001 or Material Number

Block 16 Conditionally required (Required when block 13 Assembly FAI is checked)

Part Name ex. CCA – Antenna LNA KU-BAND (not used, alternate item)

Block 17 Conditionally required (Required when block 13 Assembly FAI is checked and part is serialized)

Part Serial Number ex. 1345


Block 19 Required Signature ex. Inspector’s signature, electronic signature or stamp, John Q. Inspector

Block 20 Required Date ex. dd-mm-yy (format not important)

Block 21 Optional Reviewed By ex. Reviewer’s signature, electronic signature or stamp, Jane I. Quality

Block 22 Optional /only required if block 21 is signed

Date ex. dd-mm-yy (format not important)

Block 23 Required: Shall be signed by authorized CSW Inspector, Technician, or Supplier Quality Engineer

Customer Approval ex. Customers signature, electronic signature or stamp, Jane I. Quality



Block 24 Required: Shall be dated by Block 23 Signee

Date ex. dd-mm-yy (format not important)

4.2.1.1. Verify FAI Type (Block 13) – Verify FAI type for detail piece part or assembly.

4.2.1.1.1. Detail FAI – used for a single piece part that contains no additional components or subassemblies. Primarily used for a piece part with detailed dimensional and processing requirements.

4.2.1.1.2. Assembly FAI – used for assemblies that includes a BOM for a set of components or subassemblies. The Assembly FAI verification is to be performed on those characteristics specified on the assembly drawing.

4.2.1.2. Verify FAI type (block 14) – Full or Partial.

4.2.1.2.1. Initial First Article Inspections require the checkbox “Full” FAI to be checked in Block 14.

4.2.1.2.2. Partial First Article Inspections require the checkbox “Partial” to be checked in Block 14.

The “Baseline Material Number (including revision level)” and “Reason for Partial FAI” (block 14), will be filled out by the Supplier for a partial FAI only. The baseline material number including revision level is the material number and revision level of the most recent FAI for that material number. The EC(s) that is to be accounted for with the partial FAI should be referenced under the “Reason for Partial FAI” block along with a short description of the change.

4.2.1.2.3. If the change does not affect hardware part(s) listed on the PO, it is permitted to submit only Form 1 stating in Field 14 the reason for Partial FAI.

4.2.1.3. Verify all subassembly parts (blocks 15-17)

4.2.1.3.1. Blocks 15-17 are only completed when the FAIR is for an assembly with lower level subassemblies. Verify the Material Numbers, Names and Serial Numbers as applicable of the items that make up the assembly.

4.2.1.3.2. Verify all serialized items are accounted for by the Supplier individually in blocks 15-17.

4.2.1.3.3. It is acceptable to attach the parts list to the FAIR to account for non-serialized items, in lieu of listing them individually, as long as the attached list is referenced in Block 15.

4.2.1.4. Verify if the FAI is complete (block 19)

4.2.1.4.1. Checkbox “FAI complete” or “FAI not complete” must be checked by the Supplier based on whether or not the FAI is complete or has a nonconformance or non-verified characteristic that will require an additional Partial FAI to address.

4.2.1.4.2. If the FAIR is marked as “FAI not complete,” the CSW SQE shall be notified immediately to begin the process of flagging the material as rejected at initial FAI so that a Partial FAI will be required on next release.

4.2.2. Form 2, Product Accountability – Materials, Special Processes, and Functional Testing

This form is intended to detail any material, special processes (per AS9100 and ISO 9000 Standards), or functional testing that are defined as Design Requirements (e.g. plating, finishing or painting listed on the drawing, testing requirements, etc.).

Note: FAI form blocks will be filled by the Supplier designee with detailed information. One entry may be made for each column/row. Optional or Conditionally Required blocks may be left blank or filled with “N/A.”




Block 1 Required Part Number/ Material Number

ex. 1000382717

Block 2 Required Part Name ex. SUP SIDE, NBA GND PORT, BLANK



Block 5 Conditionally required Material or Process Name ex. OP 0200

Block 6 Conditionally required Specification Number ex. WS-010, REV 10

Block 7 Optional Code ex. 210

Block 8 Conditionally required Special Process Supplier Cage Code

ex. 05031

Block 9 Conditionally required Customer Approval Verification

ex. Yes/No/NA

Block 10 Conditionally required Certificate of Conformance number

ex. 40068689741

Block 11 Conditionally required Functional Test Procedure Number

ex.TP 60002021 Rev F

Block 12 Conditionally required Acceptance report number, If applicable

ex. 198-20

Block 13 Optional Comments ex. Such as: “Non blue print required torque values controlled in BOP 1000097471”

Block 14 Required Signature ex. Prepared by signature, electronic signature or stamp, John Q. Inspector


4.2.2.1. Special Processes – if special processes are defined as a design characteristic:

4.2.2.1.1. Verify block 6 includes the specification and revision for special process (ex. WS-010, REV 10, for outside finish operation).

