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TELEPHONICS SUPPLIER QUALITY MANAGEMENT

AS9102 FIRST ARTICLE INSPECTION GUIDELINES

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BACKGROUND
Telephonics customer base is increasingly requiring by contract that Telephonics provide full AS9102 First Article documentation. In order to comply with this requirement Telephonics must pass the same requirement to our suppliers, to be certain of obtaining all required certifications, test reports and other documentation to pass on to our customers. In the same manner Telephonics suppliers must pass the requirement to their suppliers to be certain of obtaining the needed documents for their AS9102 First Article.

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WHY WE ARE HERE

The following presentation is an attempt to identify and offer an explanation of the requirements of the AS9102 specification. Often at first glance the requirements of the specification look somewhat onerous and maybe a little scary. It is hoped that this presentation will offer clarification and a better understanding of how to approach the First Article process.

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AS9102 First Article Inspection

Elements of this presentation
Quality Clause 2.5.1
Quality Clause 6.9 SOW requirements Definitions Evaluation Activities

Partial or re-accomplishment of the FAI

Forms
Form 1 Form 2 Form 3

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Quality Clause 2.5.1

Quality Clause 2.5.1
2.5.1 SAE AS9102, First Article Inspection (FAI) is required prior to the first delivery of the product baseline configuration. FAI shall be performed on the first unit/assembly produced and shall be performed in accordance with all the requirements defined SAE AS9102 (latest revision). Telephonics Quality Assurance shall review the FAI during the source inspection of the first Production unit(s). Partial and/ or re-accomplishment of the FAI shall be required as per specification. Telephonics will either review FAI activity, subsequent to the accepted baseline FAI, during the applicable Source Inspection or the FAI report will be sent to Telephonics for review. Telephonics Quality Assurance reserves the right to perform some or all aspects of the FAI activities at the suppliers or Telephonics facilities. Telephonics disclaims responsibility for material delivered prior to first article approval. . (Note: QC Clause 2. and 6.9 are also invoked in conjunction with this clause.)
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Quality Clause 2.5.1

Clause includes Quality Clause 2 (Source Inspection) and Quality Clause 6.9 (AS9102 Documentation).
Reference to QC 2 requires on-site inspection and acceptance by Telephonics representative.
General requirement is for SQM personnel to conduct the inspection. First Article Inspection shall be identified on the Source Request.

QC 6.9 addresses documentation, requires AS9102 documentation to accompany the shipment.

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Quality Clause 6.9

Quality Clause 6.9
6.9 SAE AS9102, First Article Inspection (FAI) data is required on this Purchase Order. A copy of the First Article Inspection Report, associated drawings and all special process and finish certifications of all lower level detail parts must accompany the first shipment of unit/assemblies. Telephonics preferred method of FAI report transmittal is by way of electronic media. Telephonics disclaims responsibility for material delivered prior to first article approval.

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Quality Clause 6.9

Requires AS9102 documentation to accompany the shipment. Does not require on-site inspection and acceptance. Refers to the preference for documentation to be in electronic format but does not make this a requirement. Documentation to include
Drawings Special process certifications Finish certifications Addresses the requirement for lower level components

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AS9102 as a SOW Requirement

AS9102 First Article Inspection may be called out in the applicable Statement of Work.
Normally found in the Quality Assurance paragraphs. Hardware Quality Engineering should identify this requirement and address it through the applicable Quality Clause.
Quality Clause 8, Statement of Work, makes this a requirement even if QC 2.5.1 or QC6.9 are not referenced on the contract. SOW may be called out in the block text of the contract making this a contractual requirement.

The SOW will identify the requirements, whether on-site or documentation only.

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AS9102 Revision A
Current revision is A, rumor exists that revision B is coming. Applies to the first production run parts. Contains definitions applicable to completion of the forms. Allows the use of other forms, however
Forms other than those contained in the Appendix may be used, however they must contain all Required and Conditionally Required information and have the same field reference numbers.

Contains instructions for completion of the forms.

Contains the required form in the Appendix.

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AS9102 Definitions
The following are included in paragraph 3 of AS9102 and are referred to here to address historic supplier questions and discrepancies.
DRAWING REQUIREMENTS: Requirements of the drawing (including parts lists), specification or purchasing document to which the article is to be made. These include any notes, specifications and lower level drawings invoked.
All notes must be addressed All dimensions must be addressed

All lower level drawings must be addressed in the same manner

FIRST PRODUCTION RUN PARTS: Prototype parts, or parts built using methods different from those intended for the normal production process, shall not be considered as part of the first production run.

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AS9201 Definitions
STANDARD CATALOG HARDWARE: A part or material that conforms to an established industry or national authority published specification, having all characteristics identified by text description, National/Military Standard Drawing, or catalog item.
Certificate of Conformance required (Form 2, Field 10).

ATTRIBUTE DATA: A result from a characteristic or property that is appraised only as to whether it does or does not conform to a given requirement (for example, go/no go, accept/reject, pass/fail etc.). VARIABLES DATA: Quantitative measurements taken on a continuous scale. For example the diameter of a cylinder or the gap between mating parts.

