Incomplete Specification of Special Process Requirements in FAI
Published .
Applicable Standards
AS9102Applicable Sections
- ✓Form 2 — Product Accountability
- ✓Form 3 — Characteristic Accountability
Related
- AS9100
- Nadcap
Topics
- special-process
- fai
- as9102
- flowdown
- specification
- documentation
- nadcap
A supplier submitted a First Article Inspection (FAI) package for a component requiring multiple special processes. The FAI documentation identified the governing specifications for processes such as chemical conversion coating and heat treatment. The receiving quality engineer reviewed the package against the engineering drawing and purchase order requirements.
The FAI form listed the base specification for the special process but omitted the specific type, class, and revision required by the engineering drawing. This omission resulted in incomplete objective evidence that the process performed met the full design intent, creating an ambiguity and a non-conformance.
Key Takeaways
- The FAI package was rejected for failing to adequately document and verify all applicable design characteristics.
- The supplier was required to update the FAI forms to include the full specification details and provide corrected certification from the process source confirming adherence to the specific type and class.
- The FAI form listed the base specification for the special process but omitted the specific type, class, and revision required by the engineering drawing.
Common Mistakes
- This omission resulted in incomplete objective evidence that the process performed met the full design intent, creating an ambiguity and a non-conformance.
- Drawing notes not captured as characteristics.
Best Practice
Verify that FAI documentation captures the complete special process specification, including the correct revision, type, class, and grade as defined by the engineering authority. Listing only the base specification is insufficient for demonstrating full compliance with design requirements per AS9102.
Reflects the recommended position based on community discussion and expert review.
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