4.2.2.1.2. Verify that Supplier Cage Code or supplier name of who performed the special processes or supplying material is recorded in block 8.

4.2.2.1.3. Verify the Certification Number in block 10 match the number on the C of C documents (i.e. plating, finishing or painting listed on the drawing, testing requirements, etc.).

4.2.3. Form 3, Characteristic Accountability, Verification, and Compatibility Evaluation

This form is intended to detail and record print location and design characteristic information as well as the Supplier’s inspection data of the designated first article part.

Note: FAI form blocks will be filled by the Supplier designee with detailed information. One entry may be made for each column/row. Optional or Conditionally Required blocks may be left blank or filled with “N/A.”




Block 1 Required Part Number/ Material Number

ex. 1000382717

Block 2 Required Part Name ex. SUPPORT, BLANK SIDE, NBA GND



Block 5 Required Characteristic number ex. 13 (indicating bubble 13)

Block 6 Conditionally required Reference Location (characteristic location, drawing zone, page, location, etc.)

ex. 1C3 or Note 4, (sheet 1 zone C3)

Block 7 Conditionally required Characteristic Designator (Key characteristic, etc.)

ex. Note 4 or A3 (Reference Designator)

Block 8 Required Requirement exactly as stated on the print

ex. Dim. 6.55 +/- .03, 3X Note 2

Block 9 Required Inspection Results. Visually inspected characteristics are to be noted with a statement of either acceptance or rejection

ex. 6.57, Accept

Block 10 Conditionally required Designed Tooling (Tool asset # used to validate the requirement).

Ex. CMM prog. #41863, Functional gauge #25

Block 11 Conditionally required Nonconformance Number ex. IN213682

Block 12 Required Prepared by ex. Prepared by signature, electronic signature or stamp, John Q. Inspector


Block 14 Optional Any additional relevant comments or specifications

Additional Data / Comments: This area is reserved for optional fields; ex. IS-008 or torques spec 60083155 (Can be used for applicable comments and or conformance specification information)

RECORDS

Identification Completed First Article Inspection Reports Storage Hard copy records are scanned and stored by Quality Records. Electronic records are stored in SAP. Protection Electronic records are protected by regular backups performed by the IT department. Hard

copy records are stored in a locked room with limited access.

Retrieval Electronic records can be retrieved via SAP. Any hard copy data that may be available is obtained from Quality Records.

Retention Time Hard copy records are stored by Quality Records for 1 year per FAR 4.703 requirements. Electronic records stored in SAP are retained indefinitely.

Disposition Hard copy records will be disposed of by the Quality Records team. Electronic records N/A.

END OF DOCUMENT


DOCUMENT INFORMATION

Responsible Organization: Quality

Function/Sub-function: Supplier Quality Engineering

Governing Document(s): P-046, Receiving Inspection P-413, First Article Inspection Planning AS9102, Aerospace Standard, First Article Inspection Requirement

Subordinate Document(s): N/A

Related Document(s): N/A

Related Training: FAI 100: First Article Inspection Training

Approval Requirements: Business Change Control Board Chair Quality Business Change Control Board Representative Manager, Supplier Quality Engineering Manager, Receiving Inspection

Review Requirements: Director, Supplier Quality Engineering Manager, Component Engineering

Revision History Summary

Revision # Description of Change Date

00 Initial release 3/4/2019

01 Updated records protection, retrieval and disposition information in the Records table.

4/18/2019

02 Changed L3T to CSW throughout. Added acronym and definition for COTS and MOTS. In section 1.3, changed “required” to “not required but highly recommended”. Rewrote section 1.4 to clarify verification process. Added new section 1.6 for First Article Inspection of COTS/MOTS Material and renumbered rest of sections accordingly. Updated Form Definition and Example for Block 19 and 21 in Table 1. Updated Form Definition and Example for Block 14 in Table 2. Updated Inspection Action for Block 5 in Table 3. Updated Form Definition and Example for Block 12 in Table 3. Added “electronic signature or stamp” in section 2.6.1. Removed “Teamcenter and SAP” as the storage in section 2.6.3. Added “the Quality Records” in section 2.6.3. Updated FAI Flowchart. Removed “Teamcenter” from the storage and retrieval information in the Records table. Added Figure numbers.

7/30/2019

03 Complete restructuring of the document – sections, flowcharts, and content. 10/21/2019

http://home.csw.l-3com.com/sites/recordscenter/PALLibrary/P-046.pdf

http://home.csw.l-3com.com/sites/recordscenter/PALLibrary/P-413.pdf

supplier quality engineering/receiving and inspection first ......p-389, rev. 03 – page 1 of 9 l3...

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