Supplier Quality Requirements for First Article Inspection SQR-011. Revision Date: 30 November Approved. Frank Mariot

Transcription

1 Supplier Quality Requirements for First Article Inspection SQR-011 Revision Date: 30 November 2016 Approved Frank Mariot Supply Chain Quality Manager Suppliers may view this document via the Internet at: To obtain a hard copy, please notify Triumph Aerostructures, LLC or Triumph Aerostructures Tulsa, LLC Procurement Representative Supplier Quality Requirements for First Article Inspection Revision E Page 1 of 12

2 REVISION RECORD The latest issue of this manual may be confirmed by viewing the Suppliers web site (address shown on the cover). Revision Date Revision Date Revision Date Rev. NC 16 Mar 2011 Rev. A 26 Oct 2011 Rev. B 20 Sep 2013 Rev. C 28 Sep 2014 Rev. D 13 Mar 2015 Rev. E 30 Nov 2016 The following is for Triumph Aerostructures, LLC and Triumph Aerostructures Tulsa, LLC internal use only: The information contained in SQR-011 is controlled by the owner listed in the signature sign-off block and is linked to applicable command media. The owner is responsible for the integrity and maintenance of the SQR. PROPRIETARY RIGHTS Triumph Aerostructures, LLC and Triumph Aerostructures Tulsa, LLC proprietary rights are retained for the information contained herein. The recipient, by acceptance of this document, agrees that neither this document nor the information contained herein, nor any part thereof shall be reproduced or transferred to any other document, used or disclosed to others for any purpose, except as specifically authorized in writing by Triumph Aerostructures, LLC and Triumph Aerostructures Tulsa, LLC. Employees of Triumph Aerostructures, LLC or Triumph Aerostructures Tulsa, LLC may reproduce information contained in this document for internal purposes as necessary. All such copies must be prominently identified as REFERENCE ONLY and/or UNCONTROLLED COPY. Supplier Quality Requirements for First Article Inspection Revision E Page 2 of 12

3 Rev NC Summary of Changes New Document Rev A Summary of Changes Section 4.3 added to clarify the -FP Suffix Rev B Summary of Changes Section 2.1 clarification for mandatory fields and link updates Rev C Summary of Changes Section 1.5 at the discretion of Triumph, suppliers may be subjected to charges for recovery of costs associated with any/ all supplier responsible costs or damages which Buyer incurs due to failure of FAI review first time yield (FTY). Amendment Date November 13, 2014 Section 2.7 clarification on requirement - Copy of COMPLETED shop traveler that represents the manufacturing process Rev D Summary of Changes Adding Section The FAI requirement can be satisfied by either a dimensional report of the part or a dimensional report of the Check Fixture tool being used as a means of product acceptance. This dimensional report of the Check Fixture tool will ensure that all critical features of the part are being validated. Rev E Summary of Changes Logos information updated Triumph Aerostructures, LLC and Triumph Aerostructures Tulsa, LLC Approvals (Authorizing Signature on File) Frank Mariot -Supply Chain Quality Manager Introduction Section This Document is effective for the following Triumph Aerostructures Companies: Triumph Aerostructures, LLC and Triumph Aerostructures Tulsa, LLC from here on inclusively refer to as Triumph. Supplier Quality Requirements for First Article Inspection Revision E Page 3 of 12

4 TABLE OF CONTENTS Section Title Page Cover sheet 1 Revision Record 2 Summary of Changes 3 Table of Contents 4 Introduction 5 General First Article Inspection Requirements Net-Inspect Digital Product Definition First Article Inspection Review Definitions Acronyms 12 Attachments Attachment Title 1 FAIR Check Sheet Supplier Quality Requirements for First Article Inspection Revision E Page 4 of 12

