Internationally Harmonized Aerospace Standards for First Article Inspection

1

• Internationally Harmonized Aerospace Standards
  for First Article Inspection
• AS9102, EN 9102, SJAC 9102
• Philippe Removille
• SNECMA Moteurs

2
What is AS9102- FAI Standard?

• International Standard for First Article
  inspection (FAI), co-published as
• AS9102 by SAE in Americas
• EN 9102 by AECMA in Europe
• SJAC 9102 by SJAC in Asia
• Developed by International Aerospace Quality
  Group
• Outlines the Documentation and Inspection
  Requirements When Performing First Article
  Inspection of Aerospace Components
• Published in August 2000

3
Motivation to Develop a Common Standard

• Rationale
• Aerospace Companies Have Somewhat Common
  Requirements for First Article Inspection (FAI)
• Documentation Requirements Differ
• Common Standard and Unified Requirements
• Eliminate Common Errors and Omissions
• Simplify FAI for Suppliers
• Focus on Product Quality Rather Than Documentation

4
Key Elements of AS/EN/SJAC 9102

• When to Perform FAI- Full And/or Delta FAI
  Specific Triggers
• What to Inspect Unified Requirements for
  Inspection
• How to Document- Common Format for Documenting
  FAI Results
• Delta FAI The FAI requirements may be
  satisfied by addressing differences between
  current configuration and prior approved
  configurations

5
When to Perform First Article Inspection?

• Full FAI
• New Part
• New Supplier or New Location of Manufacture
• Lapse in Production- Default 24 Months
• Delta FAI
• Drawing Change/ Revision Change
• Manufacturing Process Change Including NC
  Programs, Material Change, Sub-tier Change
• Change in Inspection Method, Inspection Plan
• Delta FAI The FAI requirements may be
  satisfied by addressing differences between
  current configuration and prior approved
  configurations

6
Applicability

• This Aerospace Standard Applies To
• Assemblies and All Levels of Parts Within an
  Assembly, Including Castings and Forgings
• Organizations That Are Responsible for Producing
  the Design Characteristics
• Suppliers and Their Subcontractors Who Produce
  Design Characteristics,
• Suppliers Responsible for Ensuring That
  Characteristics Conform to Customer Requirements.

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What is Included in First Article Inspection?

• Verification of All Design Characteristics
• Dimensional Verification Via Marked up (or
  Ballooned) Drawing That Correlates
  Characteristic Number From FAI to the Drawing.
• Part Marking Replication
• Material and Special Process Certifications
  (Including Operator Certification (e.g. NDT,
  Welding), If Required).
• Manufacturing Process Verifications
• Manufacturing Routing Sheets.
• Referenced Exhibits Supporting the FAI (e.g. CMM
  Data Printouts, Test Data, Acceptance Test
  Procedures, Process Certifications, etc.).
• Process Capability Studies, As Applicable.
• Gauge Correlation, As Applicable.
• Tooling Traceability, If Tooling Is Used to
  Verify Design Characteristics
• Nonconformance Resolutions

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Common Documentation Requirements

• Standardized Forms With Each Field Numerically
  Coded
• Form 1 Part Number Accountability
• Form 2 Product Accountability Raw Material,
  Special Process(s), Functional Testing
• Form 3 Characteristic Accountability,
  Verification and Compatibility Evaluation
• Forms May Be Generated Electronically, However,
  They Must Contain All the Required Information
• SAE Allows Free Reproduction of the Forms of This
  Standard for FAI.

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Current Status

• Problems with Implementation / Interpretation of
  9102 requirements
• Large amount of documentation / data being
  generated
• Process for review / approval of FAI between
  customer / supplier
• Need to Revisit 9102 definition of application at
  all levels of components and assemblies
• IAQG writing team to look at revision
• DOES NOT CHANGE CURRENT APPLICATION / CONTRACT
  REQUIREMENTS

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Where to Obtain AS9102 Copies?

• Society of Automotive Engineering (SAE)
• The document is available for purchase from SAE
  http//www.sae.org/servlets/techtrack?PROD_TYPSTD
  
• (please note that there are no spaces in this (or
  the other SAE) web address...they are
  underlines.)
• The current price for the standard is
• Mail 45 List Price (36 member price)
• Fax 75 List Price (60 member price)
• Download 59 List Price (47.20 member price)