Assembly FAI Approval Depends on Compliant Sub-Tier FAIs
Published .
Related
- AS9100
Topics
- fai
- assembly
- sub-tier-control
- as9102
- flow-down
- nonconformance
A supplier submitted a First Article Inspection (FAI) package for a complex assembly. The top-level assembly report was populated, and all assembly-level characteristics were verified. However, the package also included FAIs for several detail parts and sub-assemblies manufactured to specific engineering drawings.
During review, it was discovered that the FAI for a critical sub-assembly was either missing or documented an unresolved nonconformance. The supplier believed the top-level assembly FAI could be approved independently since all final assembly-level checks were passed.
Key Takeaways
- The customer rejected the top-level assembly FAI because the non-compliant sub-tier FAI invalidated the objective evidence of overall product conformance.
- This rejection delayed production approval and required the supplier to remediate the sub-tier issue and resubmit the entire FAI package.
- During review, it was discovered that the FAI for a critical sub-assembly was either missing or documented an unresolved nonconformance.
Common Mistakes
- During review, it was discovered that the FAI for a critical sub-assembly was either missing or documented an unresolved nonconformance.
- Missing balloon numbers on the drawing.
- Title block requirements not accounted for on Form 3.
- Drawing notes not captured as characteristics.
Best Practice
An assembly FAI is a summation of its constituent parts and cannot be considered acceptable if any required sub-tier or detail-level FAI is missing, incomplete, or nonconforming. Per AS9102, ensure all lower-level FAIs are complete and approved prior to submitting the top-level assembly FAI package for review.
Reflects the recommended position based on community discussion and expert review.
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