Guide for completion of First Article Inspection

Report

What is the purpose of a FAI?

• The purpose of the First Article Inspection is to provide objective evidence:

• that all engineering design and specification requirements, including process and manufacturing validation, are correctly

– Understood – accounted for – verified – and documented.

• of a consistent documentation requirement

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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 the customer

• Partial (Delta) FAI

– Design change – A change in the method of manufacture (e.g. tooling, processes, machine, location,

numerical control program, sequence of manufacture).

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What does it apply to?

• All product defined by engineering drawings or model based definitions.

• Assemblies-for those characteristics specified on the assembly level drawing only

• All levels of detail parts within assembly – Including castings and forgings

• Modified Standard, Electronic or COTS Items as “make from” with unique engineer modifications on drawings – Only the modifications

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What does it NOT apply to?

• Standard Parts

• Electronic Components

• Commercial Off the Shelf (COTS) Items

No FAI is Required on the above items

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How to write up an FAI step by step

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There are 3 Forms to be completed

AS9102 Form 1 – Part Number Accountability

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Yellow fields are Mandatory information Required White Fields are Optional information required when available Blue or Light Grey fields are conditionally required. These fields must be completed when information is available.

Form 1 of FAI

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Form 1: Part Number Accountability shall be used to identify the part is being first article inspected (FAI part) and associated sub-assemblies or detail parts.

Item 1 thru 8

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• 1 – 3D Instruments Part Number • The actual part number that is being FAI

• 2 – 3D Instruments Part Name • The part name listed on the drawing

• 3 – Serial Number • The serial number for the part being FAI

• 4 – FAI Report Number • Suppliers Choice (must have a number)

• 5 – Part Rev • Latest part revision that affects the part being FAI. If no revisions indicate as such.

• 6– Drawing Number • Here you put the actual drawing number. Not always the same as the part number since many drawings cover

more than one part number.

• 7 – Drawing Revision • The revision of the drawing for this part that the FAI is being performed to

• 8 – Additional Changes • Always N/A

Item 9 thru 14

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• 9 – Manufacturing Process Reference • A reference number that provides traceability to the manufacturing record of the FAI part (router number,

WO #, etc.)

• 10 – Organization Name • The customer requesting this Form (3D Instruments)

• 11 – Supplier Code • If you know your supplier code, you can add it here

• 12– P.O. Number • PO Number for this Part Number

• 13 – Detail part or an assembly FAI • Check as appropriate

• 14– Full or Partial FAI • See Page 3 for explanation

Items 15, 16, 17 and 18

• This section is required only if the part number in Field 1 is an assembly requiring lower parts to be installed into the assembly

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For Suppliers, 9 out of 10 times, this will be blank. If you are making an assembly, please ask for detailed information to fill this out

Sign off – 19 thru 24

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• Check appropriate box of “FAI complete” or “FAI not Complete”

• 19 – Signature Line • Person who filled out FAI

• 20- Date • Date of FAI

• Text boxes 21 thru 24 can be filled out as needed

Form 2 of FAI

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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.

Form #2 (Materials, Special Process & Test Procedures)

• 5 – Material Specification/Certification or Special Process Name: • Enter materials (for example brass bar stock) and any special

process (anodizing, chrome plating) used in manufacturing with the product.

• 6 – Specification Number: • Enter the specification number for the material or special process

used. • 7 – Code:

• Code is always N/A • 8 – Special Process

• Customer given Supplier code for the organization performing special process(es) or supplying material, as applicable or add Special process supplier name and address.

• 9 – Customer Approval Y/N: • Review customer requirements for special process or material

source. Enter N/A if customer approval is not required.

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Form #2 (Materials, Special Process & Test Procedures)

• 10 – Certificate of Conformance Number: • Number of the certificate: special process completion certification,

raw material test report number, Standard Catalog hardware compliance report number, traceability number.

