PURPOSE - WMATA
SOP 113-12 First Article Inspection Procedures1. PURPOSEThis document describes the TIES procedures for initiating, evaluating and approvingFirst Article Inspection (FAI) of parts and components, used to maintain and enhance theWMATA rail system. The FAI process supports ensuring quality conformance to allengineering and design requirements prior to approval of new supply sources orreplacement of configuration-controlled rail car parts and components.2. SCOPEThese procedures describe preparing, processing and validating new suppliers and/ornew/replacement rail car parts or components, due to design changes or obsolescenceissues that change the approved supply sources or design configuration of equipment,components and sub-components, systems or subsystems maintained and configurationcontrolled by TIES. FAI procedures and the documentation package requirements alsoapply to Factory Acceptance Test (FAT) for unique “one of” equipment.3. RESPONSIBILITIES3.13.23.3QAAW Director: The Director of QAAW shall be responsible for thecoordination, establishment, issuance and maintenance of this procedure, and forthe assignment of qualified QAAW staff to execute the requirements.QAAW: QAAW staff assigned to direct the FAI process shall:3.2.1 Control FAI material and enforce the FAI requirements in this procedure.3.2.2 Complete the FAI reviews, as defined in this procedure.3.2.3 Approve the FAI paperwork packages.3.2.4 Provide FAI status to WMATA requesters and users.CENV: Engineering personnel assigned to support the FAI process shall:3.3.1 Establish the rail car part/component/equipment technical specifications.3.3.2 Provide approved Engineering documentation that defines the FAI or FATpart/component/equipment design, specifications, and configuration.4. DEFINITIONS4.1First Article: A rail car procured item that is representative of the supplier’sproduction output from a known, specific manufacturing process: location(s),tools/equipment, raw material(s), procedures, standards/specifications, designdocumentation, etc.SOP 113-12, Rev. 0Page 1 of 17
SOP 113-12 First Article Inspection Procedures4.2Configuration: The established, approved and maintained technical description ofa rail car part/component performance, functional and physical attributes - with itsrequirements, design and operational information documented throughout its life.4.3Obsolescence: A decline in the availability of rail carparts/components brought about by an introduction of new technology, sources of supplyno longer available, or business/marketing environment changes over time.5. ABBREVIATIONS and ACRONYMS3.1Department / Office Acronyms: CENVVehicle Program Services QAAWQuality Assurance and Warranty PRMTProcurement and Materials TIESTransit Infrastructure & Engineering Services5.2.Other Abbreviations or Acronyms:BOM:Bill of MaterialCofC:Certificate of ComplianceETP:Engineering Test PlanFAI:First Article InspectionFAT:Factory Acceptance TestKPC:Key Product CharacteristicsSDS:Safety Data SheetOEM:Original Equipment ManufacturerSDS:Safety Data Sheet6. PROCEDURESProcedure #Content6.1Requesting First Article Inspections6.2FAI CoordinationSOP 113-12, Rev. 0Page 2 of 17
SOP 113-12 First Article Inspection Procedures6.3FAI at Supplier Facility6.4FAI at WMATA6.5FAI/FAT Design Documentation Package6.6FAI Review and Disposition6.7FAI Action Items and Report6.1Requesting First Article Inspections.6.1.1 The requester shall complete and submit and FAI Request Form 113-F-005to QAAW (Attachment B).6.1.2 QAAW shall log the FAI request in the FAI Status Log (Attachment A).6.1.3 FAI is required for the first production units produced; and is required priorto implementation of part/component changes.6.1.4 FAI sample parts/component shall be submitted to QAAW, and shall befrom the Supplier’s full rate production set up. QAAW will specify thenumber of production-representative samples – typically ten (10) – that mustbe provided for the FAI. WMATA QAAW will select the specific sampleitems to be used for the FAI.6.1.5 In cases where size, complexity and/or cost prohibits the Supplier fromproviding ten units, a written request for a smaller sample size shall besubmitted to WMATA QAAW for approval.6.1.6 QAAW shall perform the FAI in accordance with this procedure6.2 FAI Coordination.6.2.1 QAAW shall provide a list of items required to complete the FAI package.In circumstances where contractual requirements are established, this effortshall be coordinated with the responsible project office.6.2.2 Depending on the type of article being evaluated, the FAI may be conductedat a WMATA facility or at the Supplier(s) manufacturing facility.6.2.3 The FAI schedule will be coordinated with QAAW.6.3 FAI at Supplier Facility.6.3.1 The Supplier shall submit in advance, all required documentation toWMATA, prior to the physical FAI visit.6.3.2 The FAI shall be conducted in a well-lit workspace with the necessaryinspection and handling aids.SOP 113-12, Rev. 0Page 3 of 17
