A first article inspection (FAI) is a design verification and design history file and a formal method of providing a reported measurement for a given manufacturing process. Both the supplier and purchaser perform the First Article on the ordered product. The evaluation method consists of comparing supplier and purchasers results from measuring the properties and geometry of an initial sample item against given specifications, for example a drawing.
Items to be checked by the supplier and purchaser FAI are wide and varied and may include distances between edges, positions of holes, diameters and shapes of holes, weight, density, stiffness, color or surface finish. Despite the name, the inspected article may not necessarily be the 'first' produced, but a random sample of 3 parts from the first lot provided to the purchaser. First article inspection is typically called for in a purchase order contract between the producer and buyer of some manufactured article, both perform the First Article inspection to ensure that the production process reliably produces what is intended, design verification of the print, and is part of the purchasing, and design control requirements.
Depending on the inspection capability, the type of product and the governing specification, a first article inspection may be conducted by an approved 2nd party supplier that is a dimensional metrology laboratory using a variety of calibrated tools such as coordinate-measuring machines (CMM), cmm/vision systems and programmable 3-axis measurement systems. First article inspections are commonplace for military subcontractors.
The protocol is, however, required for design verification, purchasing controls, from the supplier and the purchasers receiving inspection in many non-military industries, particularly aerospace, automotive and medical manufacturing. Manufacturers delivering products to government bodies or in regulated industries such as medical device must typically meet more stringent requirements than international requirements.
If there are special test requirements outside of the suppliers capability then test maybe subcontracted to a 3rd party accredited testing lab. Medical Device 21 CFR 820 Some general standards which apply to first article inspection are produced by the ISO (International Organization for Standardization), the IEC (International Electrotechnical Commission), the IAF (International Accreditation Forum) the ILAC (International Laboratory Accreditation Cooperation) however more stringent regulations may apply in the U.
S. in regulated industries. First article inspection forms part of a more comprehensive quality management system which is able to assure continuing conformance with applicable specifications. It is required to be performed by the supplier prior to delivery and the purchaser at receiving as part of the supplier approval process, design verification, and purchasing controls in 21 CFR 820. Type To verify the accuracy of drawings and ensure that they reflect any changes made to parts design during the prototype design.
To verify the production process in every parameter, rather than just concentrating on “critical” dimensions. To verify all tooling used to produce a part, to ensure that it is capable of producing parts to specifications. To verify the ability of the manufacturer to meet the needs of production. Enhanced first article inspections With the use of modern computers in the manufacturing environment, first article inspections are no longer being used with the traditional three form layout on paper but instead recorded digitally and stored on servers for easy access and organization.
Recording the first article digitally eliminates errors with the help of software that keeps track of the FAIs and generates reports immediately after successful completion of an FAI. By industry Aviation and aerospace AS9102 is the Aerospace Standard for First Article Inspection Requirements (like SJAC9102 for Japanese Aerospace standard, and EN9102 for Industry quality standard). First article inspection can be documented on Forms 1 (Part Number Accountability), 2 (Product Accountability), and 3 (Characteristic Accountability, Verification and Compatibility Evaluation).
Form 3 may often be referred to 3D data models or 2D technical data sheets (also called balooned drawings), where the characterics are uniquely identified. Some software solutions insert a grid (like in a chessboard, with parallel lines, both horizontal and vertical) on the 2D data sheets, so that the measured characteristics may be uniquely identified by the part number and the related revision number of the 2D data sheet, and the relative position of the characteristics on it (e.
g.: in quarter A2, C10). In a 3D data model, the point of each measured characteristics is uniquely identified by three numbers: the coordinate vector, that gives his Triangulation in a 3D space. In general this is the aerospace equivalent of the automotive PPAP, Production Part Approval Process. PPAP requires larger quantity of components than would be typically manufactured for aircraft components.
Many large aerospace companies including Bombardier Aerospace, and Spirit AeroSystems have recently switched to enhanced first article inspections in order to keep track of the numerous first articles received by different companies within the company's supply chain. Suppliers to these companies, including Machine Shops, are also turning to enhanced first article inspections to improve manufacturing productivity and throughput by eliminating the manual process of creating FAIs.
 Customers who perform such inspections are recommended to identify this in the contract, and to use specific forms to document the results. References ^ First Article and Production Lot Testing Defense Contract Management Agency ^ Cappels, Thomas M. (1999). Financially focused quality. CRC Press. p. 108. ISBN 978-1-57444-248-9. Retrieved 15 March 2010. ^ Bowman, Daniel R.; Daniel R. Bowman (1996).
Procurement specification guidelines for mass transit vehicle window glazing. Transportation Research Board. p. 37. ISBN 978-0-309-05720-2. Retrieved 15 March 2010. ^ Pennella, C. Robert (2006). Managing Contract Quality Requirements. American Society for Quality. pp. 48–49. ISBN 978-0-87389-694-8. Retrieved 15 March 2010. External links Modern Machine Shop - Software Speeds Inspection Documentation Quality Magazine - Enhanced First Article Inspection Quality Magazine - Case Study: Take the Heat Out of the Problem CADALYST - InspectionXpert First Article 2010 Quality Digest - DISCUS Annotating first article inspection requirements Retrieved from "https://en.
wikipedia.org/w/index.php?title=First_article_inspection&oldid=815430354"See Also: Random First Line Generator
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Quickly create your ballooned drawings and FAI forms Aerospace, automotive, and medical are industries that are governed by strict requirements for manufacturing and quality assurance. All three industries require a First Article Inspection (FAI) as part of the detailed verification of production results versus product design before on-going manufacturing begins. Since the FAI involves a complete review of all part characteristics, it involves manufacturing engineers and quality engineers reviewing the Technical Data Package (TDP – part drawings, specifications, etc).
This is a very laborious, time-consuming, and error-prone effort. In fact, it is not uncommon for a company to expend 24 hours of labor to complete a single FAI. Learn more about FAI Here. The DISCUS family of products is specifically designed to enable you to organize the TDP and capture those part characteristics much more efficiently for the setup of the FAI. DISCUS has a panel for analyzing and extracting characteristics from the drawing or model, as well as from the specifications.
DISCUS generates the list of part-specific characteristics and creates associated ballooned illustrations. The DISCUS solution for FAI enables compliance with AS9102, PPAP, or Part 820. Naturally, the FAI solution starts with DISCUS Desktop, but it can be further configured to meet your specific business situation. For example, if you are providing reports to a customer’s web-based FAI system, you may be interested in adding DISCUS Results to enable your team to be more efficient.
If you have customers that are sharing CAD models, you may be more interested in adding the DISCUS 3D Data Management module to maximize your FAI productivity. The use of DISCUS for FAI has reduced the time involved for FAI by upwards of 50%. The most common solutions for FAI consist of selected DISCUS modules packaged into bundles: 2D FAI Suite – DISCUS Desktop with DISCUS OCR and DISCUS Results add-ons 3D FAI Suite – DISCUS Desktop with DISCUS 3D add-ons You can learn more about the specific DISCUS modules on the Products page, and you can review the pricing for the discounted bundles on the Pricing page.