User Guide for First Article Inspection Report (FAI ... · User Guide for First Article Inspection ... is applied within ZODIAC AEROTECHNICS Oxygen Systems Europe ... Oxygen Systems

REF. NO. 4INR0118

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INSTRUCTION 4INR0118 Rev. 3

User Guide for First Article Inspection Report (FAI ) / First Article Inspection performed by the ZAET OSE Supplier

- PURPOSE

This guide explains how to perform and document a first article inspection of procured detail parts or sub-assemblies.

It details how PGQ-4995 is applied within ZAET OSE.

- SCOPE

This document applies to all suppliers/sub-contractors in relation to any sub-assembly or detail part that is listed in orders, purchase contracts or quality plans.

This document does not apply to standard and/or catalog products.

- REFERENCE DOCUMENTS

• EN 9102 “Aerospace series. Quality systems. First article inspection”

• ZA-Q-1030 “Requirements applicable to suppliers”

• PGQ-4995 “First Article Inspection (FAI) / Contrôle premier article performed by the supplier”

• 4INR0118 Excel form “CONTRÔLE PREMIER ARTICLE / FIRST ARTICLE INSPECTION”

Prepared by: GILBERT Aurore Reviewed by: CALMELLY Marie Hélène

Date and signature: Date and signature:

Guide to using the First Article Inspection (FAI) form

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This document is the property of Zodiac Aerotechnics. It shall not be reproduced without prior consent.

LIST OF MODIFICATIONS Revision Description Date Author

3 Updated and translated January 2017 A. GILBERT / G.LOUAZEL/ B.MANCIET


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Table of Contents

1. INTRODUCTION ........................................................................................................................... 5

2. TERMINOLOGY ............................................................................................................................ 5

3. PROCEDURES ............................................................................................................................. 5

4. LIMITATIONS AND COMMENTS .......................... ....................................................................... 5

5. CONTENTS OF “FIRST ARTICLE” FILE .................. .................................................................. 6

6. CRITERIA FOR MAJOR ACTIONS ........................ ...................................................................... 6

7. CRITERIA FOR MINOR ACTIONS ........................ ....................................................................... 7

8. ZAET OSE ORDER ....................................................................................................................... 7

9. FAI FORM...................................................................................................................................... 8

9.1. Contents ............................................................................................................................................ 8

9.2. Form legend ...................................................................................................................................... 8

10. « FORM1 » PAGE 1 OF FAI FORM ...................... ....................................................................... 9

10.1. Part description ................................................................................................................................. 9

10.2. «I. SUPPLIER / FOURNISSEUR»................................................................................................... 10

10.3. «II. INDEX SUB PART LIST / LISTE ARTICLES ASSEMBLES» .................................................... 10

10.4. «III. WAIVER REQUEST / DEMANDE DE DEROGATION (PGQ-5145) » ...................................... 10

10.5. «IV. REMARKS / OBSERVATIONS» .............................................................................................. 10

10.6. «V. APPROVAL / APPROBATION» ................................................................................................ 11

10.7. MANDATORY supplier signature: «19. Name / Nom - Signature» .................................................. 11

10.8. Optional signature: «21. Reviewed by / Revu par» ......................................................................... 11

10.9. Optional signature - ZAET only: «23. Customer approval / Approbation Client» ............................. 11

11. « FORM2 » PAGE 2 OF FAI FORM ...................... ..................................................................... 12

11.1. Part.................................................................................................................................................. 12

11.2. « VI. RAW MATERIALS - COMPONENTS / MATIERES PREMIERES - COMPOSANTS» ............ 12

11.3. «VII. SPECIAL PROCESS (Surface treatment, welding, painting…) / PROCEDES SPECIAUX (Traitements de surface, soudure, peinture…) » ........................................................................................ 13

11.4. «VIII. Functional Test if applicable / Test fonctionnel si applicable» ................................................ 13

11.5. «IX. SPECIFIC PRODUCTION FACILITIES (Mold, Test Bench, Tooling, ...) / MOYENS DE PRODUCTION DEDIES AU PRODUIT (Moule, Banc d'essai, outillages) » ............................................... 13

