FLIR AS9100C Certification Implementation Plan

AS9102 AAerospace First Article Inspection RequirementAlan W. SpreadburyProperty of AS9100 SolutionsAll rights reservedUnauthorized duplication prohibited

Why do First Articles and why do an Aerospace first article?AS9100 rev B paragraph 8.2.4.2 First Article Inspection: The organizations system shall provide for a process for the inspection, verification, and documentation of a representative item from the first production run of a new part, or following a subsequent change that invalidates the previous first article inspection result.AS9100 rev C paragraph 7.5.1.1 Production Process VerificationThe organization shall use a representative item from the first production run of a new part or assembly to verify that the production processes, production documentation and tooling are capable of producing parts and assemblies that meet requirements. This process shall be repeated when changes occur that invalidate the original results (e.g. engineering changes, manufacturing process changes, tooling changes).AS9102 is widely accepted throughout the industry as the accepted first article guideline document/process.Property of AS9100 SolutionsAll rights reservedUnauthorized duplication prohibited

What a First Article is and what a First Article isnt.A First Article is NOT just an inspection of a part to make sure that it meets the print.In fact, in some circumstances, a part that does not meet the print (nonconforming) could be acceptable as a first article (well cover that later).You cant complete a First Article if all you have is the part and the drawing.A First Article is as much about the plan and the process used to produce the part as it is about the actual part itself (output of the process).Its all about making sure the plan works and that the output of the plan (part) has all of the requirements completed, accounted for, and acceptable.Make sure that the part is correct and complete using the plan, tools, etc that we intend to use to make all of the future parts.Parts made in the prototype shop are not, typically, representative of the plan (unless that is where they intend to make them all).During the development stage of a process a lot of things are going on that can invalidate the first article (fixtures changing, software changing, schedule demands, etc.). Its important to be cognizant of these changes and be assured that the changes are accounted for.Property of AS9100 SolutionsAll rights reservedUnauthorized duplication prohibited

Delta First ArticlesOnce invoked, the First Article requirement continues to apply even after initial compliance.The whole idea is to make sure the plan works and produces complete and acceptable product, therefore it is implicit that any changes to the plan will require a new, or partial, first article.First Article requirements may be satisfied by a partial First Article that addresses the differences between the current configuration and the approved configuration.Only the affected portions of the documentation need to be completed for a partial First Article.First Article requirements may also be satisfied by a previously approved First Article performed on identical characteristics of similar parts produced by similar means.Property of AS9100 SolutionsAll rights reservedUnauthorized duplication prohibited

Documentation (Forms 1, 2, & 3)AS9102 defines 3 separate forms to document the First ArticleOther forms are permitted, but they must include the same required information and have the same reference numbersForm 1: Part Number AccountabilityUsed to identify the part that is being First Article inspected and all associated subassemblies or detail part numbers.Form 1 is like the Bill of Material and lists all of the details and their respective First Article status.Form 2: Product Accountability-Raw Material, Specifications and Special Process(s), Functional TestingUsed if any material, special processes or functional testing are defined as a design requirement.Form 2 is where we document: all special processes with specifications, sources, and certifications, all raw material that is listed by specification only (i.e. not a part number or standard catalog item), and any required functional testing.Form 3: Characteristic Accountability, Verification and Compatibility EvaluationUsed to document every measurable design characteristic with a unique identifier, characteristic detail information, and measurement results.Form 3 does a lot of the heavy lifting and is where all of the inspection results are documented.Besides these forms, a complete First Article also needs all of the supporting and documentation evidence to support the manufacturing plan.Property of AS9100 SolutionsAll rights reservedUnauthorized duplication prohibited

Form 1 Example1. Part Number 2. Part Name3. Serial Number4. FAI Report NumberYour Part NumberYour Part nameRequired if SerializedOptional5. Part Revision Level6. Drawing Number7. Drawing revision level8. Additional ChangesRevision if applicableDrawing number if different than part numberDrawing rev if applicableECOs, ECN or number for any other change docs9. Manufacturing Process Reference10. Organization Name11. Supplier Code12. P.O. NumberNumber, rev, or identifier of the current processSource name, address, etc.Source code numberPurchase order number13. Detail FAI 14.Full FAI Partial FAI Baseline Part Number including revision levelAssembly FAI Reason for Partial FAI:if above part number is a detail part only, go to Field 19 if above part number is an assembly, go to the INDEX section below.INDEX of part numbers or sub-assembly numbers required to make the assembly noted above.15. Part Number16. Part Name17. Part Serial Number18. FAI Report NumberItem 1 Part NumberItem 1 Part NameItem 1 Serial NumberItem 1 First Article report NumberItem 2 Part NumberItem 2 Part NameItem 2 Serial NumberItem 2 First Article report Number

