Internationally Harmonized Aerospace Standards for First Article Inspection

1. Internationally Harmonized Aerospace Standards for First Article Inspection AS9102, EN 9102, SJAC 9102 Philippe Removille SNECMA Moteurs

2. 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 • Outlines the Documentation and Inspection Requirements When Performing First Article Inspection of Aerospace Components • Published in August 2000

3. Motivation to Develop a Common Standard • Rationale • Aerospace Companies Have Somewhat Common Requirements for First Article Inspection (FAI) • Documentation Requirements Differ • Common Standard and Unified Requirements: • Eliminate Common Errors and Omissions • Simplify FAI for Suppliers • Focus on Product Quality Rather Than Documentation

4. 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

5. 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, Inspection Plan * Delta FAI: The FAI requirements may be satisfied by addressing differences between current configuration and prior approved configurations

6. Applicability This Aerospace Standard Applies To • 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.

7. 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 Certifications (Including Operator Certification (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

8. 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, However, They Must Contain All the Required Information • SAE Allows Free Reproduction of the Forms of This Standard for FAI.

9. Current Status • Problems with Implementation / Interpretation of 9102 requirements • Large amount of documentation / data being generated • Process for review / approval of FAI between customer / supplier • Need to Revisit 9102 definition of application at all levels of components and assemblies • IAQG writing team to look at revision • DOES NOT CHANGE CURRENT APPLICATION / CONTRACT REQUIREMENTS

10. Where to Obtain AS9102 Copies? • Society of Automotive Engineering (SAE) • The document is available for purchase from SAE http://www.sae.org/servlets/techtrack?PROD_TYP=STD (please note that there are no spaces in this (or the other SAE) 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)