11.6. «X. CLEANING / NETTOYAGE» .................................................................................................... 13

11.7. «XI. SUPPLIER SPECIFICATION / SPECIFICATION FOURNISSEUR» ...................................... 14

11.8. «13. REMARKS / OBSERVATIONS» ............................................................................................. 14

11.9. Supplier signature ........................................................................................................................... 14


12.1. Part.................................................................................................................................................. 15

12.2. Characteristics and inspection ........................................................................................................ 15


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12.3. Supplier signature ........................................................................................................................... 15

13. « FORM 4 » PAGE 4 OF FAI FORM ..................... ..................................................................... 16



16. APPENDICES: FORMS / ANNEXES: FORMULAIRES .......... ................................................... 20


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1. INTRODUCTION

This guide explains how to perform a first article inspection of procured detail parts or sub-assemblies and document it using the 4INR0118 form .

It details how PGQ-4995 is applied within ZODIAC AEROTECHNICS Oxygen Systems Europe.

2. TERMINOLOGY

• FAI: First Article Inspection

• ZAET: Zodiac Aerotechnics

• OSE: Oxygen Systems Europe

• DN: Delivery Note

• SC: Statement of Conformity

• CE: Critical Elements

• S-CE: Safety-Critical Elements

• FMECA: Failure Modes, Effects and Criticality Analysis

• NDT: Non-Destructive Testing

3. PROCEDURES

• ZA-Q-1030 “Requirements applicable to suppliers”

• ZA-Q-1080 “Risk management guideline for suppliers”

• ZA-Q-1081 “Industrial flow chart guideline for suppliers”

• PGQ-4995 “First Article Inspection (FAI) / Contrôle premier article performed by the supplier”

• PGQ-5145 “Supplier Incident Report (IR) and Corrective Action Request (CAR)”

• 4PGL1017 “DPT 4 material standard”

• 420B598 “Paint list file”

• List 2465 “ZODIAC AEROTECHNICS - List of approved special process facilities”

• S10010 “Anodizing of aluminum and aluminum alloys”

• 4PGL1151 “Critical element requirements applicable to sub-contractor suppliers”

4. LIMITATIONS AND COMMENTS

Does not apply to catalog/standard parts.


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5. CONTENTS OF “FIRST ARTICLE ” FILE The “first article” file must include the following as a minimum:

• The completed and signed FAI forms (see Section 15: Appendix)

• The Statement of Conformity (SC) for the order, including date, name, position and signature

• The part or sub-assembly drawing with balloons (numbered dimensions) or location on the inspection report

• The Delivery Note (DN) for the order

• The Statement of Conformity and/or test report for the raw materials (not the material DN). This Statement shall specify the batch/heat no. with characteristics.

• The special process treatment/protection sub-contractor Statement of Conformity (not the DN) when applicable

• The Statement of Conformity and/or test report for the sub-contracted components and operations (materials factory acceptance certificate)

• The reference of the part/s used for the FAI

• Pictures of the part (or sub-assembly) and packaging

• The results of the dimensional inspections on 100% of dimensions and drawing notes

• References and revision levels for specific inspection facility (tools, templates, test benches, etc.)

• Test results (NDT, mechanical tests, functional tests, etc.) when applicable

• Manufacturing range – Flow chart

• Monitoring plan when applicable

• Critical Items certificate when applicable

• Process FMEA when requested

• Product FMEA when applicable

6. CRITERIA FOR MAJOR ACTIONS The criteria for major actions leading to the rejection of the FAI and the parts are as follows:

• Non-compliant CE or S-CE dimension

• Missing CE or S-CE Certificate of Compliance

• Missing measurement for a dimension, including a CE or S-CE dimension, on an inspection report

• Special process sub-contractor without ZAET qualification (list 2465) or not listed on the ZOSE list

• Sub-contractor without qualification on the ZOSE list

• Missing Statement of Conformity for the order

• Missing material sub-contractor Statement of Conformity

• Missing special process sub-contractor Statement of Conformity

• Missing or incomplete test report as per specifications (when applicable)

• Missing FAI form as per EN 9102 or 4INR0118


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7. CRITERIA FOR MINOR ACTIONS The criteria for minor actions leading to the delay of the FAI and the parts are as follows:

• Statement of Conformity not signed

• Non-compliant dimension (excluding Critical Items) not reported and resolved

• Incomplete, errors in FAI reports (Form pages not signed, Missing dimensions, Incorrect revision level, etc.)

