Can someone share example of FAI Inspection Plan ?

[Corsair]

Covers,
Anyone can share with me some samples for FAI plan's.
Do you have to include a visibility log file, correct?

 

[MEDQA]

what is a "visibility log file"?

We have a drawing w/ numbered dimensions, parts are measured and recorded. Record includes, numbered drawing and results and any actions taken.

We also have an spreadsheet that lists the Part Number, Rev, drawing, and results.

 

[Corsair]

Well some customers will ask for a log file to have control over the FAI's specially if the work package is big.

 

[Wes Bucey]

Covers,
Anyone can share with me some samples for FAI plan's.
Do you have to include a visibility log file, correct?

what is a "visibility log file"?

We have a drawing w/ numbered dimensions, parts are measured and recorded. Record includes, numbered drawing and results and any actions taken.

We also have an spreadsheet that lists the Part Number, Rev, drawing, and results.

I don't have a sample plan to show you off hand, but MEDQA has outlined what mine used to contain.

In my own machining business (only custom parts-no off the shelf), we always forwarded First Article to customer along with the inspection report
First Article Inspections were essentially "redundant" events. The operator who made First Article would do all the measurements of characteristics according to a Control Plan previously designed and agreed to with operator, Quality department, design engineer, and customer. When done, he would find another operator to do a redundant inspection with his own (the other operator's) instruments. If there was a discrepancy between readings not accountable with "normal variation," then, and only then, would Quality department perform a third FAI. The check sheet with the results of the two operators' readings went to customer along with tagged sample. If everyone was happy with readings, production continued.
​

The crucial part of our practice was to "pre-agree" with the folks mentioned in the boldface part of the quote above EXACTLY how a FAI would be performed and we would JOINTLY prepare a ballooned drawing

Courtesy of Cove member Brizilla:
a ballooned drawing is one where you number each dimension on a print and write the results on a separate numbered inspection sheet. People tend to number them and then circle each number so as not to confuse them with a number that's part of the print. Thus the "balloon".

Our check sheets would then have the dimensions numbered in the order they were to be inspected along with the type and serial number of the actual instrument used (for replication purposes) the order was to make for the most efficient inspection, often entailing using one instrument first, then moving on to next instrument. Other times, beginning with critical characteristics first so they were prominently highlighted for review.

Our "log" was critical, being able to retrieve any and all inspection sheets and instruments at a moment's notice.

The "visibility" of what we would do and did do was the entire point of FAI.

Note: the customers were happy to have the "road map" for their own inspectors, PLUS we also agreed on a similar "incoming inspection" plan (only a few critical dimensions) for the customer's sampling (if he wanted) of subsequent production shipments.

 

[KathySmith]

I've moved on from the company and didn't keep an example but with Bell Helecopter and Lockheed the FAI's forms were basically homegrown spreadsheets. The inspector would hand number the drawing/prints and crossreference to the spreedsheet. The customer over years advised us on the form and we tweaked to their needs. Everything must be crossreferenced and traceability easily shown of course. I would start with your customer and have them email what they are use to seeing from their favorite suppliers. If your already established, I would do very minimun or NO reformatting to the existing forms. Reformatting forms is the first thing to catch incoming inspector's attention and prompt them to conduct a bench audit and start scrubbing through the details. Particullarly Customer Quality Engineers with nothing to do but go on fishing expeditions to make them look good and you look bad.

 

[Jim Wynne]

In my own machining business (only custom parts-no off the shelf), we always forwarded First Article to customer along with the inspection report

Do you mean "first article samples"? Surely you didn't send them the first article (singular)?

First Article Inspections were essentially "redundant" events. The operator who made First Article would do all the measurements of characteristics according to a Control Plan previously designed and agreed to with operator, Quality department, design engineer, and customer. When done, he would find another operator to do a redundant inspection with his own (the other operator's) instruments. If there was a discrepancy between readings not accountable with "normal variation," then, and only then, would Quality department perform a third FAI. The check sheet with the results of the two operators' readings went to customer along with tagged sample. If everyone was happy with readings, production continued. <snip>

I've always found that having competent and reliable people doing first articles obviates the need for any redundant inspection. In fact, I've never heard of a situation where people doing mechanical inspection--other than trainees--couldn't be trusted to do the job correctly. Even if it were necessary, who has time for all of that in a busy job shop?


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[Wes Bucey]

<snip>

I've always found that having competent and reliable people doing first articles obviates the need for any redundant inspection. In fact, I've never heard of a situation where people doing mechanical inspection--other than trainees--couldn't be trusted to do the job correctly. Even if it were necessary, who has time for all of that in a busy job shop?​

We made the time - it set us apart (a marketing ploy), giving customers a "warm feeling" when they paid us more than other, less customer-centric, shops. Actually, the pre-approval of plan and redundant FAI was probably one of the reasons we NEVER had a customer return of a First Article.

How many First Articles? Whatever was agreed in the advance pre-plan with the customer. We made relatively small components, but how many First Articles would you expect when your organization is only making five pieces of a six foot diameter turbine blade as a neighboring machine shop did about twice a year?
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[Jim Wynne]

We made the time - it set us apart (a marketing ploy), giving customers a "warm feeling" when they paid us more than other, less customer-centric, shops. Actually, the pre-approval of plan and redundant FAI was probably one of the reasons we NEVER had a customer return of a First Article.

If, as a customer, I had a job shop tell me that a part was going to be measured as many as three times by three different people, I would wonder what was wrong with the first guy. What you were saying, in essence, was you didn't trust the people doing the inspection, and why you would want to share that information with customers I don't know. If you never had a first article rejected and that record was due to redundant inspection, then you definitely had a problem.

How many First Articles? Whatever was agreed in the advance pre-plan with the customer. We made relatively small components, but how many First Articles would you expect when your organization is only making five pieces of a six foot diameter turbine blade as a neighboring machine shop did about twice a year?

I asked because you said you always sent the first article to the customer, which sounded to me like there was only one, and I was wondering why you wouldn't have kept samples representative of the run that produced the samples.

 

[Corsair]

Folk's no samples available ?

 

[Mr.Happy]

Folk's no samples available ?

Did you try Google "FAI report example" a quick search came up with several suitable hits, like the one from Goodrich , see http://www.goodrich.com/gr-ext-temp...rs/Supplier Resources/FAI_Training_9-1-10.pdf
and even a hit from the Cove http://elsmar.com/Forums/f16/as9102-fai-first-article-inspection-form-example-20933.html
hope this helps you..
Cheers,
Mr. Happy