First Article Inspection Guide

AS9102 Training

Rev A

What We Will Cover • Challenge • Approach • AS9102 Rev B – FAI Requirements • AS9102 Rev B – Embedded Guidelines • Forms Used • Questions/Answers • Examples of FAI Problems Seen

The Challenge

We may have a lot of experience, and have

performed many FAIs, but:

• Enidine’s customers have their own additional requirements that we all must

capture on the first article forms.

• AS9102B imposes stricter requirements than we may be accustomed to

• FAI reports can be voluminous

• Customers expect FAI reports that are complete and compliant

• Erroneous FAI reports are unacceptable

The Approach

Improve the FAI process by:

• Ensuring consistent FAI plans

• More clarity in FAI documentation

• Aligning with AS9102B and Enidine customer FAI requirements

Purpose of an FAI

The purpose of the First Article Inspection is to give objective

evidence that all engineering, design and specification requirements are

correctly understood, accounted for, verified, and recorded. The purpose

of this standard is to provide a consistent documentation requirement for aerospace

components FAI.

FAI Requirements First Article Inspection shall be performed by the Seller. The FAI will be

conducted in accordance with SAE AS9102, Aerospace First Article Inspection Requirement or international equivalent. FAI supporting documents shall be provided within the FAI report. Delta FAIs shall have applicable supporting

documentation, as necessary. A copy of the AS9102 standard can be obtained through the Society of Automotive Engineers

(SAE) at the following website: http://www.sae.org

Document Submittal Requirements for First Article Shipments All material certifications, test reports, special processing certification and NDT certifications for all details and sub-assemblies must accompany the first production run of parts delivered

to ITT Enidine unless the FAI is deferred by ITT Enidine to a subsequent shipment in which case the noted documents would accompany that product shipment.

Requirements of AS9102 • The Organization shall perform FAI on new Product representative of the First Production

Run.

• The Organization shall perform a full FAI, or a

partial FAI for affected characteristics, when any

of the following events occurs: o A change in the design affecting fit, form or function of the part.

o A change in manufacturing source(s), process(es), inspection method(s), location of manufacture, tooling or materials, that can potentially affect fit, form or function.

o A change in numerical control program or translation to another media that can potentially affect fit, form or function.

o A natural or man-made event, which may adversely affect the manufacturing process.

o A lapse in production for two years or as specified by the Customer.

• Nonconformance Handling: The FAI is not complete until the Organization closes all non-conformances affecting the part and implements corrective actions.

The Organization shall re-do an FAI for those affected characteristics and shall record the results.

• Record of Results: o Results from inspection of design characteristics shall be expressed in quantitative terms (Variables Data) when a Design

Characteristic is expressed by numerical limits.

o The Organization shall record the results in the units specified on the drawing or specification, unless otherwise approved by the Customer.

o Attribute Data (e.g., go/no-go) may be used if no inspection technique resulting in Variables Data is feasible. Attribute Data is permitted when the Design Characteristic does not specify numerical limits (e.g., break all sharp edges). It is also permitted where qualified tooling is consistently used as a check feature and a go/no-go feature has been established for the specific characteristic.

AS9102B

AS9102B, Para. 4 – “This Aerospace Standard applies to … • assemblies,

• subassemblies,

• detail parts, and

• all organizations responsible for producing design characteristics1 of the product.

• Requirements shall be flowed down to suppliers who produce design characteristics.

• Standard Catalog Hardware or Deliverable Software are exempt.”

AS9102B, Para. 5.2.2 – “… verify every design characteristic … and record the results.”

Therefore, ITT Enidine drawing > apply AS9102 > verify & record every design characteristic > including lower-level

dwgs

• FAI of Enidine procured parts are not limited to the part number on the purchase order.

• ALL items in an assembly’s parts list must be addressed.

1-Design Characteristics are “those dimensional, visual, functional, mechanical, and

material features or properties, which describe and constitute the design of the article

as specified by Drawing Requirements2…”

2-Drawing Requirements are “requirements of the drawing (including Parts Lists),

specification, or purchasing document to which the article is made. These may include any notes, specifications, and lower-level drawings invoked.”

AS9102 Requirements Overview FAI Guidelines – AS9102 requirements

Para. 5.1 – Perform FAI on product representative of the First Production Run • Do not use prototype/preproduction hardware

• For assemblies, use characteristics specified on the assembly drawing

• Performed on the ITT Enidine p/n as specified on the Purchase Order

• not the supplier’s “equivalent” drawing

Para. 5.2 – FAI is much more than inspecting dimensions • Review completeness of manufacturing documentation (e.g. travelers, etc.)