SOP 113-12 First Article Inspection Procedures6.3.36.3.4The inspection article shall be displayed on a stand or table.The Supplier shall provide all tools and labor to take mechanical orelectrical measurements.6.3.5 The Supplier shall have the capability to perform a functional test, orprovide evidence of a previously performed test with supportingdocumentation.6.4 FAI at WMATA.6.4.1 Submit an FAI Request Form 113-F-005 to QAAW (Attachment B).6.4.2 CENV shall provide QAAW a complete FAI documentation package.6.4.3 Any “trial” parts/components used during the performance of anEngineering Test Plan (ETP) – and new part/component samples that aredesigned as a result of the ETP – shall be provided to QAAW at the time ofthe FAI.6.5 FAI/FAT Design Documentation Package.6.5.1 All packages shall include, unless otherwise specified by QAAW, acomplete set of signed, dated and stamped drawings/documentation used tobuild/inspect/test the item to the approved revision level – as set by CENV.6.5.2 The documentation package shall include, but not be limited to, all:6.5.3SOP 113-12, Rev. 0 Mechanical drawings Electrical drawings Assembly drawings Bills of Material (BOM) Configuration data – hardware and softwareOther required technical data, as available: Dimensional inspection results, with all Key Product Characteristics(KPC) listed. NOTE: Dimensional KPC are those that affect form, fitor function. Approved Factory Acceptance Test (FAT) procedure with pass/failrequirements: evidence of acceptable functional performance – viatesting as a module, subassembly, assembly, subsystem, or system – atall applicable levels Part/component dimensional inspection report for the productionrepresentative samples Part/component material test(s) that certify meeting materialspecifications and applicable industry standards; make sure thePage 4 of 17
SOP 113-12 First Article Inspection Proceduressamples’ data is included.6.6 For subassemblies/assemblies: test/verification data that providesevidence of compliance with all technical design and functionalrequirements Documentation that supports compliance with all Safety requirements All Final Inspection results All Incoming Inspection results All Certificates of Compliance (CofC) All In-Process Inspection results used to control and accept in-processwork shall be available upon request. Surface Finish Acceptance Criteria – if applicable Safety Data Sheets (SDS) – if applicable Packaging and Shipping standards – if applicable Article identification standard (how the supplier identifies its product) Training Certifications for all operators – if applicable Manuals and Operating Instructions All required certifying agency marks – example: UL , CE , FCC Verification of calibration for measuring and test equipment used toaccept and test the FAI item Lot and Serialization Traceability documentation – if applicableFAI Review and Disposition.6.6.1 QAAW shall review the FAI package to verify compliance with the aboverequirements.6.6.2 QAAW shall complete all applicable sections of (and attach all applicabledocumentation to) the FAI Report Form 113-F-006 (Attachment C).6.6.3 QAAW shall provide a disposition (passed or failed).6.6.4 Passed FAI: 6.6.5SOP 113-12, Rev. 0QAAW completes the FAI Certificate of Compliance Form 113-F-008(Attachment D). QAAW uploads the FAI package information to the data base kept inDocumentum. QAAW notifies CENV and PRMT by providing a copy of the FAICertificate of Compliance form. QAAW shall document the disposition in the FAI Status log(Attachment A).Failed FAI:Page 5 of 17
