a5c-ai 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
Drawing Review
- Identify all dimensions
- Identify all notes
- Identify material/process requirements
- Identify special characteristics
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
- Review drawing completely before ballooning
- Ensure measurement method capability
- Document traceability to raw material
- Obtain certifications for special processes
- Address all non-conformances before approval
- 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