Clarifying the Definition and Identification of Special Processes
Published .
Related
- AS9100
- Nadcap
Topics
- special-process
- fai
- process-control
- brazing
- part-marking
- nadcap
- supplier-quality
A supplier submitted a First Article Inspection (FAI) report for a complex assembly. The manufacturing plan and FAI Form 2 listed several production steps, but there was ambiguity in how certain processes were classified. This prompted a review by the customer's quality engineering team to ensure proper process validation and control.
The supplier's documentation misidentified a standard manufacturing operation, such as part marking, as a special process, while not providing sufficient validation evidence for a true special process like brazing or heat treat. This demonstrated a misunderstanding of the definition in AS9100, which defines special processes as those where the output cannot be verified by subsequent non-destructive inspection.
Key Takeaways
- The FAI package was disapproved pending correction of the process classifications.
- The supplier was required to update their documentation to correctly identify all special processes and provide objective evidence of their validation, control, and use of approved sources (e.g., Nadcap accreditation).
- The supplier's documentation misidentified a standard manufacturing operation, such as part marking, as a special process, while not providing sufficient validation evidence for a true special process like brazing or heat treat.
Best Practice
Ensure all personnel clearly understand the definition of a special process per AS9100/AS13100. Processes whose final output can be verified (e. g.
Reflects the recommended position based on community discussion and expert review.
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