AS9102 - Assembly FAI for Use As Is or Repaired Parts

#1
Greetings. I am preparing an Assembly level FAI on a first run of Assembly production.

1. Some of the parts to be used for Assembly were a part of Notice of Escape from the Supplier, and processed as Nonconformances​
a. Some of the parts (not meeting Supplier defined process) were dispositioned/approved as Use As Is and Supplier C/A implemented​
b. Some of the parts (not meeting Supplier defined process) were dispositioned/approved as Return to Vendor for Repair and Supplier C/A implemented​
c. Some of the parts (not meeting Customer defined process) were dispositioned/approved as Use As Is and Supplier C/A implemented​
These approved parts are planned to be used on the first run of Assembly production and they were fully dispositioned/approved by all required parties. It was determined during disposition/approval that there is no impact to form/fit/function.

{AS9102B, Section 4.4, Nonconformance Handling, states that an FAI with design characteristic nonconformance(s) is "not complete". An FAI with noted nonconforming design characteristics may have Form 1, "Part Number Accountability", (see field 19) signed and shall be noted as "FAI Not Complete". }

Question1: If using Supplier parts that were non-conforming, but dispositioned as approved for Assembly and there is no impact to form/fit/function, is this still an FAI that will be "not complete"? I am reading this as, regardless of disposition/approval, the parts did not fully meet the design/process requirements during processing.​
Question2: For Assembly FAI, will this require a Partial FAI and then at a later time, another Partial FAI once the previous nonconforming parts come in 100% to the design/process requirements?​
Where I am getting confused, is these previous nonconforming Supplier parts will not have an impact on the Assembly level FAI. I can see if the parts were dimensionally different, fit different, different tools required, etc. but I do not understand how this ties in with the Assembly level FAI. Appreciate any input that will help me understand this fully.

Thank you
 
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dsanabria

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#2
Before we continue - you need to understand the purpose of the FAIR.

The primary purpose of FAIR is to validate that product realization processes are capable of producing parts and assemblies that meet engineering and design requirements.

Step 1 - on form 1 place the items (block 15 - 18) that will complete the assembly.

Step 2 - If all dimensions and functions meet the engineering and design requirement - FAIR is complete.

You just validated the product realization process.
 

sandra2014

Involved In Discussions
#3
I have a question relating to AS9102 - We are creating a client requested first article AS9102, and all of the 'off the shelf' parts and components that are used in this 1st article build do not have material certificates for trace ability purposes Our client stated they don't need this certification for 'off the shelf' components. The client requested an AS9102 1st article report without the 'off the shelf item material certification', would this be a violation in meeting the AS9102 requirements? We would appreciate an immediate response from an Aerospace expert on this issue.
 

dsanabria

Quite Involved in Discussions
#4
I have a question relating to AS9102 - We are creating a client requested first article AS9102, and all of the 'off the shelf' parts and components that are used in this 1st article build do not have material certificates for trace ability purposes Our client stated they don't need this certification for 'off the shelf' components. The client requested an AS9102 1st article report without the 'off the shelf item material certification', would this be a violation in meeting the AS9102 requirements? We would appreciate an immediate response from an Aerospace expert on this issue.
Clause 1.3 of AS9102 - Application
Unless contractually required, this standard does not apply to:

· Procured standard catalogue items, COTS, or deliverable software.



So it's ok to contue with the FAIR per AS9102 without certs - just list the COTS on Page 1
 
#6
Before we continue - you need to understand the purpose of the FAIR.

The primary purpose of FAIR is to validate that product realization processes are capable of producing parts and assemblies that meet engineering and design requirements.

Step 1 - on form 1 place the items (block 15 - 18) that will complete the assembly.

Step 2 - If all dimensions and functions meet the engineering and design requirement - FAIR is complete.

You just validated the product realization process.
Thanks for your reply. This makes sense, however, the assembly is still utilizing parts that involve 'design characteristic nonconformance'. Will it be required to note this 'design characteristic nonconformance' on the assembly level FAI?

Thanks much, David P
 

dsanabria

Quite Involved in Discussions
#7
Thanks for your reply. This makes sense, however, the assembly is still utilizing parts that involve 'design characteristic nonconformance'. Will it be required to note this 'design characteristic nonconformance' on the assembly level FAI?

Thanks much, David P
Yes - and you will also not on form 1 that FAIR is not complete.

This will alert individuals that there is an issue and how it was resolved otherwise known as a Delta fair.
 
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