9102 Rev A
Aerospace First Article Inspection Requirement (FAI)
Frequently Asked Questions (FAQ's)[/SIZE]
June 7, 2008
Forward
International Aerospace Group (IAQG) procedure 103 defines the process for providing "clarifications" to published standards. Below are clarification questions and responses received by the Sector Document Representatives (SDR's) over the past three years. It is intended that these FAQ's be updated as new questions are received.
Standards provide requirements but are prohibited from providing methods for meeting those requirements.
The 9102 standard is not intended to be used to assess compliance to any other published standard.
9102 may be self imposed or required by contract but is not required by any other published standard.
To use this document, scroll through or use the links in the Table below. To return, use "Control Home" on your keyboard.
Table:
A. Forms Usage
B. When to Perform an FAI
C. Standard Catalog Hardware (SCH)
D. Similar Parts
E. Purchase Order Requirements
F. General Questions
A. Forms Usage
A1. Question:
Are requirements defined as "CR" in the forms ( 1-3 ) to be filled only when there is a special requirement from the customer or, always filled when applicable?
A1. Response:
"Special requirement from the customer" is only an example. "CR" items must be filled in when "applicable". For example, not all parts have a serial number but when they do because of engineering, you must fill in that block (form 1 block 3). The same is true for the other "CR" blocks. When not applicable or required by engineering, leave them blank or write N/A.
A2. Question:
What are some examples entries for form 1, field 9 (required field)
A2. Response:
The intent is to provide linkage to the planning/router that was used during the manufacture of the FAI part/assembly. Some companies track parts with a production control number and a "router issue number". Production control numbers are usually for cost collection and order tracking and router issue can be directly correlated to the router. You may use anything that provides linkage to the exact router/planning used during FAI.
A3. Question:
Form 1 Field #9: Manufacturing Process Reference. Please elaborate on what is required?
A3. Response:
The purpose of field 9 on form 1 is to provide traceability from the FAI part to the router/planning used to manufacture the part. Any number or reference that provides that traceability is acceptable.
A4. Question:
Are the forms in the standard examples or are they mandatory?
A4. Response:
You may create your own forms but they must require the same information as the forms provided and must be numbered with the same box numbers. See 5.5.1..... Forms other than those contained in the Appendix may be used; however they must contain all "Required" and "Conditionally Required" information and have the same field reference numbers.
A5. Question:
Can parts lists, reports and other records be noted on the forms and attached rather than copying all the data onto the forms?
A5. Response:
Yes, you may reference the attachments on the forms and attach parts lists, reports etc. You may also attach drawings to form 3 and note the drawing on the form as long as the characteristics and results are clearly identified on the drawing. Any efficient, time saving method is acceptable but you must maintain traceability and the data on the attachments must be verified.
A5. Question:
Form 1 Field #9: Manufacturing Process Reference. Please elaborate on what is required?
A5. Response:
The purpose of field 9 on form 1 is to provide traceability from the FAI part to the router/planning used to manufacture the part. Any number or reference that provides that traceability is acceptable. (moved as A3, because of related topic)
A6. Question:
How should multiple pages of forms be numbered?
A6. Response:
Each form is to numbered independent of the others. The reason for three forms is that in some companies, different people or organizations fill out the different forms. It is acceptable to combine them.
A.7 Question:
Can an electronic signature be used in block 19 of form 1?
A7. Response:
An electronic signature is acceptable as long as it is acceptable within your Quality management system. The Quality management system must define electronic signature usage and control.
A8. Question:
Form 1 block 14 - What does baseline mean?
A8. Response:
Baseline means the last or previously "approved" FAI
A9. Question:
Form 2 box 7 - What should be entered in this field?
A9. Response:
Block 7 on form 2 is an optional field. Some companies have special codes for different processes and require an entry in this field. If you or your customer has no special code, leave the block blank or mark it N/A.
A10. Question:
If using electronic forms and have multiple pages, what fields are required on subsequent pages for each form?
A10. Response:
If you are using electronic forms, you can just add rows and additional sheets won't be required. If you are converting the forms to paper and need additional pages, follow the note at the top of the forms instructions: "NOTE: Fields 1-4 are repeated on all forms for convenience and traceability." Repeat fields 1-4 on each additional sheet.
A11. Question:
What is the purpose of block 14 on form 3?
A11. Response:
Form 3 Box 14 is an optional field for the user to add columns and information that are in addition to the requirements of the standard. Since it is optional and at your discretion, you may add columns and titles for those columns as you see fit. You may not rearrange or change any other portion of the form.
A12. Question:
What are "characteristic designators" for form 3 box 7?
A12. Response:
"Characteristic designators" are identified on engineering documents. Applicable design engineering also establishes definitions of those designators (including major/minor characteristics, key characteristics, structural characteristics, etc.). 9102 can not provide these definitions.
A13. Question:
Where are instructions for filling out the 9102 forms block by block?
A13. Response:
Instructions for completing the 9102 forms are contained within 9102, block by block. To comply with the standard, you should have an internal procedure defining your method. You can purchase 9102 in many languages from approved publishers like SAE, SJAC & ASD-STAN.
B. When to Perform an FAI
B1. Question:
When a lapse in production of 2 or more years occurs, iIs a Full or Partial FAI required?
B1. Response:
A Full FAI would be required. If you perform Partial FAI, you have to clarify the reason why you choose Partial FAI instead of Full FAI and record the reason on field No.14 of Form 1.
B2. Question:
After an initial FAI is complete, is a supplier required to complete partial FAI's when inspection frequency and methods are changed?
