Incomplete Upfront FAI Planning Leads to Documentation Gaps
Published .
Applicable Standards
AS9102Applicable Sections
- ✓Form 2 — Product Accountability
- ✓Form 3 — Characteristic Accountability
Related
- AS9100
Topics
- fai
- planning
- supply-chain
- documentation
- as9102
- configuration-management
- procurement
An organization initiated a First Article Inspection (FAI) on a new product assembly. During compilation of the FAI package, it was discovered that critical source documentation from the supply chain was missing. This included material certifications for raw stock, certificates of conformance for special processes, and FAI reports for lower-tier detail components.
The FAI Report could not be completed because the objective evidence required by AS9102 to verify conformance was incomplete. The absence of a complete documentation package prevented verification of material requirements, special process compliance, and sub-assembly configuration defined by the engineering drawing.
Key Takeaways
- The initial FAI submittal was rejected, causing a production stop until all required sub-tier documentation could be procured, compiled, and verified.
- This resulted in a significant recovery effort to coordinate with suppliers and close the documentation gaps before the FAI could be successfully completed.
- The FAI Report could not be completed because the objective evidence required by AS9102 to verify conformance was incomplete.
Common Mistakes
- The FAI Report could not be completed because the objective evidence required by AS9102 to verify conformance was incomplete.
- Drawing notes not captured as characteristics.
Best Practice
Integrate FAI documentation requirements into the earliest stages of procurement and production planning, not as a final quality activity. Proactively flow down and track the receipt of all required sub-tier evidence, such as material certs and lower-level FAIRs, to ensure a complete package is available before the first article is manufactured.
Reflects the recommended position based on community discussion and expert review.
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