8. ZODIAC AEROSPACE AET OSE PURCHASE ORDER

X1

Information to provide at corresponding no. on FORM 1 of the FAI form

XXXX

XXXX

XXXX

XXXX XXXX

XXXX

XXXX

1

6

2

7

5

12


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9. FAI FORM

9.1. Contents

The Excel form has 6 sheets:

- FORM 1: Provide information about the article, the supplier and the reasons for the FAI.

- FORM 2: Provide information about how the article was manufactured.

- FORM 3: List the characteristics stated on the drawing (dimensions and notes), and the results of the measurements performed and the means used.

- FORM 4: List the documents to be provided in the FAI file.

- FORM 5: Describe the manufacturing process (flow chart).

- FORM 6: A visual of the part and its packaging may be provided on this page.

9.2. Form legend

Optional (Recommended)

Automatic upload field

Mandatory


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10. « FORM1 » PAGE 1 OF FAI FORM

10.1. Part description

Field 13) Check box if it is an FAI for a:

• Detail part

• Assembled product (composed of several primary parts and/or catalog parts)

Field 14) Check box if it is an FAI for a:

• Full FAI / FAI complète:

o First series production

o Or after suspension of production for more than 24 months

o Or after changes to procurement sources, change of sub-contractor, transfer of production)

• Partial FAI / FAI partielle (DELTA FAI):

o After definition changes affecting the geometry, interfaces or function of the product: in addition to the initial FAI, perform an inspection of the characteristics affected by the changes

o Or after changes to the manufacturing process, tools or manufacturing location/site that could affect the geometry, interfaces or function of the product: in addition to the initial FAI, perform an inspection of the characteristics affected by the changes

Field 14.1) Refer baseline FAI number accepted by Z odiac Aerospace with its drawing revision level and any related changes Field 14.2) Check the corresponding box according s ituation

1

6

2

7

5

12


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10.2. «I. SUPPLIER / FOURNISSEUR»

10.3. «II. INDEX SUB PART LIST / LISTE ARTICLES ASS EMBLES»

This section only applies to sub-assemblies composed of several parts.

10.4. «III. WAIVER REQUEST / DEMANDE DE DEROGATION (PGQ-5145) »

10.5. «IV. REMARKS / OBSERVATIONS»


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10.6. «V. APPROVAL / APPROBATION»

10.7. MANDATORY supplier signature: «19. Name / Nom - Signature»

10.8. Optional signature: «21. Reviewed by / Revu p ar»

10.9. Optional signature - ZAET only: «23. Customer appro val / Approbation Client»


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11.1. Part

11.2. « VI. RAW MATERIALS - COMPONENTS / MATIERES P REMIERES - COMPOSANTS»

Automatic field (from FORM 1)

Drawing box OR

Drawing note


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11.3. «VII. SPECIAL PROCESS (Surface treatment, wel ding, painting …) / PROCEDES SPECIAUX (Traitements de surface, soudure, peinture …) »

11.4. «VIII. Functional Test if applicable / Test fonctio nnel si applicable»

11.5. «IX. SPECIFIC PRODUCTION FACILITIES (Mold, Te st Bench, Tooling, ...) / MOYENS DE PRODUCTION DEDIES AU PRODUIT (Moule, Banc d'essa i, outillages) »

11.6. «X. CLEANING / NETTOYAGE»


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11.7. «XI. SUPPLIER SPECIFICATION / SPECIFICATION FOURNISSEUR»

11.8. «13. REMARKS / OBSERVATIONS»

11.9. Supplier signature


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12.1. Part

12.2. Characteristics and inspection

12.3. Supplier signature

Automatic field (from FORM 1)