B2. Response:
FAI (Complete/Partial) would be required for the changed inspection when the tool listed on Form 3 field 10 is changed.
B3. Question:
If Manufacturing is moved from one location/facility to another, is a new FAI required?
B3. Response:
9102 - 5.3.2 states: A change in manufacturing source(s), process(es), inspection method(s), location of manufacture, tooling or materials, that can potentially affect fit, form or function. The key wording is "potentially affect fit, form or function". If you have good rationale supporting a position that the change doesn't "potentially affect fit, form or function" (and you can convince your customer) an updated FAI is not required. The move distance isn't a factor. Record the reason for Partial FAI on field No.14 of Form 1.
B4. Question:
Can an Assembly FAI be completed when one or more of the detail parts has not completed the FAI process?
B4. Response:
Unless the failed detail FAI affects the fit, form or function of the assembly, the Assembly FAI can be completed if it complies with 9102. The failed detail stands on its own, and it alone requires a FAI in accordance with paragraph 5.4.
B5. Question:
When engineering provides alternates (material, fasteners, etc) must the FAI be repeated when the alternate is used?
B5. Response:
At minimum, a partial FAI would be required when an alternate to that in the baseline FAI is used. This is to account for compliance to the engineering used requirement. How much more would depend on your assessment of the potential for affecting fit, form or function.
B6. Question:
When the supplier for a process specified by the drawing is changed, must the FAI be redone?
B6. Response:
Yes, you or your new supplier must perform a partial FAI covering the processes/characteristics moved. Moving to a new supplier provides the "Potential" to affect fit, form or function. Also see answer to question B3.
B7. Question:
If a baseline FAI exists but is to a system used prior to 9102, must the baseline FAI be updated to 9102 prior to performing a new partial FAI.
B7. Response:
9102 is not retroactive. A 9102 partial may be completed using the original completed baseline.
B8. Question:
In 5.3, there are conditions that require a new or partial FAI when a change occurs "that can potentially affect fit, form or function". How is this assessed?
B8. Response:
The only people able to evaluate these changes for "fit, form or function" are those knowing the product, the processes, the environment and knowing which problems occurred in the past (lessons learned). These people belong to the producer ("the organization" in 9100). You may also be influenced by your customer. Standards provide requirements but cannot provide methods for meeting the requirements.
C. Standard Catalog Hardware (SCH)
C1. Question:
Where is Standard Catalog Hardware (SCH) entered on the First Article Inspection Report (FAIR)?
C1. Response:
Standard Catalog Hardware (SCH), when used as purchased, is entered on form 1 using its catalog part number. When SCH is being used as a "make from" part or as raw material, it is entered on form 2 and the engineered part in which it is consumed is entered on form 1
C2. Question:
How is standard Catalog Hardware defined?
C2. Response:
Any item purchased from a catalog available to the public is considered Standard Catalog Hardware. 9102 A defines STANDARD CATALOG HARDWARE as: A part or material that conforms to an established industry or national authority published specification, having all characteristics identified by text description, National/Military Standard Drawing, or catalog item.
C3. Question:
Are company designed standards, like Boeing's BAC standards, considered Standard Catalog Hardware?
C3. Response:
No. Company designed standards are not available to the public and do not meet the definition. In your process you may conclude that the designer and/or the qualified manufacturer have FAI's for these standards on file. Company designed standards are entered on form 1. (see answer to Question C1).
D. Similar Parts
D1. Question:
Paragraph 5.3 states in part - FAI requirements may also be satisfied by previously approved FAI performed on identical characteristics of similar parts produced by identical means. How similar do the parts have to be?
D1. Response:
If a series of parts are made using the same processes and the parts are identical except for a few characteristics, a complete FAI can be done on one part and for the others, account for the unique characteristics. On form 3 for the "other parts", record the unique characteristics and refer back to the full FAI for the identical characteristics. The key is traceability and that all characteristics are accounted for.
E. Purchase Order Requirements
E1. Question:
Does 9102 allow inspection to Purchase Order requirements?
E1. Response:
Yes. The 9102 definition of drawing requirements indicates that the requirement may be invoked by purchasing document. 9102 Rev A definitions: "DRAWING REQUIREMENTS: Requirements of the drawing (including Parts Lists), specification, or purchasing document to which the article is to be made. These include any notes, specifications, and lower-level drawings invoked."
F. General Questions
F1. Question:
Are 9100 requirements duplicated in 9102?
F1. Response:
9102 requirements are not intended to duplicate 9100 requirements or test 9100 compliance. Each is a stand alone standard.
F2. Question:
What is the relationship between 9102 paragraph 5.3 and 9100 paragraph 7.5.1?
F2. Response:
9102 is one means of meeting 7.5.1 but is not mandated by 9100.
F3. Question:
What does ""First Production Run" mean?
F3. Response:
"First Production Run" means the first parts produced using production routing and tooling. Parts made prior to production, such as prototype parts cannot be used to satisfy the FAI requirement but using the FAI process for pre-production is not prohibited.
F4. Question:
How is a partial FAI documented?
F4. Response:
When performing a partial FAI, use from 1 and only the additional forms required to document the change. Also, reference the original FAI on form 1 on block 14. The original forms must never be altered. You may use attachments to any form if more space is needed.
F5. Question:
Can an FAI be completed when a non-conformance exists"?
F5. Response:
Paragraph 5.4 is clear. The non-conformance must be corrected and the correction verified and documented on new forms at the next production run before considering the FAI "completed".
F6. Question:
How are unique characteristic numbers established?
F6. Response:
Standards provide requirements and cannot provide methods. You may use any technique that provides traceability from the engineering to the FAI report.
