06/27/100 Internationally Harmonized Aerospace Standards for First Article Inspection AS9102, EN 9102, SJAC 9102 Chetan Date, Ph.D., P.E. Director of Design Quality Honeywell Engines and Systems Phoenix, Arizona 5

What is AS9102- FAI Standard? 06/27/100 What is AS9102- FAI Standard? International Standard for First Article inspection (FAI), co-published as AS9102 by SAE in Americas EN 9102 by AECMA in Europe SJAC 9102 by SJAC in Asia Developed by International Aerospace Quality Group (IAQG) Outlines the Documentation and Inspection Requirements Published in August 2000 7

Motivation to Develop a Common Standard Current Status Aerospace Companies Have Somewhat Common Requirements for First Article Inspection (FAI) Documentation Requirements Differ Common Standard and Unified Requirements Will Eliminate Common Errors and Omissions Simplify FAI for Suppliers Focus on Product Quality Rather Than Documentation Writing Team Charter: Standardized Aerospace FAI Requirements A Common Form of Documentation for Supplier FAI

Key Elements of AS/EN/SJAC 9102 When to Perform FAI- Full And/or “Delta * ” FAI: Specific Triggers What to Inspect: Unified Requirements for Inspection How to Document- Common Format for Documenting FAI Results * Delta FAI: The FAI requirements may be satisfied by addressing differences between current configuration and prior approved configurations

When to Perform First Article Inspection? Full FAI New Part New Supplier or New Location of Manufacture Lapse in Production- Default: 24 Months Delta* FAI Drawing Change/ Revision Change Manufacturing Process Change: Including NC Programs, Material Change, Sub-tier Change Change in Inspection Method or Inspection Plan * Delta FAI: The FAI requirements may be satisfied by addressing differences between current configuration and prior approved configurations

Applicability Assemblies and All Levels of Parts Within an Assembly, Including Castings and Forgings Organizations That Are Responsible for Producing the Design Characteristics Suppliers and Their Subcontractors Who Produce Design Characteristics, Suppliers Responsible for Ensuring That Characteristics Conform to Customer Requirements.

What is Included in First Article Inspection? Verification of All Design Characteristics: Dimensional Verification Via Marked up (or “Ballooned”) Drawing That Correlates Characteristic Number From FAI to the Drawing. Part Marking Replication Material and Special Process Certs (Including Operator Certs (e.g. NDT, Welding), If Required). Manufacturing Process Verifications Manufacturing Routing Sheets. Referenced Exhibits Supporting the FAI (e.g. CMM Data Printouts, Test Data, Acceptance Test Procedures, Process Certifications, etc.). Process Capability Studies, As Applicable. Gauge Correlation, As Applicable. Tooling Traceability, If Tooling Is Used to Verify Design Characteristics Nonconformance Resolutions

Common Documentation Requirements Standardized Forms With Each Field Numerically Coded Form 1: Part Number Accountability Form 2: Product Accountability – Raw Material, Special Process(s), Functional Testing Form 3: Characteristic Accountability, Verification and Compatibility Evaluation Forms May Be Generated Electronically... Must Contain All the Required Information SAE Allows Free Reproduction of the Forms

Where to Obtain AS9102 Copies? Society of Automotive Engineering (SAE) AS9102 available for purchase from SAE http://www.sae.org/servlets/techtrack?PROD_TYP=STD (There are no spaces in this web address...they are underlines) The current price for the standard is : Mail: $45 List Price ($36 member price) Fax: $75 List Price ($60 member price) Download: $59 List Price ($47.20 member price)

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