First Article Inspection - Moog Inc.

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First Article InspectionMike Terry9102 Team memberAugust 2014Company Confidential1

First Article Inspection (FAI) –Topics AS9102 Rev B FAI Efficiencies Common Issues FAI Resources Questions2

AS9102 Rev B3

9102 Evolution 9102: 2000-08‒ Standardized aerospace FAI requirements‒ Common form of documentation for supplier FAI 9102 A: 2004-01‒ Define What and When, not How‒ Improved layout and readability of the standard‒ Eliminated points of confusion‒ Provided open fields for company specific non-9102 use 9102 B: 2014-xx‒ Enhanced Scope & Purpose to emphasize value of FAI‒ Separated planning activities from evaluation activity‒ Addressed Digital Product Definitions (DPD)‒ Utilize FAQs and SCMH to clarify intent and provide examples ofcomplex concepts (Help Needed)How What Value4

9102 B – RationaleThis standard was revised to emphasize the value of the First Article Inspection (FAI) processto an organization, separate and enhance the planning and evaluation activities, and defineDigital Product Definition (DPD) and its relationship to the FAI process. Additional changesto the standard requirements, definitions, and associated notes were incorporated inresponse to stakeholder needs. IAQG requested feedback (250 items globally)‒Breakdown of comments5

9102 B – First Article Inspection Planning The organization shall have a process to plan for completion of FAI orshall plan FAI activities prior to the first production run FAI planning shall address the activities to be performed throughout theFAI process and identify the responsible organizations for thoseactivities“Plan” is used as a Verb6

9102 B – First production deliveryparts require an FAI Part Requirements‒ The organization shall perform FAI on new productrepresentative of the first production run‒ The first production delivery parts require an FAI7

9102 B – Digital ProductDefinition Requirements When design requirements are in a DPD format and traditional2D drawing information is not available for all applicable designrequirements, DPD design characteristics required for productrealization shall be extracted, verified, and included in the FAIR The organization shall:– Establish a process to extract the applicable DPD designcharacteristics– Extract the DPD design characteristics required for productrealization– Ensure the production, inspection, and operations requiringverification have been completed as planned to achieve DPDdesign characteristics8

9102 B – Qualified Tooling Qualified Tooling:Universal (not part specific) calibrated monitoring and measuringequipment (e.g., go/no go gauges, thread gauges, radius gauges) usedto validate product design characteristics, that are uniquely identifiedand traceable to their calibration records attribute data (e.g., pass/fail) may be used in lieu of variable datawhen: qualified tooling is consistently used as a check feature and ago/no-go feature has been established for the specificcharacteristic. When qualified tooling (e.g., radius gauges) areused as a go/no-go gauge, record the gauge value or range (e.g.,minimum/maximum value), as applicable.9

9102 B – Control of Records FAI documentation required by this standard shall beconsidered a quality record. The organization shall retain theappropriate FAI documentation while the product is beingproduced and, at a minimum, retain them according toapplicable customer or regulatory requirements.Form instructions:‒ For a partial FAI, provide the previous part number, including revision level to which thispartial FAI is performed and the reason for the current FAI (e.g., changes in design,process, or manufacturing location). For partial FAIs based on similar parts (reference9102, 4.6), provide the approved configuration FAI part number, including revision level.‒ The organization shall verify every design characteristic, during the FAI, and record theassociated results.10

9102 B – Form 3, Results When automated inspection tooling produces measurement results, those resultsmay be referenced on 9102 Form 3, identified as pass/fail, and attached only when: The characteristic numbers are clearly linked in the attached report The results in the attached reports are clearly traceable to the characteristicnumbers The results are directly comparable to the design characteristicNOTE: Coordinate Measurement Machine (CMM) data alone would not beacceptable for a positional tolerance; the results shall show the actual positionalvalue.11

FAI Efficiencies12

FAI and Your QMS (9100 7.5.1.1)The FAI will: Validate the Production System is capable Document As Built As DefinedDefine9102 FormsPlanBuildInspectMfg Plan/RouterFAI Documentation QMS Enables Production System13

FAI Technology ToolsImproving Quality, Reducing Cost and EffortPLM / ERP / SAPExisting & EmergingTechnology Reduce CostImprove QualityAutomationGenerate FAI from Source CAD ToolsBallooning ToolsSpecification ManagementAutomate Measurements P.O.Part InfoDue Date, Eliminate manual entryCADintegrationFAICompleteReportingand ace to Existing SystemsReporting and Analytics StatusProcess ImprovementWarningsWirelesscaliperFAROArmCMM14

Common Issues15

Common FAI Issues Forms not completed properly Engineering requirements not understood FAI training & processes not defined oreffective 9102 Flow-down and oversight inconsistentand ineffective16

Common Issues – Forms Forms not completed properly– Wrong information in fields/forms, signatures missing,typos– Inspection results data integrity– CMS inspection results not traceable to designcharacteristics– Attribute data recorded when Characteristic is expressed bynumerical limitsNo, this is not an acceptable 9102Form 317

Common Issues – EngineeringRequirements Engineering requirements not understood– Engineering authority incomplete– Engineering characteristics not accounted for– Missing implicit characteristics, missed notes, omittedcharacteristics18

Common Issues – Training & Processes FAI training & processes not defined or effective– FAI not performed on first production run– FAI performed to Manufacturing Planning or Tooling instead of Design– Partial FAIs not being performed when required– Depth of evaluation» 9100 8.2.4 – Monitoring and Measurement of Product Measure characteristics to verify (Specification) requirements have been met Evidence of conformity with the acceptance criteria shall be maintained» 9100 7.1.2 – Risk Management Assignment of responsibilities for risk management Identification, assessment and communication of risks throughout productrealization9102 B – First Article Inspection Planning19

Common Issues – Flow-down & Oversight 9102 Flow down and oversight inconsistentand ineffective– Sub-tier FAI review– Sub-tier FAI visibilitySupplier FAI Visibility Tool Project (A.K.A. Net-Inspect)20

FAI Resources21

FAI Resources – IAQG22

FAI Resources – IAQG tmTable:A. Forms UsageB. When to Perform an FAIC. Standard Catalog Hardware(SCH)D. Similar PartsE. Purchase Order RequirementsF. General Questions23

IAQG FAQs – example24

FAI Resources – IAQG L CODE IAQG&OBJECT PKG iaqg.businessClasses&OBJECT TYPE SCMHGeneral&PAGE gotoSCMH25

IAQG Supply Chain Management Handbook Registration is free26

IAQG Supply Chain Management Handbook Chapter 3.2 First Article Inspection (FAI)27

Questions?28

This standard was revised to emphasize the value of the First Article Inspection (FAI) process to an organization, separate and enhance the planning and evaluation activities, and define Digital Product Definition (DPD) and its relationship to the FAI process.

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