Supplier Quality Requirements for First Article Inspection SQR-011 Revision Date: 16 March 2011 Approved David Copeland, Manager Supply Chain Quality Suppliers may view this document via the Internet at: http://www.voughtaircraft.com/suppliers/ To obtain a hard copy, please notify Triumph Aerostructures - Vought Aircraft Division Procurement Representative.
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 The following is for Vought 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 - Vought Aircraft Division 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 - Vought Aircraft Division Employees of Triumph Aerostructures - Vought Aircraft Division 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. 2
Rev. NC Summary of changes: New Document 3
TABLE OF CONTENTS Section Title Page Cover sheet 1 Revision Record 2 Summary of Changes 3 Table of Contents 4 Introduction 5 General 5 1.0 First Article Inspection Requirements 5 2.0 Net-Inspect 7 3.0 Digital Product Definition 8 4.0 First Article Inspection Review 8 5.0 Definitions 9 6.0 Acronyms 12 Attachments Attachment Title 1 FAIR Check Sheet 4
Introduction This document outlines the FAI requirements for Triumph Aerostructures - Vought Aircraft Division (Vought) 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 Vought s Supplier Quality Assurance Requirements (SQAR) and intended to provide a consistent documentation requirement on FAI s submitted from Vought 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 Vought, upon Vought 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 Vought procurements require an acceptable FAI. All line items on a purchase order must be accounted for in Net-Inspect. 1. 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 Vought. 1.2. The supplier shall perform and document FAI in accordance with SAE Aerospace Standard AS9102. This document can be found and purchased at: http://www.sae.org/products/standards/hotaero.htm. 1.3. 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) 5
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. 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 Vought. 1.6. All supplier FAI s shall meet or exceed the requirements of this document and AS9102. 1.7. 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 Vought s procurement document. 1.8. If the supplier is furnishing kits to Vought, a FAI must be performed and documented by the supplier for each item in the kit, as well as the kit level part number. 1.9. For product procured in support of Airbus UK programs, Airbus UK FAI validation is required prior to shipment. Supplier shall contact Vought procurement to schedule appropriate FAI review by Vought/Airbus UK personnel. NOTE: SUPPLIER SHALL NOT CONTACT AIRBUS UK REPRESENTATIVE DIRECTLY. VOUGHT SOURCE INSPECTION SHALL PRECEED AIRBUS UK FAI INSPECTION UNLESS OTHER WISE DIRECTED. 6
2. Net-Inspect 2.1. All suppliers are required to utilize the Vought web based Net-Inspect FAI process, which is AS9102 based and compliant. Vought identifies AS9102 Customer Specific Use fields in the Net-Inspect Training located at http://www.voughtaircraft.com/suppliers/ under Quality and Net-Inspect. Use of the fields as identified in the training syllabus is mandatory. 2.2. 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: http://www.net-inspect.com/. 2.4. 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 3. 2.5. 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. Copy of the shop traveler that represents the manufacturing process. Copy of all rework travelers. Copy of the Vought furnished MOT/MOI (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) 7
NDI/NDT techniques Manufacturing plan approvals (as applicable) Withholding Tags (as applicable) Supplier Information Requests (as applicable) 3. Digital Product Definition 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. First Article Inspection Review 4.1. Vought s first article review shall be performed on all parts. The Vought FAI validation is required at the purchase order line item level. A Vought 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 Vought in advance of the need for first article review. It is the responsibility of the Supplier to coordinate and schedule Vought s first article review as early during PO execution as practical. In addition to Vought s first article review, Vought s engineering drawing or Vought s written instruction may require an engineering first article evaluation. When required, supplier shall schedule and support this requirement similar to first article review. Note: Production of deliverable items prior to Vought s acceptance of FAI will be at supplier s own risk. 8
5.0 Definitions ATTRIBUTE DATA 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/nogo, accept/reject, pass/fail, etc.) CAM 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. CMS 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. DESIGN CHARACTERISTICS 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 specified by the drawings (e.g., heat treat temperature, fluorescent Penetrant class, ultrasonic scans, sequence of welding and heat treat). These provide assurance of intended characteristics that could not be otherwise defined. DESIGN TOOLING Specially designed tooling (includes NC Programming) that is controlled by serialization and is used as a media of inspection. 9
DRAWING REQUIREMENTS 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 lower-level drawings invoked. DATASET Information prepared and maintained by electronic means (CAD/CAM), and provided by electronic data access, interchange transfer or on electronic media. DPD 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). FEATURE 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 non-destructive 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. FIRST ARTICLE INSPECTION (FAI) 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. 10
FIRST ARTICLE INSPECTION REPORT (FAIR) The forms and package of documentation for a part number or assembly, including FAI results. INSPECTION PLAN (CRITERIA) 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 instructions and a list and/or graphic representation of the features to be inspected. MBD Model Based Definition A Vought dataset containing the exact solid, its 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. MDI 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 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) 11
PARTIAL FAI 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. REFERENCE ONLY (REF) 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. SUPPLIER An entity working under supplier contract(s) and providing products or services on Vought programs. VARIABLE DATA Quantitative measurements taken on a continuous scale. For example, the diameter of a cylinder or the gap between mating parts. 6.0 Acronyms CMM Coordinate Measuring Machine FAI First Article Inspection GDT Geometric Dimensions and Tolerance MOT/MOI Manufacturing Operations Transmittal/Manufacturing Operations Instructions NC Numerical Control PO Purchase Order TSSP Triumph Supplier Specification Plan UK United Kingdom 3-D Three Dimensional 12