fai-inspection

First Article Inspection Skill

Purpose

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.

Capabilities

• FAI plan development per AS9102
• Balloon drawing preparation
• Measurement method specification
• CMM programming guidance
• Characteristic accountability matrix
• Partial FAI and delta FAI management
• FAI report generation (Forms 1, 2, 3)
• Non-conformance disposition

Usage Guidelines

AS9102 Requirements

FAI Triggers

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

Partial FAI (Delta FAI)

Allowed when:
- Minor design change
- Controlled process change
- Tooling modification

Only affected characteristics need re-inspection

FAI Planning

Characteristic Identification

1. Drawing Review

• Identify all dimensions
• Identify all notes
• Identify material/process requirements
• Identify special characteristics

1. 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 |

Balloon Drawing

Ballooning requirements:
- Unique number for each characteristic
- Sequential numbering preferred
- Reference to original dimension
- Include notes and specifications
- Mark special characteristics

AS9102 Forms

Form 1: Part Number Accountability

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)

Form 2: Product Accountability - Materials, Processes, Functional Testing

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

Form 3: Characteristic Accountability

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)

Measurement Methods

Measurement Selection

| 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 |

GD&T Measurement

| 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 Programming

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

Non-Conformance Handling

Disposition Options

| 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 |

Documentation Requirements

Non-conformance record:
- NC number
- Characteristic affected
- Requirement
- Actual condition
- Root cause analysis
- Corrective action
- Disposition and approval

FAI Approval Process

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

Process Integration

• ME-023: First Article Inspection (FAI)

Input Schema

{
  "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"
  }
}

Output Schema

{
  "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"
  }
}

Best Practices

1. Review drawing completely before ballooning
2. Ensure measurement method capability
3. Document traceability to raw material
4. Obtain certifications for special processes
5. Address all non-conformances before approval
6. Maintain FAI records per retention requirements

Integration Points

• Connects with GD&T Drawing for requirements
• Feeds into Design Review for verification evidence
• Supports Process Planning for capability verification
• Integrates with Quality systems for record keeping