Supplier Requirements For First Article Inspection Reports
TITLE: Supplier Requirements for First Article Inspection ReportsNUMBER: B25279 Revision EDATE: 13 Aug 2018FUNCTION: SQASupplier RequirementsForFirst Article Inspection ReportsPrepared ByElectronic Systems Inc.65 Spit Brook RoadNashua, NH 03061
Document No. B25279Revision: EDate: 13 Aug 2018Document Change HistoryDate11 April 2017Rev.–25 April 2017A30 August 2017B14 December 2017C16 March 2018D13 August 2018EDescriptionOriginal Release per DCR DRB18283Revised per DCR DRB20820Revised Form 1 instructions for Field 10, 15 and 18.Revised Form 2 instructions for Field 5 and 6.Add Definitions in Appendix D for COTS and Standard Part.Italicized all (CR) references within document.Modified format to keep page count the same.Revised per DRB21130Added appendix G (FAI Plan), QA Code 175 requirement for material,revised form 1, form 2 & form 3 instructions, updated definition of AssemblyFAIR and Detail Part, and clarified/expanded section 1.2 - Partial or Reaccomplishment of FAIRRevised per DRB26619Update Form 3, field 9 and 10 instructions when using attributeinformation and Designed/Qualified Tooling.Update Form 3 instructions for field 9Update Form 3 instructions for field 8Update Form 3, field 8 and 9 with additional decimal allowances andadded requirements for Internal and External Threaded features.Revised Section 1.2 (4).Revised Definition for Balloon Drawing, Appendix DRemoved original Appendix A. Renamed Appendix G to Appendix A (FAIPlanning). Revised all references to each appendix within document.Changed Title of Section 1 to Scope and General Requirements.Revised Section 1 requirements.Section 2.1 – Consolidated requirements 3 and 4 are combined in 2.1(3)Changed all “block” references to “field”.Added Bonus Tolerance to Terms and Definitions and Form 3, field 8instructions when utilizing MMC/LMC.Update Scope and General RequirementsAdd Section 1.3 – How to build a FAIR for Altered/Modified SCI/COTSUpdate Section 2 – Documentation for FAIRUpdate Section 5. Para 2.Update Form 1, Field 15 & 18 – buyer furnished material (CFM)Update Form 1, Field 15 - Altered/Modified SCI/COTSUpdate Form 2, Field 5 and 6 - Altered/Modified SCI/COTSRevised Form 3, Field 8 & 9 for Part Marking RequirementsForm 3, Field 9 added permitted uses of attribute inspection resultsForm 2, Field 12 – Removed Pass/Fail requirementForm 1, Field 18 – Update CofC requirementsUpdated Table of ContentsRevised per DCR DRB34268.Updated Form 1, field 8, 10, 16, 19, 21 instructions & requirementsUpdated Form 2, field 6 requirementsUpdated Form 3, field 9 requirementsUpdated section 2 added “otherwise enter N/A.”Removed: “Otherwise leave field blank or enter N/A” from all CR fields1
Document No. B25279Revision: EDate: 13 Aug 2018Add: Attribute Data to Appendix DAdd: Appendix G and update Form 3, Field 5, 8 & 9.Update Appendix B2
Document No. B25279Revision: EDate: 13 Aug 2018TABLE OF CONTENTS1. SCOPE AND GENERAL REQUIREMENTS . 41.1Evaluation Activities . 51.2Partial or Re-accomplishment of FAIR (Including by Similarity) . 51.3FAI for Altered/Modified Standard Catalog (SCI) and Commercial-Off-The-Shelf (COTS) Items. 62.DOCUMENTATION REQUIRED FOR A FAIR . 63. FORM 1 – PART NUMBER ACCOUNTABILITY . 74. FORM 2 – MATERIALS, PROCESSES AND FUNCTIONAL TESTING . 95. FORM 3 – CHARACTERISTIC ACCOUNTABILITY, VERIFICATION AND EVALUATION. .11APPENDIX A – FAI PLANNING REQUIREMENTS .16APPENDIX B – EXAMPLES - COMPLETED FORM 1, 2, 3 AND BALLOONED DRAWING .17APPENDIX C - SPECIAL AND CHEMICAL PROCESSING .21APPENDIX D - TERMS AND DEFINITIONS .22APPENDIX E - NONCONFORMANCE HANDLING .24APPENDIX F - SUPPLIER BASIC PARTS LIST REPORT (EXAMPLE) .25APPENDIX G – DRAWINGS WITH BEND TABLES .263
Document No. B25279Revision: EDate: 13 Aug 20181. Scope and General RequirementsThis document outlines the completion of AS9102 Forms 1, 2 and 3 used for First Article Inspection Reports (FAIR)submitted to BAE Systems and FAIR planning requirements. It provides consistency in approach resulting incompliant FAIR documentation. The Supplier shall have a process to plan for completion of FAI or shall plan FAI activities prior to the firstproduction run, reference Section 1.1.o An FAI Plan is provided as guidance in Appendix A. FAI Plans may require review by BAE Systems. A FAIR is required if the BAE Systems Purchase Order has a Quality Code of 114, 214, x14, etc. or asspecified in the BAE Systems Purchase Order, Subcontract or Statement of Work. Supplier(s) shall flow downthis requirement to all sub-tiers and those sub-tiers shall flow down applicable first article requirements to theircontracts/purchase orders.o Initial FAIRs shall be completed on new product using a representative item from the first productionrun. This document applies to all purchased or manufactured assemblies, sub-assemblies, detail parts includingcastings, forgings, machined