Skill for first article inspection planning and execution per AS9102
The First Article Inspection skill provides capabilities for planning and executing first article inspections per AS9102, enabling comprehensive verification of manufacturing processes and design conformance.
Full FAI required when:
- New part number
- Design change affecting form/fit/function
- Change in manufacturing process/location
- Tooling inactive > 2 years
- Manufacturing process change
- Natural/human-made event affecting process
Allowed when:
- Minor design change
- Controlled process change
- Tooling modification
Only affected characteristics need re-inspection
Drawing Review
Characteristic Types
| Type | Symbol | Definition |
|---|---|---|
| Standard | None | Normal inspection |
| Critical | Triangle/diamond | Safety/function critical |
| Major | M in circle | Important for assembly |
| CTQ | Key symbol | Customer specified |
Ballooning requirements:
- Unique number for each characteristic
- Sequential numbering preferred
- Reference to original dimension
- Include notes and specifications
- Mark special characteristics
Required fields:
- Part number and name
- Part revision level
- Drawing number and revision
- Organization name and code
- FAI report number
- Signature and date
- Part serial number
- FAI reason (new/change)
Material verification:
- Material specification
- Raw material supplier
- Material certifications
- Heat/lot traceability
Process verification:
- Special processes (heat treat, plating, NDT)
- Process specification
- Processor certification
- Process parameters
Functional testing:
- Test requirements
- Test results
- Pass/fail status
For each characteristic:
- Characteristic number (balloon)
- Reference location (drawing zone)
- Characteristic designator (if special)
- Requirement (nominal and tolerance)
- Results (actual value)
- Designed tooling (Y/N)
- Non-conformance number (if applicable)
| Tolerance | Accuracy Required | Typical Method |
|---|---|---|
| +/- 0.5 mm | 0.05 mm | Caliper |
| +/- 0.1 mm | 0.01 mm | Micrometer |
| +/- 0.025 mm | 0.002 mm | CMM |
| +/- 0.005 mm | 0.0005 mm | Precision CMM |
| Characteristic | Measurement Method |
|---|---|
| Flatness | CMM scan, optical flat |
| Perpendicularity | CMM, square fixture |
| Position | CMM, functional gage |
| Concentricity | CMM, roundness tester |
| Runout | V-blocks + indicator |
| Profile | CMM, optical comparator |
CMM measurement strategy:
1. Establish datum reference frame
2. Measure datum features first
3. Measure located features
4. Use appropriate probe compensation
5. Verify measurement uncertainty
6. Document probe configuration
| Disposition | Application | Authority |
|---|---|---|
| Use As-Is | Minor deviation, no impact | Engineering |
| Rework | Can be brought to spec | Quality |
| Repair | Alternate method to restore | Engineering |
| Scrap | Cannot be made conforming | Quality |
| Return to Supplier | Vendor issue | Purchasing |
Non-conformance record:
- NC number
- Characteristic affected
- Requirement
- Actual condition
- Root cause analysis
- Corrective action
- Disposition and approval
Approval workflow:
1. Inspector completes inspection
2. Quality review forms
3. Engineering review (if NC exists)
4. Quality approval signature
5. Customer approval (if required)
6. Archive and distribution
{
"part_info": {
"part_number": "string",
"revision": "string",
"description": "string",
"drawing_number": "string"
},
"fai_type": "full|partial|delta",
"trigger": "new_part|design_change|process_change|other",
"previous_fai": "string (if partial/delta)",
"special_requirements": {
"customer_approval": "boolean",
"special_processes": "array"
}
}
{
"fai_plan": {
"fai_number": "string",
"balloon_drawing": "file reference",
"characteristic_count": "number",
"measurement_methods": "array"
},
"fai_forms": {
"form_1": "document reference",
"form_2": "document reference",
"form_3": "document reference"
},
"results_summary": {
"total_characteristics": "number",
"conforming": "number",
"non_conforming": "number",
"nc_numbers": "array"
},
"approval_status": {
"status": "approved|conditional|rejected",
"conditions": "array (if conditional)",
"approved_by": "string",
"date": "date"
}
}