• Review referenced exhibits (e.g. inspection data, test data, ATPs, etc.)

• Review nonconformance documentation, if any

• Review material certifications

• Verify that only approved Special Process providers were used

• Verify Key Characteristic requirements have been met

• Verify part specific tooling and gages are qualified and traceable

• Verify every Design Characteristic is accounted for, uniquely identified, and has recorded

inspection results (record actual measurements for Variable Data)

• Cannot skip some Design Characteristics (requirements) because features cannot be

accessed for measuring

AS9102 Requirements, continued Para. 5.3 – may use a partial FAI (“delta-FAI”)

• to address differences between current configuration and previously approved-by-FAI

configurations

• or a modification of Standard Catalog Hardware (e.g. ITT Enidine R1000xxxx dwgs)

• Also, correction of an FAI nonconformance

• May address multiple revision updates (e.g. B > C > D > E)

• But cannot jump revision changes (e.g. B > E, without addressing C and D is not

allowed)

• MUST validate the existence of an earlier, approved FULL FAI

• use Engineering Change Order (ECO) to identify revision updates

• Reference applicable Change Notices on Form 1, field 14

Para. 5.4 – Nonconformances must be corrected, verified and recorded on

NEW forms (think “partial FAI”) • FAI is redone for the affected characteristics

• Original forms must never be altered. Use New forms for affected characteristics.

• Note implementation of corrective action is also a part of this requirement paragraph

Para. 5.5.1 – Forms other than those contained in AS9102 may be used, but: • Must contain all “Required” information,

• Must contain all “Conditionally Required” applicable information, and

• Must have the same (“identical”) field reference numbers

AS9102 Requirements, continued

Para. 5.5.1 – Forms must be completed electronically, or in permanent ink.

Para. 5.5.2 – Must verify every Design Characteristic • Every Design Characteristic must be verified, and must have a unique characteristic

number.

• Characteristics verified at the detail level may be referenced in the assembly-level

FAI

• Address every drawing note on Form 3, including marking and labeling

requirements

Para. 5.5.3 - Go/No-go (Pass/Fail) • results may be used for Attribute Data

• e.g. mylar or 3-D mockups for cable curvatures

AS9102B – embedded guidelines required conditionally required optional

Appendix A

AS9102B – Form 1 required

conditionally required

optional

i.e. no open nonconformances

For an Assembly FAI, all items in the Parts List of the assembly drawing need to be addressed in this section. Also include part numbers called out on the face of the assembly drawing, even if there is no parts list. Also include any “make from” supplier p/n’s listed on Enidine drawings.

AS9102B – Form 1 example

AS9102B – Form 2 required

conditionally required

optional

AS9102B – Form 2 example

Include performance specification number in Field 11, and associated test report in Field 12.

AS9102B – Form 3 required conditionally required optional

Field 7 = “n/a”, if Enidine drawings do not identify characteristic type (e.g., key, flight safety, critical, major, etc)

EXAMPLE OF AN FAI

Balloon all notes and dimensions, including reference and basic dimensions.

Form 1

- All fields are filled in, no blanks.

- Form 1 is signed and checked complete.

Form 2

- Fill in the cert number for the material and/or special process.

- Fill in the special process supplier code, if applicable, box 8.

- Fill in test data, box 11 & 12, as required.

Form 3 - Not all of the ballooned dimensions are on

form 3 for this presentation. - Note the Enidine preferred way to fill out

form 3. This incorporates Enidine’s customers requirements for first articles.

- Enter the drawing zone location of the feature if zone locations appear on the drawing.

- Enter Accept/Complies/Pass for results not requiring dimensional limits.

- Dimensions that appear more than once (2x, 3x, 10x, etc.) require more than one result. A min-max range can be recorded or a result for each measured

- value. - Requirement, box 8, should include the

tolerance. - Include the tool used and the serial number.

Enidine has customers that require this traceability.

- Be cautious of rounding. If the limit is .350 and the result is recorded as .350 could it be measured as .3502? That would make the feature oversized.

- Bores should be measured with a bore gauge when ever possible. Pins do not capture possible oversized areas.

- CMM data for True Position must be included in the FAI report, per AS9102.

Form 3, cont. - Not all of the dimensions are on form 3

for this presentation. - Note the Enidine preferred way to fill out

form 3. This incorporates Enidine’s customers requirements for first articles.

