Clarifying FAI Requirements for Detail Parts vs. Assemblies
Published .
Applicable Standards
AS9102Applicable Sections
- ✓Form 1 — Part Number Accountability
- ✓Form 3 — Characteristic Accountability
Topics
- fai
- assembly
- definitions
- training
- bom
A supplier submitted a top-level assembly First Article Inspection (FAI) package to the prime customer. The FAI package incorrectly listed the individual components of a sub-assembly directly on the top-level Bill of Materials (Form 1). This occurred because the team did not differentiate between detail parts and assemblies as defined by the governing quality standard.
The FAI was non-compliant because it failed to demonstrate that the sub-assembly itself was separately verified. Per AS9102, each level of assembly that introduces new characteristics requires its own FAI to establish conformity.
Key Takeaways
- The FAI package was rejected, requiring the supplier to create a new, separate FAI for the sub-assembly.
- The top-level FAI was then revised to reference the sub-assembly's unique FAI report number, causing delays in product acceptance.
- The FAI was non-compliant because it failed to demonstrate that the sub-assembly itself was separately verified.
Common Mistakes
- Missing balloon numbers on the drawing.
- Title block requirements not accounted for on Form 3.
- Incorrect or incomplete Form 1 part number traceability.
Best Practice
Personnel must be trained on the specific definitions of 'detail part', 'sub-assembly', and 'assembly' within AS9102. Correctly identifying each item's classification is essential for structuring a compliant FAI package, ensuring each manufacturing level is properly verified with its own linked FAI report.
Reflects the recommended position based on community discussion and expert review.
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