International Aerospace Standard for First Article Inspection(FAI) Dick Pocock VP, Quality Assurance Honeywell Engines

1. International Aerospace Standard for First Article Inspection(FAI) Dick Pocock VP, Quality Assurance Honeywell Engines and Systems Phoenix, Arizona

2. What is the FAI Standard? • International Standard for First Article Inspection (FAI); published as: • AS9102 by SAE in Americas • EN 9102 by AECMA in Europe • SJAC 9102 by SJAC in Asia • Developed by an IAQG Team • Published in August 2000 • Defines the Documentation and Inspection Requirements for FAI’s

3. Why Develop a Common Standard? • Currently: • Aerospace Primes Have Somewhat Common Requirements for First Article Inspection (FAI) • Documentation Requirements Differ • Writing Team Charter: • Standardized Aerospace FAI Requirements • Provide a Common Format for FAI Reporting • Common Standard and Unified Requirements Will: • Simplify FAI for Suppliers • Eliminate Common Errors and Omissions • Assure Consistency in FAI rigor Across the Industry

4. Key Elements of AS/EN/SJAC 9102 • When to Perform FAI • Specific Triggers • What to Inspect • Standard Requirements for Inspection • How to Document • Common Format for Documenting FAI Results

5. When to Perform First Article Inspection? • Full FAI • New Part • New Supplier or New Location of Manufacture • Break in Production of 24 Months • Partial (delta) FAI • Drawing Change / Revision Change • Manufacturing Process Change: Including NC Programs, Material Change, Sub-tier Change • Change in Inspection Method or Inspection Plan * Partial FAI: The FAI requirements may be satisfied by addressing differences between a new configuration and the previous approved configuration

6. 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 Whose Production must meet Characteristic Design Requirements • Suppliers Responsible for Ensuring That Characteristics Conform to Requirements (e.g. Inspection Sources)

7. What is Included in First Article Inspection? • Verification of All Design Characteristics: • Dimensional Verification via Marked-up (or “Ballooned”) Drawings that Correlate Characteristic Number from FAI to the Drawing. • Part Marking • Material and Special Process Certifications Including Operator Certs (e.g. NDT, Welding) • 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 Numbered Fields • 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 • Available electronically from SAE, or • Generate Own Form • Must include all information using same data field reference numbers

9. Where to Obtain AS9102 Copies in the U.S. ? • Society of Automotive Engineering (SAE) • AS9102 available for purchase from SAE http://www.sae.org/servlets/techtrack?PROD_TYP=STD • 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)

10. Where to Obtain AS9102 Copies in Europe? • BNAE France • Technopolis 54 199 rue JJ Rousseau 92138 ISSY LES MOULINEAUX Paris - France • Phone : 00 33 1 47 65 70 21 (English speaking) • Fax : 00 33 1 47 65 70 20 • e-mail : commercial@bnae.asso.fr • http://www.bnae.asso.fr (e-mail or Phone is preferred)

11. Where to Obtain AS9102 Copies in Europe? (Contd) • BSI (British Standards Institute) 389 Chiswick High Road London W4 4AL - UK tel: 020 8996 9001 • ISO- Switzerland 1 rue de Varembe 1211 Geneva 20 Switzerland tel: +41 22 749 0111/ fax: +41 22 734 1079

12. Questions?