Quality First Article Inspection

FIRST ARTICLE INSPECTION (FAI)

1.0 The purpose of carrying out an FAI is to give objective evidence that all engineering, design and specification requirements are correctly understood, accounted for, verified and recorded. The document is intended to guide how this is achieved. An FAI should be performed on all new products that are representative of the first production run. The FAIs should be performed in accordance with SAE AS9102. In support of the FAI, The Supplier should review:a) Documentation for the manufacturing process, including Route Cards, manufacturing/quality plans, manufacturing Work Instructions and any other document that may affect the final product. b) Inspection data, test data acceptance test procedures. c) Non-Conformance data for completeness and correct implementation. d) Material certifications for compliance. e) That any special processes are documented and implemented correctly and that any manufacturing planning/routing documents correctly relate to relevant specifications. f) That key characteristics have been met. g) That specific gauges and tooling is qualified/calibrated and traceable as applicable. h) That every design characteristic requirement is accounted for, is uniquely identified and has inspection results traceable to each unique identifier. 4.0 The FAI requirement, once invoked, should continue to apply even after initial compliance. When a partial FAI is performed, only the affected fields on the FAI form shall be completed. The remaining fields shall be completed when possible, or previous data may be referenced if it applies to identical characteristics of similar parts produced by identical means. A full or partial FAI shall be performed when there is: a) A change in design, affecting Fit, Form or function of the product. b) A change of manufacturing source(s), process(es), inspection method(s), location of manufacture, tooling or materials, that can affect fit, form or function. c) A change in a program (computer generated) that can affect fit, form or function. d) An event that can affect the manufacturing process (natural or man made) e) A lapse in production for a period of 2 years or as specified by the customer - SIRS. 7.0 For components or assemblies regularly manufactured by the supplier, that have had an initial FAI but require a set up prior to each manufacture that may involve tool setting, sharpening, adjustment; a new FAI will be required. The FAI shall not be considered complete until all relating non-conformances are closed and corrective actions - implemented. The documents attached can be used as templates to complete the FAI. Record of Results: the results from inspection of design characteristics should be expressed in quantative terms (variables data) when a design characteristic is

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Quality First Article Inspection

expressed by numerical limits. 11.0 The recorded results shall be expressed in the same units as those specified on the drawing or within the specification. Control of FAI Records: The FAI records should be considered as Quality Records and controlled for retention for at least 7 years. Instructions to complete the FAI forms are detailed within AS9120 available from the ISO website. SIRS will provide assistance if required For Assemblies, the assembly level FAI shall be performed on those characteristics specified on the assembly drawing. The documentation used by the supplier to record the data shall be based upon attached :Form 1: Part Number Accountability shall be used to summarise associated part numbers and associated FAIs for Assemblies. Form 2: Product Accountability shall be used for raw materials, specifications, processes and functional tests. Form 3: Characteristic Accountability shall be used to summarise actual specific design characteristics. Each characteristic shall have its own unique characteristic number and this number shall be marked on the relevant drawing/specification document. Characteristics not measurable in the final product shall be verified in the manufacturing process. 16.0 The FAI policy should be flowed down to all SIRS suppliers and sub-tier suppliers. FAIs will be required for products that fall within the requirements detailed in Para 6.0 above. The FAI procedure used by all Suppliers, shall be based upon AS9100.

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FIRST ARTICLE INSPECTION

FORM 1 PART NUMBER ACCOUNTABILITY
1. Part Number 2. Part Name 3. Serial Number

Company:
Sheet 1 of ___
4. FAI Report

5. Part Revision Level

6. Drawing Number

7. Drawing Revision Level

8. Additional Changes

9. Manufacturing Processes

10. Organisation Name

11. Supplier Code

12. P.O. Number

13. Detail FAI

14. Full FAI Partial FAI Reason for Partial FAI:

Baseline Part Number Including Revision Level

Assembly FAI

a) if above part number is a detail only, go to field 19 b) if above part number is an assembly, go to the INDEX section below.

Index of part numbers or sub-assembly numbers required to make the assembly noted above
15.Part Number 16. Part Name 17. Part Serial Number 18. FAI Report Number

1) Signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition

2) Indicate if the FAI is complete:

19. Signature 21. Reviewed By 23. Customer Approval

FAI Complete

FAI Not Complete

20. Date 22. Date 24. Date

FIRST ARTICLE INSPECTION

1. Part Number 2. Part Name 3. Serial Number

Company:
Sheet 1 of ___
4. FAI Report Number

FORM 2 Product Accountability Raw Material, Specifications and Special Process(es), Function Testing.

5. Material or Process Name

6. Specification Number

7. Code

8. Special Process Supplier Code

9. Customer Approval Verification (Yes/No/NA)

10.Certificate of Conformance Number

11. Functional Test Procedure Number

12. Acceptance Report Number, if applicable

13. Comments

14. Prepared By

15. Date

FIRST ARTICLE INSPECTION

FORM 3
1. PART NUMBER 2. PART NAME

Company:
Sheet 1 of ___
3. SERIAL NUMBER: W/O #: 4. FAI REPORT #

FAI/
14. Comments

Characteristic Accountability
5. Characteristic Number (1,2,3 etc) 6. Reference Location (if reqd) 7. Characteristic Designator (e.g. Critical, Key etc) 8. Requirement (Dimension + Tolerances, Performance requirement, colour etc)

Inspection / Test Results

9. Results (Actual results identified) 10. Designed Tooling (Tool References etc) 11. Non-Conformance Number (if Applicable)

The signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition. Date 12. Comments

Prepared by:
12.

Approved by Production Manager or Chief Engineer: