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SUPPLIER FIRST ARTICLE INSPECTION INSTRUCTIONS AND FORMS

1-4.10-FM-35, Rev. A

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SUPPLIER FIRST ARTICLE INSPECTION INSTRUCTIONS AND FORMS Document Name: Supplier First Article Inspection Instructions and Forms Revision: A Document No.: 1-4.10-FM-35

1.0 APPLICABILITY This procedure applies to production products, assemblies, subassemblies, and purchased parts. This procedure does not apply to standard catalog components, commercially available hardware and deliverable software.

2.0 PROCESS

First Article Inspection, (FAI) is required when: 1. New parts/products released to production. 2. A change in the design affecting form, fit or function. 3. A change in manufacturing source, process, inspection method,

location of manufacture, tooling or materials that can potentially affect form, fit or function.

4. A change in a CNC program or translation to another media that can potentially affect form, fit or function.

5. A natural or man-made event, which may adversely affect the manufacturing process.

6. A lapse in production for two or more years or as specified by contract. A partial FAI is acceptable under the following circumstances: (1) In response to an Engineering Change Order, only the changes need to be addressed, and (2) when a variation of a part is created and manufactured using the same process as the parent part. The FAI for the parent part and the FAI for the delta of the variation may be used.” Please note that the box numbers on page 4 are not always contiguous intentionally because they are the same numbers as on the full FAI forms. Each section represents an AS9102 compliant form. Part Number Accountability (form is on page 4)

1) Part Number: Number of the part (FAI part).

2) Part Name: Name of the part as shown on the drawing.

3) Serial Number: Serial number of the part if required

4) FAI Report Number: Reference number that identified the FAI. ___________________________________________________________________ *(CR)- Conditionally Required – This field must be completed when applicable.

This field is shown in Bold Italic font.

5) Part Revision Level: Latest part revision that affects the part being first article

inspected. If there is no revision, indicate as such. Note: The latest drawing revision (Field 7) does not always affect all parts contained on a drawing.

6) Drawing Number: Drawing number associated with the FAI part. 7) Drawing Revision Level: The revision level of the engineering drawing. If

there is no revision, indicate as such. 8) Additional Changes: Provide reference number(s) of any changes that are

incorporated in the product but not reflected in referenced drawing/part revision level (e.g., change in design, engineering changes, manufacturing

changes, deviation or exclusion from certain drawing requirement, etc.).

9) Manufacturing Process Reference: A reference number that provides traceability to the manufacturing record of the FAI part (e.g., router number, manufacturing plan number, etc.).

10) Organization Name: Name of the Organization performing this FAI. 12) P.O. Number: Enter Customer Purchase Order Number, if applicable or

required. 13) Detail part or an Assembly FAI: Check as appropriate. 14) Full FAI or Partial FAI: Check as appropriate. For a partial FAI, provide the

baseline part number (including revision level) to which this partial FAI is performed and the reason for it. For example, changes in design, process, manufacturing location, etc.

15) 16) 17) and 18): This section is required only if the part number in Field 1 is an

assembly requiring lower level parts to be installed into the assembly. 15) (CR) Part Number: Detail or next level sub-assembly part number to be included

in the assembly. 16) (CR) Part Name, as shown on the drawing. 17) (CR) Part Serial Number of the part that is installed in the assembly, when

applicable. 18) (CR) FAI Report Number for detail part. Enter N/A if not used.

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SUPPLIER FIRST ARTICLE INSPECTION INSTRUCTION Document Name: Supplier First Article Inspection Instructions and Forms Revision: A Document No.: 1-4.10-FM-35

Product Accountability – Raw Materials, Specifications, and Special Process(es)Functional Testing

5) (CR) Material or Process: Enter the name of material or process. 6) (CR) Specification: Enter material or process specifications number (include

permitted alternates, if used), class, and material form (e.g., sheet, bar, etc.). Include all “Make From” materials that are incorporated into the FAI part. For raw materials, include all materials that are incorporated into the FAI part, (e.g. unique identifier that will enable traceability back to the Certificate of Conformance, weld/braze filler materials, balls for ball brazing, etc.), and Standard Catalog hardware (e.g., AN, MS fasteners); but do not include processing materials such as acid etchants.

10) (CR) Certificate of Conformance number: Number of the certificate (e.g.,

special process completion certification, raw material test report number, Standard Catalog hardware compliance report number, traceability number.)

11) (CR) Test Procedure Number: Functional Test Procedure called out as Design

Requirement. 12) (CR) Acceptance Report Number: The functional test certification indicating

that test requirements have been met.

Signature Requirements 19) Signature: name and signature of the person who prepared FAI Form. Also

check appropriate box if the FAI is complete. Note: The signature box on this form certifies the following two things:

1) That all characteristics are accounted for; meet drawing requirements or are properly documented for disposition,

2) Indicate FAI is complete or partial.

20) Date when this FAI Form was prepared. 21) Name of the person signing the form. FAI Characteristics Accountability, Verification and Compatibility Evaluation

(Form is on page 5)

5) Characteristic Number: Unique assigned number for each Design Characteristic.

8) Requirement: Specified requirement for the Design Characteristic (e.g.,

drawing dimensional characteristics with nominal and tolerances included, drawing notes, specification requirements, etc.)

9) Results: List measurement(s) obtained for the Design Characteristics.

For Multiple Characteristics list each characteristic as individual values or list once with the minimum and maximum or measured values attained. If a characteristic is found to be non-conforming then that characteristic must be listed separately with the measured value noted.

If a Design Requirement requires verification testing, then the actual results

will be recorded on the form. If a laboratory report or certificate of test is included in the FAIR, then these results need not be written on the form, record the reference number in this field. The laboratory report or certificate of test must show specific values for requirements and actual results.

For metallurgical characteristics with visual verification requirement that

are rated against standard photographs, list the photo number of the closest comparison. A statement of conformance is acceptable (record the reference number in this field).

For processes that require verification per Design Characteristic, include

statement of compliance (e.g. certification of compliance, verification indicator such as “accept”, etc.)

For part marking, ensure that marking is legible, correct in content and size

and properly located, per applicable specification.

9a) (CR) Accept/Reject: Use A or R to denote if the inspection is acceptable or unacceptable.

10) (CR) Designed Tooling: If a specially designed tooling (including NC

programming) is used as a media of inspection, record the tool identification number.

11) (CR) Non-Conformance Number: Record a non-conformance document

reference number if the characteristic is found to be non-conforming. Records The original FAI documents will remain on file at the supplier’s facility

for seven years, unless otherwise specified by contract.

Submittal Submit First Article Inspection (Pages 4 and 5) with the First Article sample to Kollsman Inc. Reference Kollsman Product Assurance Provisions Clause Code number 1.

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SUPPLIER FIRST ARTICLE INSPECTION REPORT

(Pages 4 & 5 shall be submitted with FAI sample to Kollsman, Inc.)

PPaarrtt NNuummbbeerr AAccccoouunnttaabbiilliittyy 1. Part Number 2. Part Name 3. Serial Number (CR) 4. FAI Report Number

5. Part Revision Level (CR) 6. Drawing Number (CR) 7. Drawing Revision Level (CR) 8. Additional Changes (CR)

9. Manufacturing Process Reference

10. Organization/Supplier Name (R) 12. P.O. Number

13. Detail FAI Assembly FAI

14. Full FAI Partial FAI Baseline Part Number Including Revision Level (for partial FAI)

Reason for Partial FAI:

a) if above part number is a detail part only, go to Field 5 below. b) if above part number is an assembly, go to the Field 15 below.

Index of part numbers or sub-assembly numbers required to make the assembly noted above.

15. Part Number 16. Part Name 17. Part Serial Number 18. FAI Report Number

PPrroodduucctt AAccccoouunnttaabbiilliittyy ffoorr RReeqquuiirreemmeennttss ffoorr FFoorrmm RRaaww MMaatteerriiaallss,, SSppeecciiffiiccaattiioonnss aanndd SSppeecciiaall PPrroocceessss((eess)),, FFuunnccttiioonnaall TTeessttiinngg

5. Material or Process Name 6. Specification Number

10. Certificate of Conformance Number

11. Functional Test Procedure Number 12. Acceptance Report Number, if Applicable

SSuupppplliieerr SSiiggnnaattuurree aanndd AApppprroovvaall 1) Signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition. 2) Also indicate if the FAI is complete: FAI complete FAI not complete 19. Signature 20. Date

21. Name (print)

Form 1-4.10-FM-35, Rev. A

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FAI CHARACTERISTICS ACCOUNTABILITY, VERIFICATION AND COMPATIBILITY EVALUATION

(Supplier to make additional copies of this form, as required, to record and measure all drawing characteristics)

1. Part Number & Rev. 2. Part Name 3. Serial Number (CR)

4. FAI Report Number (R)

Part No.

Part Rev.

Meth.. Rev.

1a. Program Name: 2a. WO No. (CR)

Characteristic Accountability Inspection/Test Results 5. Char No. 6.Reference

Location (CR) 7. Characteristic Designator (CR) 8. Requirement 9. Results 9a.Accept/Reject 10. Designed Tooling 11. Non-conformance

No.

NOTE: SHADED AREAS ARE NOT REQUIRED TO BE FILLED IN. Form 1-4.10-FM-35, Rev. A