items, BAE Systems designed tooling, and only the modifications to StandardCatalogue Items (SCI) and Commercial-Off-the-Shelf (COTS) items.o Supplier shall submit a FAIR traceable back to the part number and revision levels listed in the BAESystems purchase order.oAll Lower Level FAIRs shall be included with the upper level FAIR. Lower level items include but notlimited to; All levels of designed part(s) specifically manufactured to be used in the FAI Part External and Internal manufactured part(s) BAE Systems and Supplier DesignedModified or altered SCI/COTS, modifications only (Refer to Section 1.3) This document does not apply to development, prototype parts and unique single run production orders notintended for ongoing production.o SCI/COTS items do not require a FAIR. Assemblies and sub-assembly FAIRs require a list of COTSparts used in the assembly. This shall be included with the FAIR, Form 1 or provided as anattachment.o SCI/COTS CofCs shall be included with the FAIR. CofCs will show traceability to BAE SystemsSupplier Basic Parts List and to Original Component Manufacturer, as applicable per Purchase Orderrequirements. Raw Material and Special Process Certifications must match requirements on the BAE SYSTEMS drawing,and be included in the FAIR package. Accredited processes shall be used for special processes (NADCAP orBAE SYSTEMS approved) when Special Processes are identified on BAE Systems PO as Quality Codes 102and 185. See Appendix C. Visual and dimensional requirements shall be verified to meet those on the BAE SYSTEMS drawing,including all Notes. A balloon drawing shall be created and is required for every FAIR submission. Reference Appendix B & D. The terms and definitions in this document are the same as those in AS9102 Aerospace First ArticleInspection Requirement, current revision. Appendix D lists Terms and Definitions used in this document. BAE Systems FAI documents are available at www.BAESystems.com/suppliercenter.4
Document No. B25279Revision: EDate: 13 Aug 20181.1 Evaluation ActivitiesThe supplier shall conduct the following activities to ensure part conformance for the FAIR.1. Supplier ensures the current hardware/part number revision and drawing revision levels on file matches theBAE Systems Purchase Order Revision levels.2. Review supporting documentation for completeness (e.g., inspection data, test data, Acceptance TestProcedures, special process approvals and certifications).3. Verify that the raw material, special process certifications, and material used in the FAI part such assolder, flux, Loctite, etc., call out the correct specification, material types, conditions, and approvals.Validation documentation shall be referenced on Form 2, and a copy is included as an attachment.4. Verify part dimensions reported meet drawing requirements, including Notes Section. This includes any BAESystems drawing embedded in those notes.5. If applicable, verify the BAE Systems Supplier Basic Parts List/Revision levels are included in the FAIR.6. All lower level FAIRs shall be included. A FAIR is not required for COTS items unless specified on thePurchase Order.1.2 Partial or Re-accomplishment of FAIR (Including by Similarity)The FAIR requirement is in effect for the duration of the BAE Systems Purchase Order. A Partial or ReAccomplishment FAIR addresses changes from a baseline part, including changes to product and processes at theassembly and sub-assembly level. Refer to form 1, Field 14 instructions. This is applicable to any change invalidatingoriginal results of an approved FAIR.A Full FAIR or a partial FAIR is submitted for affected characteristics, when any of the following CHANGE(S) occur:1. Design characteristics affecting form, fit or function of the part (revision level change). If no change to form,fit, or function, only Form 1 is required to identify clerical changes.2. Source(s) supply for product or service.a. Manufacturing sourceb. Special Process source3. Inspection method(s): When the difference between the two methods reduces the accuracy of inspectionresults.4. Location of manufacture, tooling, material or raw materials that can potentially affect fit, form, or function.5. Numerical control program or translation to another media that can potentially affect form, fit or function.Including changes to ATP, ATE, and associated Software programs affecting product.6. A natural or man-made event, which may adversely affect the manufacturing process.7. A lapse in production as defined on the Purchase Order requires a full FAI/FAIR.By Similarity FAIR - Form 1 Field 14FAIR requirements may be satisfied by a previously approved, full FAI performed on identical characteristics of similarparts produced by identical means. Identify the “Baseline Part Number” and Revision Level and associated FAIRnumber. Enter Reason “By Similarity”. Record differences on the FAIR Forms 1, 2 and 3, as appropriate.Existing Supplier FAIRs: When the drawing is not under BAE Systems control, then FAI may be performed to thecontracted part drawing and Form 1 will reflect the part number on BAE Systems P.O., providing traceability.5
