AS9102 FAI Requirements: A Guide to First Article Inspection

Índice
  1. What is AS9102 First Article Inspection?
  2. AS9102 Report Form
  3. Importance of FAI in Quality Control
  4. When is FAI Conducted?
  5. Key Elements of FAI
  6. AS9102 FAI Forms
  7. Contents of an FAI Package
  8. Steps to Create a First Article Inspection Report
  9. The First Article Inspection Process
  10. Key Components of a Completed FAIR
  11. Expert Services for First Article Inspection

What is AS9102 First Article Inspection?

AS9102 First Article Inspection (FAI) is a detailed process that allows manufacturers and clients in the aerospace industry to capture product requirements, inspect and document product features, and document materials and processes used in manufacturing. It is a crucial part of the quality control plan for ensuring product conformity and verifying the manufacturing process.

AS9102 Report Form

The AS9102 report form is a standardized form that ensures product alignment with client specifications. It includes three forms: Part Number Accountability, Product Accountability, and Characteristic Accountability. These forms capture all the necessary information about the assembly or part being verified, materials, special processes, functional testing, and evaluation and verification of every identifiable characteristic of the product.

Importance of FAI in Quality Control

First Article Inspection is an essential part of quality control in the aerospace industry. It serves as a baseline measurement of processes and provides peace of mind for both the buyer and the manufacturer. FAI verifies material and special process documentation, tooling, and ensures product conformity. It also helps in identifying any potential issues or nonconformities early in the production process, allowing for timely corrective actions.

When is FAI Conducted?

FAI is conducted in various scenarios, including:

  • After finalizing a purchase order contract
  • After the first production run of a new product
  • After implementing a change in a product's design
  • After changing sources or materials used in production
  • After two years have passed since the initial product run
  • After any change in tools, processes, or location of manufacturing
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These scenarios ensure that FAI is conducted whenever there is a significant change in the product or manufacturing process to maintain quality control.

Key Elements of FAI

The key elements of First Article Inspection include:

  • Selecting one sample part from the initial production run, known as the first article
  • Verifying the manufacturing process and ensuring product conformity
  • Inspecting and testing the selected part to ensure it meets all the specified requirements
  • Documenting the results of the inspection and creating a First Article Inspection Report (FAIR)

These elements are crucial for maintaining product quality and process quality in the aerospace industry.

AS9102 FAI Forms

The AS9102 FAI includes three forms:

  1. Part Number Accountability: This form includes information about the assembly or part being verified, such as part number, revision level, description, and drawing number.
  2. Product Accountability: This form captures information about the materials, special processes, and functional testing performed on the product.
  3. Characteristic Accountability: This form includes the evaluation and verification of every identifiable characteristic of the product, such as dimensions, tolerances, and performance requirements.

These forms ensure that all the necessary information is documented and verified during the First Article Inspection process.

Contents of an FAI Package

An FAI package includes various documents that provide evidence of product conformity and the verification of the manufacturing process. These documents may include:

  • Material certifications
  • Process certifications
  • Completed FAI forms
  • Nonconformance documents
  • Test reports
  • Any other relevant documentation

These documents are compiled and submitted as part of the FAI package to demonstrate compliance with customer requirements and industry standards.

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Steps to Create a First Article Inspection Report

Creating a First Article Inspection Report involves the following steps:

  1. Plan the inspection: Determine the scope of the inspection, including the number of parts to be inspected and the inspection methods to be used.
  2. Create an inspection plan: Develop a detailed plan that outlines the specific requirements, inspection criteria, and methods to be used during the inspection.
  3. Manufacture the first article: Produce the first article or select it from the initial production run.
  4. Collect data: Perform the necessary inspections and tests on the first article, documenting all the measurements and results.
  5. Create the report: Compile all the collected data and create a comprehensive First Article Inspection Report (FAIR) that includes all the required information and documentation.

Following these steps ensures a systematic and thorough approach to conducting a First Article Inspection and creating an accurate and reliable inspection report.

The First Article Inspection Process

The First Article Inspection process involves the following steps:

  1. Limited production run: Conduct a limited production run of the product to ensure that the manufacturing process is stable and capable of producing conforming parts.
  2. Select assemblies or parts to test: Choose representative assemblies or parts from the production run for inspection and testing.
  3. Test and inspect each part: Perform the necessary tests and inspections on each selected part to verify its conformity to the specified requirements.
  4. Document the results: Record all the measurements, test results, and observations during the inspection process.
  5. Create the report: Compile all the collected data and document the results in a comprehensive First Article Inspection Report (FAIR).
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Following these steps ensures a thorough and systematic approach to conducting a First Article Inspection and documenting the results.

Key Components of a Completed FAIR

A completed First Article Inspection Report (FAIR) must include the following key components:

  • Revision level
  • Part numbers and descriptions
  • Drawing numbers
  • Purchase order number
  • Name and signature of the person completing the inspection
  • Date of the inspection
  • Proof of customer's approval
  • Review of processes and materials
  • Functional test methods and results
  • Certificate of Conformance (COC) number
  • Measurement of physical characteristics

These components ensure that all the necessary information is included in the FAIR and provide a comprehensive overview of the inspection results and product conformity.

Expert Services for First Article Inspection

For companies in need of expert services for First Article Inspection, NTS Unitek offers comprehensive solutions. NTS Unitek has extensive experience in the aerospace industry and can assist in creating and implementing inspection reports that meet AS9102 FAI requirements. Their expertise ensures accurate and reliable inspection results, helping companies maintain the highest standards of quality control.

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