5 Introduction This Document is effective for the following Triumph Aerostructures Companies: Triumph Aerostructures, LLC and Triumph Aerostructures Tulsa, LLC from here on inclusively refer to as Triumph. This document outlines the FAI requirements for Triumph suppliers to ensure that all design features of a deliverable product are captured and that its sub components meet all applicable levels of design drawing, material and process specification requirements. This document is a supplement to Triumph s Supplier Quality Assurance Requirements (SQAR) and intended to provide a consistent documentation requirement on FAI s submitted from Triumph supplier. General FAI is a process imposed on assemblies, sub-assemblies and detail parts (including castings, forgings, machined, composite, raw material cut to an engineering shape/part number, etc.). An acceptable first article product is a representation of those planned, capable and repetitive manufacturing processes and proven tooling which produced it. A complete FAI must be submitted prior to shipment of product. The supplier must be able to demonstrate to Triumph, upon Triumph s request that the intent of FAI was successfully accomplished, and show objective evidence thereof. The supplier will ensure FAI s submitted on behalf of sub-tier suppliers have been reviewed and are compliant with the requirements of this document. Sister companies and/or divisions of the same company are considered as sub-tier suppliers and are subject to the requirements of this document. All Triumph procurements require an acceptable FAI. All line items on a purchase order must be accounted for in Net-Inspect. 1.0 First Article Inspection Requirements 1.1 The FAI should be performed on a representative item from the first production run of a new part using the planned build package unless otherwise negotiated with Triumph. 1.2 The supplier shall perform and document FAI in accordance with SAE Aerospace Standard AS9102. This document can be found and purchased at: The FAI will not be considered complete until all build package issues are resolved. Build package consists of: Engineering Specifications Planning Tooling NC Data (as applicable) Supplier Quality Requirements for First Article Inspection Revision E Page 5 of 12

6 1.4 The FAI will not be considered complete until nonconformance s affecting the part or assemblies have been closed and corrective action implemented. Partial FAI s will be performed for those affected characteristics and the results recorded. 1.5 At the discretion of Triumph, suppliers may be subjected to charges for recovery of costs associated with any/ all supplier responsible costs or damages which Buyer incurs due to failure of FAI review first time yield (FTY). 1.6 The FAI requirement shall continue to apply even after initial compliance. Partial or complete re-accomplishment of the FAI for affected characteristics is required for the following events: A change in the design affecting the form, fit or function of part. A change in manufacturing source(s), processes, processors, inspection method(s), location, tooling or material with the potential of affecting form, fit or function. When required as part of a corrective action for a part number with repetitive rejection history (typically a part with three repeated rejections or as required by the customer). A change in numerical control program or translation to another media. A natural or man-made occurrence, which may adversely affect the manufacturing process. A lapse in production for two years or as specified by Triumph. 1.7 All suppliers FAI s shall meet or exceed the requirements of this document and AS When the supplier chooses to procure subassemblies and parts, these FAI requirements shall be imposed by the supplier upon the sub-tier supplier. These requirements in no way limit, supersede, or abrogate any contractual obligations specified in Triumph s procurement document. 1.9 If the supplier is furnishing kits to Triumph, a FAI must be performed and documented by the supplier for each item in the kit, as well as the kit level part number For product procured in support of Airbus UK programs, Airbus UK FAI validation is required prior to shipment. Supplier shall contact Triumph procurement to schedule appropriate FAI review by Triumph / Airbus UK personnel. NOTE: SUPPLIER SHALL NOT CONTACT AIRBUS UK REPRESENTATIVE DIRECTLY. TRIUMPH SOURCE INSPECTION SHALL PRECEED AIRBUS UK FAI INSPECTION UNLESS OTHER WISE DIRECTED The FAI requirement can be satisfied by either a dimensional report of the part or a dimensional report of the Check Fixture tool being used as a means of product acceptance. This dimensional report of the Check Fixture tool will ensure that all critical features of the part are being validated. The following are required to use the tool to satisfy the dimensional verification of the part and/or assembly: Supplier Quality Requirements for First Article Inspection Revision E Page 6 of 12

7 2.0 Net-Inspect The tool will be identified The tool will be validated by dimensional report to ensure that all critical features of the part and/ or assembly will be validated The tool will be called out in the supplier s planning The tool will be periodically re-valuated to assure it still complies with engineering requirements 2.1 All suppliers are required to utilize the Triumph web based Net-Inspect FAI process, which is AS9102 based and compliant. Triumph identifies AS9102 Customer Specific Use fields in the Net-Inspect Training located under: Quality Requirements/ Business Unit Quality Requirements / Triumph / Net Inspect Utilization. Field 11, Field 12 and Field 18 (As Required) are considered mandatory. Access to view the training syllabus from the following URL: All fields are required to be populated with the respective data and should not be left blank. Any field that does not require data should be identified as N/A. 2.3 Access Net-Inspect website from the following URL: If the supplier is currently utilizing an electronic AS9102 based FAI process or is still utilizing a paper AS9102 form (either of which must include customer directed options), then you may include these as attachments after initiating and completing Form 1 in Net-Inspect in lieu of completing the Net-Inspect Form 2 and Form See Attachment 1 for FAIR check sheet that describes the most common elements of review. Review may not be limited to these elements. Each deliverable site has the option to activate a mandatory FAIR check sheet within Net-Inspect. Once activated, supplier delivering product to that site will be required to complete check sheet prior to final FAI submission. 2.6 This requirement shall apply to the line item deliverable part number only; unless the deliverable is a kit then it applies to the details that comprise the kit (this requirement does not apply to FAI s for details contained within an assembly). 2.7 The following items/documents (as applicable) shall become a part of the electronic record and shall be referenced and attached to the electronic FAI file for the applicable part number: Material Certifications Process Certifications Test Reports/ Results CMM Reports point maps and set-up instructions are mandatory. Supplier Quality Requirements for First Article Inspection Revision E Page 7 of 12

