In efforts to improve quality, the International Aerospace Quality Group (IAQG) was founded in 1998 by the Aerospace industry. To provide direction, improve process and organize documentation, AS9102 standard was established for First Article Inspection (FAI) reports for the Aerospace industry.
What is AS9102?
AS9102 is a standard which highlights documentation requirements for First Article Inspection (FAI) reports intended for the Aerospace industry. The SAE Aerospace Standard (AS) released AS9102 standard for FAI reports, which was sponsored by IAQG and developed with the assistance of engineers and developers.
Purpose of AS9102
As defined by SAE, a FAI report is developed to provide objective evidence that all engineering design specification requirements are properly understood, accounted for, verified and documented. In efforts to enhance the FAI reports, AS9102 established documentation requirements. The intent of the standard as per SAE, is to provide a quality record via FAI report, of the supplier and customer for the following purposes:
- Review of accountability and planning
- Performing periodic surveillance and audits to verify conformance
- Evaluating root cause and corrective action for non-conformance
- Assist with problem investigations
Performing FAI – AS9102
A first article inspection is usually conducted with the first production run parts, defined in the AS9102 standard as, “the first group of one or more parts that are the result of a planned process designed to be used for future production of these same parts.” Prototype parts or parts developed using different methods are not considered first production run parts. The sample of parts is used for comparison, usually against a blue print. All specified measurements are taken into account and compared accordingly, to determine whether each dimension meets the specified requirements. All dimensions listed on the print must be accounted for the in the FAI report.
AS9102 Documentation and Application
The FAI reports subject to AS9102 standard require the submission of three distinct forms, assisting in the validation of new processes. The following are the form submission to be completed:
Form 1: Part number accountability – this form is used to review part numbers and associated FAI accordingly àassists in confirming dependability when introducing new parts
Form 2: Product accountability – used for raw materials, specifications, processes and functional tests & assists in repeatability during production
Form 3: Characteristic accountability – summarize design characteristics and assists in validating process
AS9102 Standard applies to assemblies, sub-assemblies and detail parts including castings and forgings, for all parties that are responsible for producing design characteristics of the part. There are three distinct elements that are noted for the AS9102 process for determining the requirement of submission:
- (R) – When R is listed in a given field on any of the forms, filling this field is required.
- (CR) – When CR is listed in a given field on any of the forms, filling this field is conditionally required.
- (O) – When O is listed in a given field on any of the forms, filling this field is optional.
Common reasons for FAI – AS9102 Rejection
Subject to IAQG, the following tend to be reasons why FAI reports may not always be accepted, or where common issues arise:
- Forms not completed properly
- Engineering requirements not understood
- FAI training & processes not defined or effective
- 9102 flow-down and oversight inconsistent or ineffective
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