• 11 – Test Procedure Number and Revision: • Enter all functional test procedures (for example, ATP, and ESS) used

to test the product. Include document revision.

• 12 –Acceptance Report Number, if applicable: • The functional test certification indicating that test requirements

have been met. Some reports will not have a report number – enter ‘N/A

• 13 – Comments:

• Enter comments if necessary

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Example – Form #2 (Materials, Special Process & Test Procedures)

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Form 3 of FAI

Form 3 – Characteristic Accountability, Verification And Compatibility Evaluation Shall be used to record an Actual measurement or Inspection/verification of the FAI part for every design Characteristic on drawing, Including notes.

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Form #3 Characteristic Accountability

• 5 – Characteristic Number • Unique assigned number for each design characteristic

• 6 – Reference Location • Location of the design characteristic (e.g., drawing zone (page number and section),

specification, etc.)

• 7 – Characteristic Designator • If applicable, record characteristic type (e.g., key, flight safety, critical, major, etc.)

• 8 – Requirement • Specified requirement for the Design Characteristic (e.g., drawing dimensional

characteristics with nominal and tolerances included, drawing notes, specification requirements, etc.).

• Make sure that you add the tolerances .025 (+,-).002. FAI’s are rejected because the tolerances are left off the form

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Form #3 Characteristic Accountability

• 9 – Results • List measurement(s) obtained for the Design Characteristics

– For Multiple Characteristics list each characteristic as individual values or list once

with the minimum and maximum of measured values attained. If a characteristic is found to be non-conforming then that characteristic must be listed separately with the measured value noted.

– If a Design Requirement requires verification testing, then the actual results will

be recorded on the form. If a laboratory report or certificate of test is included in the FAIR, then these results need not be written on the form, record the reference number in this field. The laboratory report or certificate of test must show specific values for requirements and actual result.

– For metallurgical characteristics with visual verification requirement that are rated against standard photographs, list the photo number of the closest comparison. A statement of conformance is acceptable (record the reference number in this field).

– For processes that require verification per Design Characteristic, include statement of compliance (e.g., certification of compliance, verification indicator such as .accept., etc.).

– For part marking, ensure that marking is legible, correct in content and size and

properly located, per applicable specification.

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Form #3 Characteristic Accountability

• 10 – Designated Tooling • If a specially designed tooling (including CNC programming) is used as a media of

inspection, record the tool identification number.

• 11 – Non-Conformance Number • Record a non-conformance document reference number if the characteristic is

found to be non-conforming.

• 12 – Prepared by: • Name of person who prepared form.

• 13 – Date • Date when this form was completed

• 14 – Extra Column if Needed • This field is reserved for optional comments.

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Example – Form #3 Characteristic Accountability

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Ballooned Drawings

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•A ballooned drawing is optional and considered an industry best practice to support Box 5 of Form 3

•Identify 100% of characteristics

•Balloon and number all dimensions

•Balloon and number all surface finish callouts •Including exclusion and inclusion area callouts

•Balloon and number all material and hardness callouts •Don’t forget the requirements identified in the title boxes at the bottom of the drawings.

Most Common Reasons for FAI Rejection

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•C of C’s do not accompany the FAI Report.

•Missing FAI Reports or Test Reports for sub-assemblies and/or fabricated detail parts

•Variable data requirements from the engineering drawing are not provided with numerical results.

•Missing or wrong information provided.

•Missing special processor full address on AS9102 A Form 2, Box 8

•Missing tolerances on AS9102 A Form 3, Box 8.

•Customer flow down requirements not met.

•Not all 3 forms are signed

Revisions

74F-PUR-23 Rev. B 24

Revision Pages Description Date By Approved

A All Original Release 11/7/2014 Sheila Ivy Jose Rodriguez

B 23 Added Page For Most common

Errors 1/13/2015 Sheila Ivy Jose Rodriguez

If you have any questions, please contact supplierquality@3dinstruments.com