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13. « FORM 4 » PAGE 4 OF FAI FORM


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16. APPENDICES: FORMS / ANNEXES: FORMULAIRES

1. Part Number /Référence de l'article

2. Part Name /Désignation de l'article

3. Serial Number /Numéro de série

4. FAI Report Number /Numéro du rapport revue 1er article

5. Part Revision Level /Indice de révision de l'article

6. Drawing Number /Référence du plan

7. Drawing Revision Level / Indice de révision du plan

8. Additional Changes / M odifications supplémentaires

12. P.O. Number /Numéro de commande

14. FAI type / Type de 1er Article :

9. Manufacturing Process Reference / Référence du dossier de fabrication

10. Organization Name /Nom de l'entreprise

10.1 Manufacturing site / Site de fabrication

11. Supplier Code / Code société Fournisseur (Dun's Number)

15. Part Number / Référence de l'article16. Part Name /

Désignation de l'article17. Serial Number /

Numéro de série18. FAI Report Number / Numéro du

rapport revue 1er article

19. Name / Nom - Signature 20. Date

21. Reviewed by / Revu par : 22. Date

23. Customer approval /Approbation Client :

24. Date

CONTROLE PREMIER ARTICLE / FIRST ARTICLE INSPECTIONFORM 1

III. WAIVER REQUEST / DEMANDE DE DEROGATION (PGQ-51 45)

IV. REMARKS / OBSERVATIONS

14.2. Origin of First Article Inspection / Origine du contrôle 1er Article

14.1. Partial FAI (Delta) /Revue 1er article partielle

13. Part Type / Article :

Reason for partial FAI / Raison de la revue 1er Article partielle :

Baseline Part Number including revision level / Référence de l'article initiale et sa révision :

V. APPROVAL / APPROBATION

a) Signature indicates that all the characteristics have been taken into account, comply with the definition requirements or are correctly documented for subsequent action to be taken / La signature indique que toutes les caractéristiques sont prises en compte, satisfont les exigences de définition ou sont correctement documentées pour suite à donner.b) Also indicate if the FAI is complete according to § 5.4 of EN9102 (Non conformance handling) Indiquer également si l’Inspection Premier Article est terminée conformément au § 5.4 (Traitement des non-conformités)

II. INDEX SUB PART LIST / LISTE DES ARTICLES ASSEMB LES

INDEX of part numbers or sub-assembly numbers required to make the assembly noted above / Liste des références d'articles ou sous ensembles nécessaires à la réalisation de l'ensemble mentionné ci dessus.

a) If above part number is a detail part only, go to f ield 19 / Si la référence de l'article est une pièce primaire, aller au champ 19 (Cf . II) .b) If above part number is an assembly, go to the "INDEX" section below / Si la référence de l'article est une pièce assemblée, allez à la section INDEX (Cf. II) .

I. SUPPLIER / FOURNISSEUR

New product / Nouveau Produit

Evolution of manufacturing process / Evolution des procédés

Manufacturing interruption greater than 24 months / Interruption de fabrication supérieure à 24 mois

Other / Autre

Detail part / Pièce primaire

Assembly part / Pièces assemblées (Cf. II) Full FAI / FAI complète

Partial FAI / FAI partielle

Design change / Evolution de la définition

FAI COMPLETE / REVUE 1ER ARTICLE TERMINEE FAI NOT COMPLETE / REVUE 1ER ARTICLE NON TERMINEE


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1. Part Number / Référence de l'article


0 0

6. Drawing material specification /

Spécification matière cité au plan

8. Supplier Name / Nom Fournisseur

7. Code (drop down / menu déroulant)

9 Customer approval / validation client

10. Certificate of conformance Number / Référence

Déclaration de conformité

6. Drawing specification /

Spécification du plan

5. Process Name / type de procédé

16. Supplier Specification /

procédure fournisseur

8 Supplier Name / Nom Fournisseur

7. Code (drop down / menu déroulant)

9. Customer approval / Validation client

10. Certificate of conformance Number / Référence

Déclaration de conformité

VIII. Functional Test if applicable / Test

fonctionnel si applicable

16. Part Number / Référence

19. Next verification date / Prochaine

vérification

20. Equipment Record number /Numéro d'enregistrement du

moyen

26. Cleaning Specification / Procédure de nettoyage

22. Number & revision level /Référence & Indice de la

procédure

14. Name / Nom & Signature 15. Date

0

13. REMARKS / OBSERVATIONS

Inspection Criteria (Type of defect) / Critères d’acceptation (type de défaut)