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Form 2 Example1. Part Number2 Part Name3. Serial Number4. FAI Report NumberYour Part NumberYour Part NameRequired if SerializedOptional5. Material or Process Name6. SpecificationNumber7. Code8. Special Process Supplier Code9. Customer Approval Verification(Yes/No/NA)10. Certificate of Conformance numberAluminum6061-T6OptionalNortheast AluminumHartford, CT112113N/A121267Chem FilmMIL-C-5541OptionalSouthwest CoatersGlobe, AZ131765Yes115116

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How can anyone possibly make sense of this!!!

-C--B- -C- .0010.750 .0022.0001.2501.500 .0020.750 .002 0.750 .002 thru+ .005 m -A- -B- m -C-

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What about these two?Basic dimensions are not recordable dimensions and as such do not require numberingProperty of AS9100 SolutionsAll rights reservedUnauthorized duplication prohibited

1. Part Number2. Part Name3. Serial Number4. FAI ReportYour Part NumberYour Part NameRequired if SerializedOptional if usedCharacteristic AccountabilityInspection / Test ResultsOptional Fields5. Char No.6. Reference Location 7. Characteristic Designator8. Requirement9. Results10. Designed Tooling11. Non-Conformance Number 14.[Insert columns, etc, as required by Organization or Customer]1Note 1Material: Aluminum 6061-T6Conforms2Note 2Remove all burrs and break all sharp edges .010 maxConforms3Note 3Finish: Chem film per Mil-C 5541Conforms4Note 4All diameters to be true position w/in .004 to relative datums unless otherwise specifiedSee table5Note 5Tolerances apply after platingConforms6Note 6

Form 3 ExampleMaterial specifications, be careful here. Stating conforms means that someone reviewed the certification and lab report against the material specification and confirmed ALL of the requirements (chemical, physical, heat treat, hardness, etc.). Assume nothing, verify everythingAttribute results would be acceptable. Its not feasible to measure variable data around every edge of every surface accurately to report variable results. But, conforms means that it was evaluated all over and not assumed.Be sure to read the specification and determine if any measurable characteristics need to be reported. Any measurable characteristics from the specification must be numbered and accounted for.This callout is a little different. The drawing has several holes and only this one true position requirement to tolerance the hole locations. This could be handle several ways: they could all be listed here, they could be listed later on with each of the diameter callouts, or as shown here included in an attached table. In either case a location result must be recorded for each diameter covered by this note.Depending on the thickness of the plating, the mfg plan may require some in-process dimensions to be modified to account for plating thickness.Property of AS9100 SolutionsAll rights reservedUnauthorized duplication prohibited

1. Part Number2. Part Name3. Serial Number4. FAI ReportYour Part NumberYour Part NameRequired if SerializedOptional if usedCharacteristic AccountabilityInspection / Test ResultsOptional Fields5. Char No.6. Reference Location 7. Characteristic Designator8. Requirement9. Results10. Designed Tooling11. Non-Conformance Number 14.[Insert columns, etc, as required by Organization or Customer]1Note 1Material: Aluminum 6061-T6Conforms2Note 2Remove all burrs and break all sharp edges .010 maxConforms3Note 3Finish: Chem film per Mil-C 5541Conforms4Note 4All diameters to be true position w/in .004 to relative datums unless otherwise specifiedSee table5Note 5Tolerances apply after platingConforms6Note 6

Form 3 ExampleWhat about Block 14? What is supposed to go here?The revision A version of AS9102 removed fields from this area to permit some flexibility by the organization or customers to specify additional fields. Some additions include:Measurement Method (Final)Measurement Method (in-process)Op No. GeneratedOp No. InspectedJustification for