8 Copy of COMPLETED shop traveler that represents the manufacturing process Copy of all rework travelers Copy of the Triumph furnished TSSP Unique Characteristic Accountability must correspond with unique identifier on bubbled drawing/sketch Photos (as applicable) Casting / Forging approvals (as applicable) Weld maps (as applicable) NDI/NDT techniques Manufacturing plan approvals (as applicable) Withholding Tags (as applicable) Supplier Information Request (SIR) (as applicable) 3.0 Digital Product Definition (DPD) 3.1 When the engineering is based on Digital Product Definition the following guidelines shall be taken into account: All features that are defined by the 3-D model must be included in the product acceptance plan and accounted for as part of the FAI documentation. When the dimensional characteristics are not defined by either a standard linear tolerance or GDT feature control frame on the face of the model, these features are defined in the parts list and/or notes on the drawing. o Examples of un-dimensioned part characteristics include but not limited to, gage thickness, surface locations, and part periphery. The FAI shall account for the entire engineering dataset (i.e., the general/flag notes, parts list, all features/characteristics per defined tolerances.) 4.0 First Article Inspection Review 4.1 Triumph s first article review shall be performed on all parts. The Triumph FAI validation is required at the purchase order line item level. A Triumph quality representative shall validate that the supplier has performed the FAI s on all detail components below the line item level where applicable. The supplier shall make available any detail FAI as requested by the quality assurance representative. 4.2 Supplier shall notify Triumph in advance of the need for first article review. It is the responsibility of the Supplier to coordinate and schedule Triumph s first article review as early during PO execution as practical. In addition to Triumph s first article review, Triumph s engineering drawing or Triumph s written instruction may require an engineering first article evaluation. When required, supplier shall schedule and support this requirement similar to first article review. 4.3 Supplier shall mark all deliverable products and documents in accordance with the purchase order, manufacturing planning, or engineering drawing in that order of precedence. It is not the intent of Triumph to require two separate FAI s that fall under the _FP transition period. The first production lot shall require an FAI. An FAI requirement shall not be generated due to the addition of or deletion of -FP. Supplier Quality Requirements for First Article Inspection Revision E Page 8 of 12

9 5.0 Definitions The FAI shall be identified to the PO part number without the -FP suffix In the event there is a conflict between the requirements defined and the engineering drawing and/or specification, the drawing/specification takes precedence Initial Purchase Order (PO) Part Number may contain a -FP suffix utilized internally at Triumph to control work orders issued during the Make to Buy transition. The related Triumph Planning instructions will direct the supplier to disregard the FP suffix when identifying the part or assembly Example: PO Part Number: 65B FP Planning ID Operation Text: Supplier shall omit the FP suffix when performing part marking activity. For example: 65B FP shall be part marked as 65B NOTE: Production of deliverable items prior to Triumph s acceptance of FAI will be at supplier s own risk. ATTRIBUTE DATA CAM CMS DESIGN CHARACTERISTICS A result from a characteristic or property that is appraised only as to whether it does or does not conform to a given requirement. (For example, go/no-go, accept/reject, pass/fail, etc.) Computer Aided Manufacturing Also known as numerical control (NC). The use of computers and computer data in the development and production of all part types (products) including fabrication, assembly and installation. Coordinate Measurement Systems - Also known as Computer Aided Inspection (CAI) and Computer Aided Measurement Systems (CAMS). Measurement equipment such as Coordinate Measuring Machines (CMM), Laser Tracker, and numerical controlled machinery with inspection probe capability, which are used to support inspection activity. Those dimensional, visual, functional, mechanical, and material features or properties, which describe and constitute the design of the article as specified by Drawing Requirements. These characteristics can be measured, inspected, tested, or verified to determine conformance to the design requirements. Dimensional features include in-process locating features such as target-machined (or forged/cast) dimensions on forgings and castings, and weld/braze joint preparation necessary for acceptance of finished joint. Material features or properties may include processing variables and sequences, which are Supplier Quality Requirements for First Article Inspection Revision E Page 9 of 12

