FAI of Electronic Assembly Manufacturing

Sirixim

Registered
Hello everyone,

I hope this message finds you well. I am reaching out to seek some guidance and insights regarding FAI in the context of DIN EN 9102:2016-12 (equivalent to AS 9102 B). This is our first FAI and the goal is to streamline the process and minimize the effort invested in the inspection report.

Our company (< 15 employees) specializes in manufacturing electronic assemblies comprising enclosures, printed circuit boards, as well as passive and active electronic components. The majority of our components are standard catalog products, with the exception of the PCBs, which are of course manufactured to our specifications using a standard external process. Additionally, one of our active components has undergone an external modification (SnPb replating).
Here is the component list and kind of drawing for reference, I hope that helps for understanding:

/--- Top enclosure part
|
|- Inner PCB
| |- standard passive and active electronic components
| \- modified active component
|
\--- Bottom enclosure part with feed-through
|
\- Outer PCB for surface mounting the whole assembly

We are currently grappling with the determination of when to conduct an Assembly FAIR or Detail FAIR. Furthermore, we are uncertain about the specific components that should be documented in each form and the documents required (CoC, Detail FAIR...). I have already searched the forum and consulted the SCMH\FAI but need some more details.

Your expertise and experiences would be greatly appreciated in shedding light on these aspects. Thank you in advance for your valuable input.

Looking forward to your insights!
 

ARAK100

Starting to get Involved
Hi Sirixim, good question. For me AS9102 is straightforward, however as you may have seen here some find it a challenge.

The best advice I can give you at this stage is to employ a consultant or subject matter specialist to train you and your team. Preferably someone with solid FAA conformity experience. Do your research and choose wisely, you may find someone on here available.

You may need to source an experienced & trustworthy supplier quality engineer.

With my UM hat on I have come across far too many companies with non-compliant products being delivered in some cases years. This includes some of the big blue chip companies, mostly they had mismanaged this process and it causes a world of hurt. There seems to be a lot of individuals out there completing FAIRs who should be used elsewhere...
 

John Predmore

Trusted Information Resource
@Sirixim, in the USA, we are working with a new version of AS9102, revision C (June 2023).

You ask when to conduct Assembly versus Detail FAIR. The definitions in section 3 explain – an assembly is two or more parts you join together. A detail part is one you produce or have produced to your engineering specification. A detail part may have coating and that does not make it an assembly. A Commercial off-the-shelf part (COTS) is one sold to the public, not produced particularly for you. A COTS part which you modify becomes a detail part in the assembly list (per section 3.15). If you fabricate parts and then assemble them, you do one FAI report for each part you fabricate, which are then referenced on Form 1 when you prepare the assembly FAI report.

There may be a contractual mandate to consult your customer’s Supplier Quality Engineer early in the FAI planning stage, for guidance and oversight. AS9102B 4.2.c reinforces the need to consult with the customer SQE in the FAI planning stage. If you have little experience with FAI, you are better off to have agreement with the SQE on your approach before you spend a lot of time and submit a FAI report that is rejected. Good luck to you.
 

Sirixim

Registered
Hi Sirixim, good question. For me AS9102 is straightforward, however as you may have seen here some find it a challenge.

The best advice I can give you at this stage is to employ a consultant or subject matter specialist to train you and your team. Preferably someone with solid FAA conformity experience. Do your research and choose wisely, you may find someone on here available.

You may need to source an experienced & trustworthy supplier quality engineer.

With my UM hat on I have come across far too many companies with non-compliant products being delivered in some cases years. This includes some of the big blue chip companies, mostly they had mismanaged this process and it causes a world of hurt. There seems to be a lot of individuals out there completing FAIRs who should be used elsewhere...
Hello... Thanks for the advice and insight into your world, I completely agree...
 

Sirixim

Registered
@Sirixim, in the USA, we are working with a new version of AS9102, revision C (June 2023).
In Europe there still is only a draft of the new version, but some customers request the FAIR in accordance to the old revision.

You ask when to conduct Assembly versus Detail FAIR. The definitions in section 3 explain – an assembly is two or more parts you join together. A detail part is one you produce or have produced to your engineering specification. A detail part may have coating and that does not make it an assembly. A Commercial off-the-shelf part (COTS) is one sold to the public, not produced particularly for you. A COTS part which you modify becomes a detail part in the assembly list (per section 3.15). If you fabricate parts and then assemble them, you do one FAI report for each part you fabricate, which are then referenced on Form 1 when you prepare the assembly FAI report.

There may be a contractual mandate to consult your customer’s Supplier Quality Engineer early in the FAI planning stage, for guidance and oversight. AS9102B 4.2.c reinforces the need to consult with the customer SQE in the FAI planning stage. If you have little experience with FAI, you are better off to have agreement with the SQE on your approach before you spend a lot of time and submit a FAI report that is rejected. Good luck to you.

Many thanks for the advice, and again for the summary and clarification, that's how I understood it as well.
Some statements from quality engineers in our business area as well as posts in the forum (e.g. this one: what-are-the-fai-requirements-for-an-assembly-new-to-as9102 #4 (post-277457 by Jeff Frost), but from 2008) point to a simpler way of dealing with FAIRs. Also because the customer's Source Controlled Drawing only specifies form and function to the outside (which is checked accordingly in the FAIR), and does not describe the internal structure - hence my question in contrast to the example from mechanics in the SCMH (SCMH 3.2.3 FAI Scenario Example 1).

Am I right in thinking that a PCB always requires a FAIR detail?
The entire report should then be composed as follows?
Assembly FAIR of the whole Product
+ parts listed on form 1:
- SCIs (enclosure)
- Detail FAIR Outer PCB
- Assembly FAIR of populated Inner PCB
+parts listed on form 1:
- SCIs (standard passive and active electronic components)
- Detail FAIR Inner PCB
- Detail FAIR modified active components
+ solder etc. on form 2
+ solder etc. on form 2

Thank you again for your valuable input.
 

Sirixim

Registered
Oh, sorry... the formatting got mixed up:
  • Assembly FAIR of the whole Product
    • parts listed on form 1:
      - SCIs (enclosure)
      - Detail FAIR Outer PCB
      - Assembly FAIR of populated Inner PCB
      • parts listed on form 1:
        - SCIs (standard passive and active electronic components)
        - Detail FAIR Inner PCB
        - Detail FAIR modified active components
      • solder etc. on form 2
    • solder etc. on form 2
 
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