Inspection Plan / Gamme de Contrôle

Manufacturing Range - Flow chart / Gammes de fabrication - Synoptique

….

Packaging / Conditionnement

5. Raw material- component name / designation Matière - Composant

VII. SPECIAL PROCESS (Surface treatment, welding, p ainting, ...) PROCEDES SPECIAUX (Traitements de surface, soudure, peinture, ...)

12. Acceptance report number / Référence du rapport d'essai

11. Functional Test Procedure Number / Référence de la procédure

d'essais

IX. SPECIFIC PRODUCTION & INSPECTION EQUIPEMENT (Mold, Test bench, Tools, ...) MOYEN DE PRODUCTION ET DE CONTROLE DEDIE AU PRODUIT (Moule, Banc d'essai, Outillages, ...)

18. Last Verification Date / Dernière vérification17. Production Equipment Name /

Désignation du moyen

21. Process Name / Nom des Processus :

Operator Training / Formation des opérateurs

X. CLEANING / NETTOYAGE (If Requested / si requis)

25. Cleaning Equipment / Moyen de nettoyage24. Type of Cleaning / Type de nettoyage ?23. Cleaning Process Name /

Nom du nettoyage

XI. SUPPLIER SPECIFICATION / PROCEDURES FOURNISSEUR

21. Process Name / Nom des Processus :22. Number & revision level /

Référence & Indice de la procédure

CONTRÔLE PREMIER ARTICLE / FIRST ARTICLE INSPECTIONFORM 2

4. FAI Report Number /Numéro de rapport revue 1er article

2. Part Name / Désignation de l'article

VI. RAW MATERIALS - COMPONENTS / MATIERES PREMIERES - COMPOSANTS

00


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5. Balloon drawing number/ Numéro sur

Plan bullé

6. Reference Location /

Localisation

7. Characteristic Designator /Classification

8. REQUIREMENT / EXIGENCE

8.1. TOLERANCE

MIN.(- XX)

8.2. TOLERANCE

MAX. (XX)9. RESULTS / RESULTATS

15. PASS - FAIL - N.A./ OK - NC - NA (Auto.)

10. Inspection Equipment /Moyen de contrôle

11. Non conformance number /

Numéro de non-conformité

12. Prepared By (signature)

13. Date 16. Completed by (signature) 17. Date 0

CONTRÔLE PREMIER ARTICLE / FIRST ARTICLE INSPECTIONFORM 3

3. Serial Number / Numéro de série

0

2. Part Name / Désignation de l'article

0


0

1. Part Number / Référence de l'article

0

Characteristics / Caractéristiques

14. Comments / Commentaires

Inspection / Contrôle

The signature indicates that all characteristics are accounted for; meet draw ing requirements or are properly documented for disposition. La signature signif ie que toutes les caractéristqiues sont vérifiées, en accord avec les exigences du plan ou correctement documentées, de façon appropriée.


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1. Part Number /Référence de l'article

2. Part Name /Désignation de l'article



0 0 0 0

Photo pièce dans son conditionnement / Color Pict ure within the packaging

FORM 6

PART PICTURE / PHOTO DE L'ARTICLE

PACKAGING PICTURE / PHOTO DU CONDITIONNEMENT

CONTRÔLE PREMIER ARTICLE /FIRST ARTICLE INSPECTION

Photos couleur obligatoire / Color Pictures Mandato ry

Documents

User Guide for First Article Inspection Report (FAI ... · User Guide for First Article Inspection ... is applied within ZODIAC AEROTECHNICS Oxygen Systems Europe ... Oxygen Systems