When to do First Article Inspection - AS9102

[absolutefunk]

hi,

i'm an amateur in FAI....i went through the standard 9102....i've some doubt request for clarification ....
Clause 5.1 says '....on new production representative of the First Production Run....".
Now the situation is...I have an LRU (Line Replaceable Unit) comprising of both mech parts and electronic sub-asssemblies....it's in final design stage and due for first time production....our company plans to do a batch production of the same.
I'll definetly do the FAI for the first case of the production....if we start a second batch of production after say 3 or 6 months then again should i do FAI on the first case of second batch production ?
our product has the diversity...small amount of software and hardware change can be used in another aircraft...then should i do partial FAI or the full FAI on the same ?

 

[Jeff Frost]

You do an AS9102 when your customer contractually requires you to do so. You must list and show evidence that you have met all applicable requirements imposed on the drawing, applicable specifications and purchase order requirements.

Having misplaced my copy of AS9102 at the moment I believe it is only associated with hardware but I am working off of memory at the moment. The 9102 details when you must do a full or partial FAI of the product.

My advice would be read the standard in full, cover-to-cover, and do not skip the terms and definition section (yes we all have done this at one time or another) and if another standard is reference as a normative document also read that document.

Good Luck

 

[andygr]

Short answere for if a new FAI is needed for the 2nd production run is no as long as the original FAI is complete and acceptable.

You perform a complete FAI on the first production run .
If everthing checks out then you do not have to perform a new FAI except for things as defined in section 5.3 of the standard.

If you change a conector then you only have to perform a FAI on the change and anything that might be affected by it.

Software is part of the AS9102 requirements

 

[Big Jim]

I think the best answer is "it depends".

The need to repeat all or part of a first article inspection rests in if there have been any changes that would invalidate the last one.

One company I call on feels that for them and the product they make they need to repeat it every time they break set-up. Most circumstances would not require it just from a new set-up.

Other companies will run the same part for years without seeing the need to repeat the first article inspection.

In your case, is there anything that would invalidate the original first article inspection? Has anything changed since the last one? If there was a change, will it invalidate the last one?

We don't have enough information to answer that.

 

[Quality Chap]

It's important to keep in ones mind the "intend" for performing a FAI. According to AS9102 section 5.5.2 " Characteristic Accountability: The Organization shall verify every Design Characteristic during the FAI and record the result"
If there are any changes to the Design Characteristic (regardless how minor, hardware or software) the Organization has to have Accountability to demonstrate that the Product is manufactured according to Design.

Once this Accountability is established, any changes to this "process" requires Delta FAI to prove that the manufacturing Process is still in control (as per 5.3). The definition of change in "process" is subjective and should be defined according to Customer requirements. Change in "process" could be: change of material supplier, change in the manufacturing plan (major or minor), change in CNC program, etc.
In some cases it maybe easier or better to perform a Full FAI rather then a Delta since it maybe difficult to determine the changes that have occurred (Change in a 3D model).

I always ask myself if I have Full Design Characteristic Accountability or will I have to recall the part from my Customer (or Aircraft) if I can not demonstrate Accountability to my Customer (e.g. FAA or Boeing)? Keeping in mind the costs related to this omission.

Hope this helps.
Think Safe!!!
Quality Chap