Document No. B25279Revision: EDate: 13 Aug 20181.3 FAI for Altered/Modified Standard Catalog (SCI) and Commercial-Off-The-Shelf (COTS)ItemsAny SCI or COTS item that is altered/modified require PPV/FAI for only the modifications completed unto theitem. Form 1, 2 & 3 are completed per this document’s instruction.1. Record SCI/COTS part information and specification information, as procured, in Field 5, 6, 8, 9 &10 of Form 2. This information is prior to its modification. Recorded information in these fields areconsidered the “material information” since the SCI/COTS item is incorporated into the FAI Part(Field 1 of Form 1). Refer to Form 2 instructions for additional information.2. Any specification or drawing associated with the FAI Part, other than SCI/COTS industry standards,are applicable documents that shall be ballooned and assigned a unique identifier as per thisdocument’s requirements listed in Form 3.3. FAIRs for Altered/Modified may be submitted for review when referencing other FAIRs of similarmanufacturing and inspection methods. This is most often done through the dash conditions.4. When a BAE System’s drawing/specification is modified, adding a new part number to the list ofcross references, a FAI is not required for all previous part numbers (i.e. “Dash” or “P” conditions).2. Documentation Required for a FAIRAppendix B contains completed examples of AS9102 Forms 1, 2, 3 and balloon drawing/specification.Each field in the forms is designated with a unique reference number and is identified as: (R) - Required: This is mandatory information. (CR) - Conditionally Required: This field is completed, when information is available, otherwiseenter N/A. (O) - Optional: This field is provided for convenience; the field may be left blank.Use of the AS9102 Forms 1, 2, and 3, latest revision is preferred. The forms shall be completed in accordance withthis document’s sections 3, 4, and 5 field identifiers (R/CR/O). These designations are compliant to AS9102, but dodiffer from the standard.Note: Non AS9102 forms may be used; however, they shall contain all “Required” and “Conditionally Required”information and have the same field reference numbers, per this document’s instruction.All forms shall be completed either electronically or permanent ink and in English.Continuation sheets, attachments and insertion of additional rows are acceptable.6
Document No. B25279Revision: EDate: 13 Aug 20183. FORM 1 – Part Number AccountabilityField 1-15 Instructions. Note: See Appendix B for exampleBAE Systems Purchase Order Information is used for Field 1, 5,7,10 and 12 of Form 11 thru 4 Fields are repeated on all forms for convenience and traceability.Changes to 1 thru 4 fields shall be made on each Form 1, 2, and 3.1. (R) Part Number: Record the part number from the Item Number Field of BAE Systems purchase order.Note: Supplier’s part number may be listed underneath the BAE Systems part number.2. (R) Part Name: Record the Part Name found in the Title Field of the BAE Systems drawing.3. (CR) Serial Number: When applicable, record the Serial number of the part measured for FAIR.Otherwise leave field blank or enter N/A.4. (R) FAIR Number: Record Supplier’s assigned unique FAIR identifier for traceability purposes.5. (R) Part Revision Level: Record BAE Systems hardware revision from the BAE Systems purchase order.PO format is Hardware Revision level / Drawing Revision Level. Record left side Revision for Part Number.NOTE: Supplier’s part revision level may be listed underneath the BAE Systems part revision level.NOTE: Asterisks (**D) as shown in in PO example above as part of the hardware revision are optional, these aresystem generated place holders6. (R) Drawing Number: Record Number found in the Title Field of the BAE Systems drawing.Typically, a part number without any suffix.7. (R) Drawing Revision Level: Record the drawing revision from the BAE Systems Purchase Order. PO format isHardware Revision level / Drawing Revision Level. Record right side Revision for the Drawing. Ensure the PO andactual drawing revision match.NOTE: Supplier’s drawing print revision level may be listed underneath the BAE Systems drawing print revision level.8. (CR) Additional Changes: When applicable, record reference numbers of changes incorporated in the product,but not reflected in drawing/part revision level. (e.g. ECO # or accepted Supplier Variation Request # (SVR#)).7
