FAI Finding Prevention

TacitBlue

Involved In Discussions
#1
We have had a couple findings from our external auditor for FAIs. We cannot receive another or we can lose our certification.

Our current FA logging setup is really lacking and our internal auditors always have the hardest time locating records. We obviously need to improve there. We also need to improve our inspections.

My question is, how can we improve in these areas to avoid findings? What has worked for your company in streamlining your FAI process?
 
Elsmar Forum Sponsor

Tidge

Trusted Information Resource
#2
I am not in the aviation field, so I apologize if this question is either "too fundamental" or otherwise "off base".

Are the First Article Inspections specific to some sort of engineering change, or do these refer to a more general incoming inspection activity?

If the FAI are always tied to engineering changes: I can imagine that there are opportunities to procedurally require the FAI results be attached to the record of the specific engineering change that motivated the FAI. (I am imagining that the records of engineering changes are well maintained!)
 

Mike S.

Happy to be Alive
Trusted Information Resource
#3
Lose your cert (to what standard?) over FAI findings? Did the registrar tell you this? Seems extreme.

Are you doing AS9102 FAIRs or something else?

Are the errors mostly paperwork/logging errors, wrong measurements, measurements not done, or what? Can you Pareto the defect types?

I guess I don't understand the problem well enough to try to give advice.
 

John Predmore

Trusted Information Resource
#5
One problem @TacitBlue mentioned is finding records.

One tip I can share is to create a folder on your computer (or network drive) for each project/part-number. Everything you look at in the course of preparing the FAI, put an archival copy in that folder - material certs, supplier CoAs, work instructions, etc. - you can use subfolders as necessary to organize for retrieval. Better yet, save as PDF so there is less chance your archival copy is modified or confused with the original file. Computer storage is cheap, certainly cheaper than an hour spent searching for a file in various places, definitely cheaper than an audit finding. This save-a-copy-of everything discipline makes you look totally prepared in an audit situation, and protects you against deletions, edits or revisions to the source documents between when you first looked and when the FAI is reviewed.
 
Thread starter Similar threads Forum Replies Date
L FAI Charge General Auditing Discussions 3
D "FAI" Requirements/Process for New Supplier Materials Design and Development of Products and Processes 3
H FAI Requirement After Moving CNC Machine? AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 15
DuncanGibbons Pre FAI production terminology AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 4
NDesouza Is my Partial FAI an Assembly or Detail? AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 3
R FAI & P.O. Requirements AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 21
M Weld Symbol--Bubble Drawings for FAI Document Control Systems, Procedures, Forms and Templates 4
briteme4 Customer Requests FAI on Tooling Fixture AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 3
F Circuit board FAI reports- How do you folks deal with these? Inspection, Prints (Drawings), Testing, Sampling and Related Topics 3
R AS9102 FAI Change in Material / Process Supplier AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 4
NDesouza COTS Items CoC for FAI Documentation AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 12
NDesouza FAI Due Date Calculator AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 4
Q Change the shape of the raw material FAI AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 5
P FAI Ballooning ASME Y14.5 AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 5
Q Full or Partial FAI? AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 5
D Partial FAI - AS9102 - One single drawing has 10 part numbers AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 5
M AS9102B Detail Part/Assembly FAI Form 1 box 13; AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 2
A When there is a 2 year lapse in production, is a full FAI required? AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 7
M When is FAI required? AS9100 8.5.1.3 and 8.4.3 requirements AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 10
M AS9102 FAI Report formats - Boxes in form 1, 2, 3 of AS9102 AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 4
A AS9100D FAI requirements needed? AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 3
R AS9100 DELTA FAI - Sub-supplier for plating changed AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 2
B FAI and ANSI Y14.5 Trailing Zeros and Print Tolerances Manufacturing and Related Processes 3
D AS9102 - Assembly FAI for Use As Is or Repaired Parts AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 6
A AS9102 Delta FAI Require after Rework stock item from stock AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 1
B AS9102 - Completing Partial FAI's for Baseline Part Numbers AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 1
K First Article Inspection (FAI) - Equipment used - Dimensions vs. Go/No-Go ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 7
E AS9102 FAI - What makes a COTS modified? (PCB assemblies) AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 11
C Is a First Article Inspection (FAI) Procedure required by ISO 13485? ISO 13485:2016 - Medical Device Quality Management Systems 3
B AS9102 FAI & Lower Level Drawings - How should we perform the FAI? AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 1
P AS9102 full FAl or a partial FAI after production inactivity period AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 3
M FAI AS9102 - What does a First Article Inspection cover? AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 11
ScottK Statistical basis for 30 pieces for FAI 21 CFR Part 820 - US FDA Quality System Regulations (QSR) 7
U Whether First Article Inspection Report- FAI is mandatory for regular Human Factors and Ergonomics in Engineering 4
D FAI. Form 2, process or functional test? AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 0
G FAI Objective Evidence AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 3
M FAI Requirements of Detail and Assembly AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 4
O AS9102 FAI report Forms 1-3 Document Control Systems, Procedures, Forms and Templates 6
J FAI per AS9102 affecting Fit, Form, Function AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 6
R AS9100 FAI - First Article Inspection to a prior Customers PO AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 7
R AS9102 FAI with No Drawings Supplied AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 1
G FAI (First Article Inspection) Responsibility - QC or Engineering? ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 3
APHX02 AS9102 FAI Requirements that pertain to a Dimension 'delta' AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 3
R FAI (First Article Inspection) on source-controlled parts AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 5
K FAI (First Article Inspection) vs PPAP (Production Part Approval Process) APQP and PPAP 16
W Am I allowed to ship parts without FAI approval from the customer? AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 6
G Is it mandatory to record all processes in form 2 of AS9102 FAI report AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 4
T FAI (First Article Inspection) of Large Assemblies/Tooling after move to new building AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 12
W Certification on AS9100C - FAI or PPAP? Project Management or APQP? AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 11
Q FAI IAW AS9102 - First Article Inspection Documentation Question AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 20

Similar threads

Top Bottom