- Enter the drawing zone location of the feature if zone locations appear on the drawing

- Enter Accept/Complies/Pass for results not requiring dimensional limits.

- Dimensions that appear more than once (2x, 3x, 10x, etc.) require more than one result. A min-max range can be recorded or a result for each measured value.

- Requirement, box 8, should include the tolerance.

- Include the tool used and the serial number. Enidine has customers that require this traceability.

- Be cautious of rounding. If the limit is .350 and the result is recorded as .350 could it be measured as .3502? That would make the feature oversized.

- Bores should be measured with a bore gauge when ever possible. Pins do not capture possible oversized areas.

- CMM data for True Position must be included in the FAI report, per AS9102.

UNLESS OTHERWISE SPECIFIED BOX

- Balloon the UNLESS OTHERWISE SPECIFIED BOX. The intent of the drawing interpretation, feature finishes, part free of burrs, fillets and edge breaks, coaxial feature limits and workmanship should all be understood and accounted for on form 3.

Example of an assembly FAI

Balloon the drawing

- Balloon the drawing including notes, all reference dimensions and basic dimensions.

Remember, no blanks allowed. All fields noted with a question mark should have relevant information filled in.

Examples of Problems Seen

• Supplier FAIs are not in compliance with AS9102 format

• Must have the same (“identical”) field reference numbers

• Reports are not signed (including all sheets)

• Missing traceability linkage to Enidine part number

• Actual dimension/weight is not recorded. Shown as pass/fail.

• Referenced documents are not included

• Assembly FAIs are not including the subassembly information

• Raw materials, specifications and functional testing are not being listed on Form 2 or

are being listed on Form 1

Examples of Problems Seen Supplier Name required conditionally required optional

All required information is present. What’s the problem?

Examples of Problems Seen Supplier Name required conditionally required optional

5.5.1. Forms other than the AS9102 or international equivalent may be used, however they must contain all “Required” and “Conditionally Required” information and have the same field reference numbers.

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Examples of Problems Seen required conditionally required optional

Actual values are recorded. What’s the problem?

Examples of Problems Seen required conditionally required optional

Form 3. For Multiple Characteristics list each characteristic as individual values or list once with the minimum and maximum of measured values attained. ALSO: No characteristic number, and No characteristic tolerance

? ?

Examples of Problems Seen required conditionally required optional

Report shows Item numbers, Tolerances, Zero rejects… What’s the problem?

Supplier Name

Examples of Problems Seen required conditionally required optional

5.5.3. Results from inspection of design characteristics shall be expressed in quantitative terms (Variables Data) when a Design Characteristic is expressed by numerical limits.

Supplier Name

Summary

FAI Checklist

FAI package • FAI package has been reviewed by

Supplier and dated

• Verify all values in package are within the stated tolerance

• Verify accept/reject status exist for all items listed in report

• Each page of FAI package has been signed

• Drawing is released/approved by Enidine

Verify signature and date exists on package. (Approval dates must be consistent with package revisions)

Any blank item is cause for rejection. Validate item that is designated as “not applicable”.

Use of approved Redline drawings must be specifically identified in Statement of Work on Enidine PO.

FAI Checklist, continued

• All notes on drawing are addressed in FAI package

• All tolerance values on drawing have been assessed in FAI package

• Where tolerance is identified, measure value is recorded

• Marking requirements have been verified

• Torque requirement have been verified

• Connector or part keying is verified

• Verification of Mechanical Inspection features (depth, location, angle) has been verified

Notes must match callout on drawing wording

Actual value needs to be recorded for weight and variable dimensions

Actual value needs to be recorded to ensure dwg requirements.

CMM printout is acceptable for verification

FAI Checklist, continued

Test Data Documentation • Verification that all values in ATP have

been entered

• Verify all parameters are within stated value

• For test failures, approved dispositions are presented within test report

• Verify supplier review and approval of results with signature or stamp and date

Material Certificate of Analysis or Compliance • Analysis is consistent with drawing

specification callouts

FAI Checklist, continued

General • Verify part specific gages or tooling are

qualified and traceable, as applicable

• Verify that approved Special Process sources are used (as applicable), and that the manufacturing planning or routing document calls out the correct specification

• Review nonconformance documentation (if any), for completeness

IAQG FAI On-line Training

Link to IAQG FAI page:

http://www.iaqg.sae.org/iaqg/hand

book/scmhtermsofuse.htm

International Aerospace Quality Group

Additional FAI on-line training information offered by the International Aerospace Quality Group. No charge to access.