Does the AS9102 FAI requirement apply to wire assembly sub-kits?

N

n8vebeauty

#1
:bigwave: Hello,

I am fairly new at my company. I am concerned that we are not meeting the AS9102 FAI requirement for our wire assembly sub-kits.

When I started there were no FAI records for wire assembly sub-kits. So, we began completing them for all sub-kits, this has caused several jobs held for the completion of a FAI. (An example of each kit contains, Wire that has been cut and coded; Connectors; Contacts; Pins; Lacing Tape; Wire Bundle Identification Labels/Tapes). We are no longer completing FAI's for Wire Assembly Sub-Kits due to the amount of man power and $$$ needed.

Do sub-kits require first article inspection records? If so, any suggestions how we can satisfy the AS9102 requirement in a simple manner that will not cost our non-profit company a great amount of man power and money? My interpretation of AS9102 (clause 5.3) is that we can satisfy the requirement if there has been "previosly approved FAI performed on identical characteristics of similar parts produced by identical means". Meaning we can complete a FAI report for each family number of wire assembly sub-kits. Does anyone agree or disagree??? :thanks:
 
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A

andygr

#3
For those cases in subcomponents that have common sub-subcomponents:confused: You only have to perform the FAI on one PN that would then have the FAI recored number "assigned" to mutiple FAI at the next level up.
For a simple example you have a print showing that you cut an individal wire 10 inchs long. This wire ( fabricated to a print) is then used in 20 differant wire harness subassemblies. You only have to perform the FAI once on a single wire and assign the FAI report number for the wire 20 times at the next level in block 18 of the next level assembly FAI report.
:2cents:
 
#4
Which parts in the kit do you produce and which parts do you buy? Can any of the purchased parts be considered “standard catalog hardware”? Personally, I would focus on the differences between the kits regarding those parts that you produce and exempt any purchase standard catalog hardware. Then, when you do an FAI for a sub-kit, just inspect those components and characteristics that are unique to the kit. If you produce components that are common to all kits, just make reference to that FAIR within the FAIR’s for the individual kits. Clear as mud, eh?

BTW, it seems to me that a non-profit AS9100 certified company is a bit of a rarity. Do you have a customer that is requiring AS9102 compliance?
 
A

alspread

#5
Does the kit have a part number or other designation with any requirements? Or is it a compilation of other part numbers with their own requirements.

If the kit is has it's own part number with requirements, then yes, it does require a first article. These requirements (probably very little) should be listed on the form 3. All of the items in the kit would be listed on form 1 and reference all of their own unique first articles. Form 2 would probably be blank, assuming you perform no special processes or procure any raw material.

Imagine if you revised the kit to replace one item with another. You would then perform a delta first article, revising the form 1 and any affect this item change would of had on the requirements listed on form 3.

It sounds like a lot, but its probably more paperwork documentation than anything else. At least someone had to go through a structured approach to the change and consider the affects.

Good Luck
 
N

n8vebeauty

#6
Thanks to all that responded. This is my first time posting and I am impressed with your responses. It's still unclear how we should handle these.

BagerMan: Depending on our customer, all parts are supplied by the customer or are purchased by us. Yes, some of the parts that will become part of the kit are "standard catalog hardware". And yes. Our customer is Boeing, which requires us to be AS9102 complaint.

alspread: Yes, each kit has it’s own part number. The only thing we alter is the wire that we laser code and cut to length and imprint text on labels/tapes and include them with the kit. The issue is that there are so many different components (standard catalog hardware) required. It is taking a tremendous amount of time completing the FAI record.

Is it acceptable to attach the drawing to the FAI record and reference that page on the record itself? The drawing list all components needed for the kit.
 
A

alspread

#7
I don't know if it has been pointed out yet, but stabdard catalog hardware does not require a first article. So, if your delivered part number is a compliation of catalog hardware, then your first article is mostly paperwork to reconcile all of these items. You may have a few characteristics that you generate that you will have to account for and take care of.

I'm not sure I understand all of your constraints but, but if you want some help, or just want to talk about it, please contact me.
 
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