10 specified by the drawings (e.g., heat treat temperature, fluorescent Penetrant class, ultrasonic scans, and sequence of welding and heat treat). These provide assurance of intended characteristics that could not be otherwise defined. DESIGN TOOLING DRAWING REQUIREMENTS DATASET DPD FEATURE FIRST ARTICLE INSPECTION (FAI) FIRST ARTICLE INSPECTION REPORT (FAIR) INSPECTION PLAN (CRITERIA) Specially designed tooling (includes NC Programming) that is controlled by serialization and is used as a media of inspection. Requirements of the drawing (including parts lists), specification, or purchasing document to which the article is to be made. These include any notes, specifications, and lowerlevel drawings invoked. Information prepared and maintained by electronic means (CAD/CAM), and provided by electronic data access, interchange transfer or on electronic media. Digital Product Definition- The electronic data elements that specify the 3-D Computer Aided Design (CAD) geometry and all design requirements for a product (including notation and parts lists), and the use of this data throughout an integrated CAC/Computer Aided Manufacturing (CAM) and Coordinate Measurement Systems (CMS). Any hardware design attribute or characteristic. This includes physical portion of hardware such as a surface, face, edge, radius, hole, tab, slot, pin, etc., and requirements such as nondestructive inspection (NDI) and interchangeability and replaceability (I&R). All features require validation to conform the product to the design authority. All features have associated notes and/or Geometric Dimensioning and Tolerance Feature Control Frames (FCF) and one note or FCF may refer to several features. A complete, independent, and documented physical and functional inspection process to verify that prescribed production methods have produced and acceptable item as specified by released engineering product definition, planning, purchase order, engineering specifications, and/or other applicable design documents. The forms and package of documentation for a part number or assembly, including FAI results. A description of 2-D and/or 3-D computer generated inspection media/methods derived from authority DPD datasets and used to communicate inspection requirements and media usage to manufacturing and inspection area. Typical plans include engineering and plan configuration/traceability, overlay/setup Supplier Quality Requirements for First Article Inspection Revision E Page 10 of 12

11 instructions and a list and/or graphic representation of the features to be inspected. MBD MDI Model Based Definition A Triumph dataset containing the exact solid, it s associated 3-D geometry and 3-D annotation of the product s dimensions and tolerances (and may include parts/notes list/ to specify a complete product definition. This dataset does not contain a conventional 2-D drawing. MBD is on possible format of DPD. Master Dimensions Identifier A number identifying an array of coordinate data used by Design, Manufacturing and Inspection to describe an element of a surface or product configuration. The data may be an extraction from an MDD or any CATIA/APT designed surface. MDS Master Dimension Surface A computer generated, mathematically controlled CATIA 3-D surface definition. Each surface is uniquely identified by number. MEDIA OF INSPECTION PARTIAL FAI REFERENCE ONLY (REF) SUPPLIER VARIABLE DATA A tool used by Inspection to verify the acceptance of specific physical characteristics of a component, part or assembly. (e.g., physical tool, paper, Mylar, electronic data) A Partial FAI addresses differences between the current configuration and prior approved configurations, and/or addresses features that failed the original FAI. When a partial FAI is performed, the Organization shall complete only the impacted fields in the original or partial FAI form(s). The partial FAI will inspect 100% only those features that have been addressed for the current configuration and/or that failed the original/partial FAI. The characteristics that are used for information only or to show relationship. These are dimensions without tolerances and refer to other dimensions on the drawing. An entity working under supplier contract(s) and providing products or services on Triumph programs. Quantitative measurements taken on a continuous scale. For example, the diameter of a cylinder or the gap between mating parts. Supplier Quality Requirements for First Article Inspection Revision E Page 11 of 12

12 6.0 Acronyms CMM FAI GDT NC PO TSSP UK Coordinate Measuring Machine First Article Inspection Geometric Dimensions and Tolerance Numerical Control Purchase Order Triumph Supplier Specification Plan United Kingdom 3-D Three Dimensional Supplier Quality Requirements for First Article Inspection Revision E Page 12 of 12