Internationally Harmonized Aerospace Internationally Harmonized Aerospace Standards for First Article InspectionStandards for First Article Inspection

AS9102, EN 9102, SJAC 9102AS9102, EN 9102, SJAC 9102

Philippe RemovillePhilippe Removille

SNECMA MoteursSNECMA Moteurs

What is AS9102- FAI Standard?What is AS9102- FAI Standard?

International Standard for First Article inspection International Standard for First Article inspection (FAI), co-published as(FAI), co-published as– AS9102 by SAE in AmericasAS9102 by SAE in Americas– EN 9102 by AECMA in EuropeEN 9102 by AECMA in Europe– SJAC 9102 by SJAC in AsiaSJAC 9102 by SJAC in Asia

Developed by International Aerospace Quality Developed by International Aerospace Quality Group Group

Outlines the Documentation and Inspection Outlines the Documentation and Inspection Requirements When Performing First Article Requirements When Performing First Article Inspection of Aerospace ComponentsInspection of Aerospace Components

Published in August 2000Published in August 2000

Motivation to Develop a Common Motivation to Develop a Common StandardStandard

RationaleRationale– Aerospace Companies Have Somewhat Common Aerospace Companies Have Somewhat Common

Requirements for First Article Inspection (FAI)Requirements for First Article Inspection (FAI)– Documentation Requirements DifferDocumentation Requirements Differ

Common Standard and Unified Requirements:Common Standard and Unified Requirements:– Eliminate Common Errors and OmissionsEliminate Common Errors and Omissions– Simplify FAI for Suppliers Simplify FAI for Suppliers – Focus on Product Quality Rather Than Focus on Product Quality Rather Than

DocumentationDocumentation

Key Elements of AS/EN/SJAC Key Elements of AS/EN/SJAC 91029102

When to Perform FAI- Full And/or “Delta When to Perform FAI- Full And/or “Delta ** ” FAI: Specific Triggers ” FAI: Specific Triggers

What to Inspect: Unified Requirements What to Inspect: Unified Requirements for Inspectionfor Inspection

How to Document- Common Format for How to Document- Common Format for Documenting FAI ResultsDocumenting FAI Results

* * Delta FAI: Delta FAI: The FAI requirements may be satisfied by addressing differences The FAI requirements may be satisfied by addressing differences between current configuration and prior approved configurationsbetween current configuration and prior approved configurations

When to Perform First Article When to Perform First Article Inspection?Inspection?

Full FAIFull FAI– New PartNew Part– New Supplier or New Location of ManufactureNew Supplier or New Location of Manufacture– Lapse in Production- Default: 24 MonthsLapse in Production- Default: 24 Months

DeltaDelta** FAI FAI– Drawing Change/ Revision ChangeDrawing Change/ Revision Change– Manufacturing Process Change: Including NC Manufacturing Process Change: Including NC

Programs, Material Change, Sub-tier ChangePrograms, Material Change, Sub-tier Change– Change in Inspection Method, Inspection PlanChange in Inspection Method, Inspection Plan

* * Delta FAI: Delta FAI: The FAI requirements may be satisfied by addressing differences between The FAI requirements may be satisfied by addressing differences between current configuration and prior approved configurationscurrent configuration and prior approved configurations

ApplicabilityApplicability

This Aerospace Standard Applies ToThis Aerospace Standard Applies To Assemblies and All Levels of Parts Within an Assemblies and All Levels of Parts Within an

Assembly, Including Castings and ForgingsAssembly, Including Castings and Forgings Organizations That Are Responsible for Organizations That Are Responsible for

Producing the Design CharacteristicsProducing the Design Characteristics– Suppliers and Their Subcontractors Who Suppliers and Their Subcontractors Who

Produce Design Characteristics, Produce Design Characteristics, – Suppliers Responsible for Ensuring That Suppliers Responsible for Ensuring That

Characteristics Conform to Customer Characteristics Conform to Customer Requirements.Requirements.