SOP 113-12 First Article Inspection Procedures QAAW completes the FAI Not Approved Notification Form 113-F009 (Attachment E).QAAW notifies CENV and PRMT by providing a copy of the FAI NotApproved Notification Form. 6.7QAAW shall document the disposition in the FAI Status log(Attachment A).FAI Action Items and Report.6.7.1 QAAW shall complete all applicable blocks, document all Supplier andWMATA Action Items approved by QAAW, and sign the FAI Report Form.6.7.2 QAAW shall distribute copies of the form to CENV and PRMTrepresentatives. File a copy of the FAI documentation package and updatethe FAI status tracking log.7. REFERENCES7.1OAP 113-06, First Article Inspection Policies8. ATTACHMENTS1)2)3)4)5)Attachment A – Sample FAI Status LogAttachment B – Sample FAI Request FormAttachment C – Sample FAI Checklist and ReportAttachment D – Sample FAI Certificate of ComplianceAttachment E – Sample FAI Not Approved NotificationSOP 113-12, Rev. 0Page 6 of 17
SOP 113-12, Rev. 0First ArticleInspectionNubmerSupplier / contact infoPage 7 of 17WMATA Parag BhagwatPhone : 202-962-5973Cell : IFAIFAI6/13/2013 QAAW2013-0406/14/2013 QAAW2013-0416/21/2013 QAAW2013-0426/26/2013 QAAW2013-043WMATA Parag BhagwatPhone : 202-962-5973Cell : 202-594-6647SEPSA NANot assigned yetMcCrae Road,Balston Spa, NYMGI Steve Fecica416 892-8017Not assigned yetFAI5/31/2013 QAAW2013-039SEPSA NANot assigned yetMcCrae Road,Balston Spa, NYFrank UrsoneNot assigned yet Alp Rail Industries, Inc.610-328-1100EUROTECHCraig Ross QA ManagerNot assigned yetJon Tandy Manager913.549.1000 x232WMATA PartNumberFAIFAIReason(EMI, ETP,ER IIUR5/24/2013 QAAW2013-0384/29/2013 QAAW2013-037DateDrawing Number / Revison073389; 073396073399Event Recorder, ATCID moduleTRVPB Module70 degree inspection gageOriginatorBaldassano Parag BhagwatBaldassano Parag BhagwatBaldassano Jeff ThompsonBaldassano Tara SoesbeeBaldassano Sachit KakkarS061886 Rev G, S062377 Rev DBaldassano Tara SoesbeeS062405 Rev Dw669-11WDX000269-AWDX000262-AWDX000271-ASee FAI PackageDynaCOR Mobile Computer; WiFiAntenna and CablesWDX000269-A GageWDX000262-A Right Side 70 degree70 degree wheel profiles and inspectionprofilegageWDX000271-A Left Side 70 degree profileMFG: 4M-2041-3 Rev HWDR000254w669-11QAAWOfficerS061886 Rev G, S062377 Rev DBaldassano Tara SoesbeeS062405 Rev D(list both WMATA & MFG if available)Cap Screw Hex 1/2-20 UNRF 3A x 3.5"Long2K/3K Disk Mounting BoltEvent Recorder, ATCID moduleTRVPB ModuleFirst Article Inspection DescriptionMGI Crossbar Assembly for 1k HVACCP-00215-11 Rev 1See Report4M-2041-3073389; 073396073399Supplier Part NumberComments201140OpenFAI Approved. Will send CoC when 2action items are closed.FAI approved. Sent CoC to supplier andClosed 6/13/2013 report on 06/13/2013 -- copied JeffThompsonWDX000269-A Gage -- Not ApprovedWDX000262-A Right Side 70 degree profile-- ApprovedWDX000271-A Left Side 70 degree profile -Closed 6/21/2013ApprovedCENV purchased a new gage fromWinchester Industries Inc. See FAI ReportQAAW2013-042w669-11 Serial Number 001 ApprovedClosed 6/22/2013FAI approved for 2nd set of samplesClosed 5/24/2013 provided and responses received from theaction item list per QAAW2013-036FAI approved. Sent CoC to suppliers andreport on 06/13/2013.Closed 6/13/2013Issued "FAI Not Approved Notification" to10 Closed 5/2/2013 T. Soesbee on 05/02/2013.NuFAImb Status Closed oner (Open,SOP 113-12 First Article Inspection ProceduresAttachment A – Sample FAI Status Log
SOP 113-12 First Article Inspection ProceduresAttachment B – Sample FAI Request FormOFFICE OF QUALITY ASSURANCE AND WARRANTYFIRST ARTICLE INSPECTION (FAI)REQUEST FORM113-F-005 Rev 1Requestor's Information:Office:Name:Date:Part / Component InformationNew Part to WMATA?YESNONew Supplier for anexisting part?YESNOYESNOPart Description:WMATA part number:Supplier's part number:Is a MSDS required?Supplier InformationSupplier's Name:Supplier Address:Contact Person:Phone #:E-mail (if available):SOP 113-12, Rev. 0Page 8 of 17
SOP 113-12 First Article Inspection ProceduresAttachment C – Sample FAI Report (seven pages)SOP 113-12, Rev. 0Page 9 of 17
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SOP 113-12 First Article Inspection ProceduresAttachment D – Sample FAI Certificate of ComplianceSOP 113-12, Rev. 0Page 16 of 17
SOP 113-12 First Article Inspection ProceduresAttachment E – Sample FAI Not Approved NotificationSOP 113-12, Rev. 0Page 17 of 17
First Article Inspection (FAI) of parts and components, used to maintain and enhance the WMATA rail system. The FAI process supports ensuring quality conformance to all engineering and design requirements prior to approval of new supply sources or replacement of configuration-controlled rail car parts and components. 2. SCOPE
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