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

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

Dick PocockDick Pocock

VP, Quality AssuranceVP, Quality Assurance

Honeywell Engines and SystemsHoneywell Engines and Systems

Phoenix, ArizonaPhoenix, Arizona

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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 (IAQG)Group (IAQG)

Outlines the Documentation and Inspection Outlines the Documentation and Inspection Requirements Requirements

Published in August 2000Published in August 2000

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Motivation to Develop a Common StandardMotivation to Develop a Common Standard Current StatusCurrent Status

– Aerospace Companies Have Somewhat Common Requirements Aerospace Companies Have Somewhat Common Requirements for First Article Inspection (FAI)for First Article Inspection (FAI)

– Documentation Requirements DifferDocumentation Requirements Differ

Common Standard and Unified Requirements WillCommon Standard and Unified Requirements Will– Eliminate Common Errors and OmissionsEliminate Common Errors and Omissions

– Simplify FAI for Suppliers Simplify FAI for Suppliers

– Focus on Product Quality Rather Than DocumentationFocus on Product Quality Rather Than Documentation

Writing Team Charter:Writing Team Charter:– Standardized Aerospace FAI RequirementsStandardized Aerospace FAI Requirements

– A Common Form of Documentation for Supplier FAIA Common Form of Documentation for Supplier FAI

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Key Elements of AS/EN/SJAC 9102Key Elements of AS/EN/SJAC 9102

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 for What to Inspect: Unified Requirements for InspectionInspection

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

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When to Perform First Article Inspection?When to Perform First Article 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 Programs, Material Manufacturing Process Change: Including NC Programs, Material

Change, Sub-tier ChangeChange, Sub-tier Change– Change in Inspection Method or Inspection PlanChange in Inspection Method or 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

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ApplicabilityApplicability

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 Produce Suppliers and Their Subcontractors Who Produce

Design Characteristics, Design Characteristics,

– Suppliers Responsible for Ensuring That Suppliers Responsible for Ensuring That Characteristics Conform to Customer Characteristics Conform to Customer Requirements.Requirements.

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What is Included in First Article Inspection?What is Included in First Article Inspection? Verification of All Design Characteristics:Verification of All Design Characteristics:

– Dimensional Verification Via Marked up (or “Ballooned”) Drawing That Correlates Characteristic Dimensional Verification Via Marked up (or “Ballooned”) Drawing That Correlates Characteristic Number From FAI to the Drawing.Number From FAI to the Drawing.

– Part Marking ReplicationPart Marking Replication

Material and Special Process Certs Material and Special Process Certs (Including Operator Certs (e.g. NDT, Welding), If Required).(Including Operator Certs (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, Acceptance Test Referenced Exhibits Supporting the FAI (e.g. CMM Data Printouts, Test Data, Acceptance Test Procedures, Process Certifications, etc.). 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

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Common Documentation RequirementsCommon Documentation Requirements

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 Form 2: Product Accountability – Raw Material, Special

Process(s), Functional TestingProcess(s), Functional Testing Form 3: Characteristic Accountability, Verification and Form 3: Characteristic Accountability, Verification and

Compatibility EvaluationCompatibility Evaluation

Forms May Be Generated Electronically... Must Forms May Be Generated Electronically... Must Contain All the Required Information Contain All the Required Information

SAE Allows Free Reproduction of the FormsSAE Allows Free Reproduction of the Forms

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Frequently Asked QuestionFrequently Asked Question Visit:Visit: http://www.iaqg.sae.org/iaqg/publications/faq9102.htmhttp://www.iaqg.sae.org/iaqg/publications/faq9102.htm

ORORhttp://www.sae.org/iaqg/publications/faq9102.htmhttp://www.sae.org/iaqg/publications/faq9102.htm

Contact Your Sector Designated Representative Contact Your Sector Designated Representative (SDR)(SDR)

Chet Date, Honeywell (Americas)Chet Date, Honeywell (Americas) Cristobal Casado, CASA (Europe)Cristobal Casado, CASA (Europe) Nori Kobayashi, IHI (Asia)Nori Kobayashi, IHI (Asia)

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Where to Obtain AS9102 Copies in US?Where to Obtain AS9102 Copies in US?

Society of Automotive Engineering (SAE)Society of Automotive Engineering (SAE)– AS9102 available for purchase from SAEAS9102 available for purchase from SAE

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

(There are no spaces in this web address...they are underlines)(There are no spaces in this web address...they 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)

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Where to Obtain SJAC 9102 Copies in Where to Obtain SJAC 9102 Copies in Japan?Japan?

SJAC9102 - Japanese language version of 9102 SJAC9102 - Japanese language version of 9102 standard is available from Japanese Standards standard is available from Japanese Standards Association (JSA)Association (JSA)

Address:Address:JSA JSA

1-24, 4 chome, Akasaka, Minato-ku, 1-24, 4 chome, Akasaka, Minato-ku,

Tokyo 107-8440Tokyo 107-8440 Tel: 03-3583-8002Tel: 03-3583-8002 Fax: 03-3583-0462Fax: 03-3583-0462

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Thank You!Thank You!