Document No. B25279Revision: EDate: 13 Aug 20189. (R) Manufacturing Process Reference: Record the reference number of the manufacturing document providingtraceability to the production lot of the part (e.g., router number, manufacturing plan number). Lot number, batchnumber, date code, may also be included.10. (R) Organization Name: Record the name of the supplier or manufacturer who produced the FAI Part (Form 1,Field 1) and performed the FAI. Example: Name of supplier from the PO. When an outside company performs the FAI for the supplier or manufacturer, record that company’s nameunderneath name of the supplier or manufacturer supplying BAE Systems FAI Part and final FAIR. For Distributors, sales offices and etc.: FAIRs provided from their suppliers shall comply with this documentand can be submitted to BAE Systems for review. Field 10 shall name the BAE Systems purchase ordersupplier and manufacturer(s) (if different) who performed FAI.11. (O) Supplier Code: Record BAE Systems assigned supplier ID number or supplier CAGE code.12. (R) P.O. Number: Record BAE Systems Purchase Order number. The BAE Systems PO supplier and manufacturer(s) PO (if different) shall be listed in Field 12.13. (R) Detail Part / Assembly FAI: Check, as appropriate as defined.Detail FAI: Does not contain a Supplier Basic Parts List (i.e. a single item).Assembly FAI: Contains Supplier Basic Parts Lists of manufactured or procured sub-assemblies, etc., orhardware as called out on the BAE Systems drawing. (e.g. list of lower level parts present that are necessaryto manufacture, assemble or maintain a product.)14. (R) Full FAI / Partial FAI: Check the appropriate level of inspection, per this document.If a Partial FAIR is submitted, provide 1) the previous baseline part number (including revision level), 2) the previousFAIR number and 3) the reason for the change, such as design changes, engineering change order, testing, processchange, and/or modified COTS. When accomplishing FAI requirements by Similarity, requirements may be satisfied by a previously approved,Full FAI performed on identical characteristics of similar parts produced by identical means. Record the“Baseline Part Number”, Revision Level and associated FAIR number. Enter Reason “By Similarity”.o Differences in drawing features of identical characteristics, record any differences on FAI Forms 1, 2and 3, as appropriate.15. (CR) Part Number: Verify the use and record part numbers of components and/or sub-assemblies present in theFAI Part; this includes:1. All purchased and made part numbers from the associated Supplier Basic Parts List. All items shall be traceableto the BAE Systems Supplier Basic Parts List, when applicable. When the part listed is a buyer furnished/supplied part, complete entries for Fields 16-18. (e.g. CustomerSupplied, Government Supplied etc.)2. Any lower level parts purchased or fabricated by the organization manufacturing the Upper Level part.When recording Standard Catalogue or COTS items that are “non-modified”, list each item separately. Also see Form1, Field 18 note. Alternate method: Generate and attach a separate list that contain these items. State in Field 15, “Seeattached COTS list.” Include all lower level FAIRs within the Upper Level FAIR. See field 18. For “Modified” Standard Catalogue or COTS items refer to Section 1.3.16. (CR) Part Name: Record the name of the component and/or sub-assemblies associated with Field 15(abbreviated names are permissible/acceptable).17. (CR) Part Serial Number: Record if serial numbers are assigned to the part.18. (CR) FAIR Number (Cert No.): When Field 15 contains a part number that is a lower level detail, sub-assembly,and “Modified” Standard or COTS item; the supplier shall verify the FAIR is valid and record that FAIR number.8
Document No. B25279Revision: EDate: 13 Aug 2018 Any lower level FAIR that is used in the Upper Level part, include that FAIR as an attachment. For Standard Catalogue and COTS items record “COTS Item” within field and include traceabledocumentation (e.g. packing slip or CofC). When the part listed in field 15 is a buyer furnished/supplied part, record the document identifier that provesownership of the part listed. (e.g. Customer Supplied, Government Supplied etc.)Note: Form 2 may also be used to record Standard Catalogue and COTS items and their Cert No. Form 1 must stillcontain a record of Standard Catalogue and COTS items used in the FAI Part.Note: Supplier Basic Parts List which is provided/included within the TDP (technical data package) shall be as shownin appendix F. This
This document outlines the completion of AS9102 Forms 1, 2 and 3 used for First Article Inspection Reports (FAIR) . The Supplier shall have a process to plan for completion of FAI or shall plan FAI activities prior to the first production run, reference Section 1.1.
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2 Supplier Directory Services 3 Supplier User Management 4 Assessments 5 Managing Supplier Registration and Qualification 6 Managing Supplier Profiles 7 Managing Supplier Performance 8 Notifications 9 Managing Supplier Classifications 10 Managing Supplier Hierarchy. x