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Evaluation Activities
The organization should conduct the following activities in support of the FAI.
1. Review documentation for the manufacturing process to ensure all operations are complete as planned.
Routing sheets, quality plans, work instructions etc.

2.

Review reference exhibits supporting the FAI for compliance.

Inspection data, test data, Acceptance Test Procedures etc.

3.

Review nonconformance documentation (if any) for completeness.

AS9131 may be used as a guidance.

4.

Review material certifications for compliance.

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Evaluation Activities
5. Verify that approved Special Process sources are used and that the manufacturing/routing document calls out the correct specification. Verify that Key Characteristic requirements have been met.
See AS9103 for guidance.

6.

7. Verify part specific gages and/or tooling are qualified and traceable as applicable. 8. Verify that every design characteristic requirement is accounted for, uniquely identified and has inspection results traceable to each unique identifier.

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Partial or Re-Accomplishment of FAI

The FAI requirement, once invoked, shall continue to apply even after initial compliance. The organization shall perform a full or partial FAI when there is1. A change in design affecting form, fit or function. 2. A change in manufacturing source, process, inspection method, location of manufacture tooling or materials. 3. A change in numerical control program or translation to another media. 4. A natural or man-made event which may adversely affect the manufacturing process. 5. A lapse in production for two years or as specified by the customer.

The FAI is not complete until the organization closes all non-conformances affecting the part and implements the corrective actions. The organization shall re-do the FAI for those affected characteristics.
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AS 9102 Forms
The Appendix of the Standard contains the forms that comply with the documentation requirements. Each field of the forms is designated with a unique reference number. Each field is also identified as:
(R) Required, mandatory information (CR) Conditionally Required, must be completed when there exists a customer requirement. (O) Optional, this field is provided for convenience.

Forms other than those contained in the Appendix may be used, however they must contain all Required and Conditionally Required information and have the same field numbers.

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AS9102 Forms
The organization shall verify every Design Characteristic during FAI and record the results. Every Design Characteristic shall have its own unique identifier. Reference characteristics may be omitted from the FAI. Characteristics not measurable in the final product shall be verified during the manufacturing process (as long as they are not affected by subsequent operations) or by destructive means. Characteristics verified at the detail level may be referenced in the assembly level FAIR.

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AS9102 Form 1

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AS9102 Form 1
Form 1: Part Number Accountability
This form is used to identify the part that is being first-article inspected and associated subassemblies or detail parts. Fields 1-4 (repeated on all forms) identify the part number and name, serial number (CR) and FAI report number (O).

Fields 5-8 (CR) identify drawings, revisions, and any changes from the drawing (i.e. SVRs). Field 9 (R) provides traceability to the manufacturing record (router number, manufacturing plan number, etc.). Fields 10-12 provide identification of the organization. Field 13 (R) identify if a detail part or assembly FAI. Field 14 (R) Identify either a Full or Partial FAI Fields 15-18 apply if the part number in Field 1 is an assembly requireing lower level parts to be installed in the assembly.
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AS9102 Form 2

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AS9102 Form2
Form 2: Product Accountability
This form is used if any material, special processes or funtional testing are defines as a Design Requirement. Field 5 (CR) The name of the material or the process Field 6 (CR) Material or process specification
Include all Make From materials Include all Raw Materials incorporated Include Standard Catalog Hardware

Fields 8-9 (CR) Apply if Special Processes are required to be approved by the customer Field 10 (CR) Certificate of Conformance number
Special Process completion certification Raw Material test report Standard Catalog hardware compliance number Traceability number
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AS9102 Form 2
Form 2 Continued
Field 11 (CR) Functional Test Procedure Number
When Functional Test (ATP) is a Design Requirement

Field 12 (CR) Acceptance Report Number

Certification indicating that test requirements have been met.
ATP results Outside testing results certifications

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AS9102 Form 3

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AS9102 Form3
Form 3: Characteristic Accountability, Verification and Compatibility Evaluation
Field 5 (R) Unique characteristic number for each Design Characteristic Field 6 (CR) Reference Location i.e. drawing zone, page number and section, specification etc. Field 7 (CR) Characteristic Designator i.e. key, critical, flight safety, major etc. Field 8 (R) Requirement i.e. dimensional characteristics with tolerances, drawing notes, specification requirements etc. Field 9 (R) Results
Multiple Characteristics list each characteristic as an individual value
Or list once with the minimum and maximum values noted If a characteristic is found to be non-conforming then that characteristic must be listed separately with the measured value noted.

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AS9102 Form 3
Form 3 Continued
Field 9 Continued
If a Design Requirement requires verification testing actual values will be recorded on the form.
An attached laboratory report listing specific values may be referenced in this field.

For metallurgical characteristics with a visual verification requirement list the photo number of the closest comparison.
A C of C is acceptable, record the reference number in this field.

For processes that require verification per Design Characteristic include a statement of compliance. For part marking ensure marking is legible, correct and properly located.
Attach photo if possible.

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AS9102 Form 3

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AS9102
Questions?

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