What is Included in First Article What is Included in First Article Inspection?Inspection?

Verification of All Design Characteristics:Verification of All Design Characteristics:– Dimensional Verification Via Marked up (or “Ballooned”) Drawing That Dimensional Verification Via Marked up (or “Ballooned”) Drawing That

Correlates Characteristic Number From FAI to the Drawing.Correlates Characteristic Number From FAI to the Drawing.– Part Marking ReplicationPart Marking Replication

Material and Special Process Certifications (Including Material and Special Process Certifications (Including Operator Certification (e.g. NDT, Welding), If Required).Operator Certification (e.g. NDT, Welding), If Required).

Manufacturing Process VerificationsManufacturing Process Verifications– Manufacturing Routing Sheets.Manufacturing Routing Sheets.– Referenced Exhibits Supporting the FAI (e.g. CMM Data Printouts, Test Data, Referenced Exhibits Supporting the FAI (e.g. CMM Data Printouts, Test Data,

Acceptance Test Procedures, Process Certifications, etc.). Acceptance Test Procedures, Process Certifications, etc.). – Process Capability Studies, As Applicable.Process Capability Studies, As Applicable.– Gauge Correlation, As Applicable.Gauge Correlation, As Applicable.– Tooling Traceability, If Tooling Is Used to Verify Design CharacteristicsTooling Traceability, If Tooling Is Used to Verify Design Characteristics

Nonconformance ResolutionsNonconformance Resolutions

Common Documentation Common Documentation RequirementsRequirements

Standardized Forms With Each Field Numerically Standardized Forms With Each Field Numerically CodedCoded Form 1: Part Number Accountability Form 1: Part Number Accountability Form 2: Product Accountability – Raw Material, Special Process(s), Form 2: Product Accountability – Raw Material, Special Process(s),

Functional TestingFunctional Testing Form 3: Characteristic Accountability, Verification and Form 3: Characteristic Accountability, Verification and

Compatibility EvaluationCompatibility Evaluation

Forms May Be Generated Electronically, Forms May Be Generated Electronically, However, They Must Contain All the Required However, They Must Contain All the Required Information Information

SAE Allows Free Reproduction of the Forms of SAE Allows Free Reproduction of the Forms of This Standard for FAI. This Standard for FAI.

Current StatusCurrent Status

Problems with Implementation / Problems with Implementation / Interpretation of 9102 requirementsInterpretation of 9102 requirements– Large amount of documentation / data being Large amount of documentation / data being

generatedgenerated– Process for review / approval of FAI between Process for review / approval of FAI between

customer / suppliercustomer / supplier Need to Revisit 9102 definition of Need to Revisit 9102 definition of

application at all levels of components and application at all levels of components and assembliesassemblies

IAQG writing team to look at revisionIAQG writing team to look at revision DOES NOT CHANGE CURRENT DOES NOT CHANGE CURRENT

APPLICATION / CONTRACT REQUIREMENTSAPPLICATION / CONTRACT REQUIREMENTS

Where to Obtain AS9102 Where to Obtain AS9102 Copies?Copies?

Society of Automotive Engineering (SAE)Society of Automotive Engineering (SAE)– The document is available for purchase from The document is available for purchase from

SAE http://www.sae.org/servlets/techtrack?SAE http://www.sae.org/servlets/techtrack?PROD_TYP=STD PROD_TYP=STD

(please note that there are no spaces in this (or the other SAE) web address...they (please note that there are no spaces in this (or the other SAE) web address...they are underlines.)are underlines.)

– The current price for the standard is :The current price for the standard is : Mail: $45 List Price ($36 member price)Mail: $45 List Price ($36 member price) Fax: $75 List Price ($60 member price)Fax: $75 List Price ($60 member price) Download: $59 List Price ($47.20 member price)Download: $59 List Price ($47.20 member price)