1.0 The purpose of carrying out an FAI is to give objective evidence that all engineering,design and specification requirements are correctly understood, accounted for, verified and recorded. The document is intended to guide how this is achieved.
2.0 An FAI should be performed on all new products that are representative of the first production run. The FAIs should be performed in accordance with SAE AS9102.
3.0 In support of the FAI, The Supplier should review:-
a) Documentation for the manufacturing process
b) That any special processes are documented and implemented correctly and that any manufacturing planning/routing documents correctly relate to relevant specifications.
c) That key characteristics have been met.
d) That specific gauges and tooling is qualified/calibrated and traceable as applicable.
e) That every design characteristic requirement is accounted for, is uniquely identified and has inspection results traceable to each unique identifier.
4.0 The FAI requirement, once invoked, should continue to apply even after initial compliance.
5.0 When a partial FAI is performed, only the affected fields on the FAI form shall be completed. The remaining fields shall be completed when possible, or previous data may be referenced if it applies to identical characteristics of similar parts produced by identical means.
6.0 A full or partial FAI shall be performed when there is:
a) A change in design, affecting Fit, Form or function of the product.
b) A change of manufacturing source(s), process(es), inspection method(s), location of
manufacture, tooling or materials, that can affect fit, form or function.
c) A change in a program (computer generated) that can affect fit, form or function.
d) An event that can affect the manufacturing process (natural or man made)
e) A lapse in production for a period of 2 years or as specified by the customer – SIRS.
7.0 For components or assemblies regularly manufactured by the supplier, that have had an initial FAI prior to each manufacture that may involve tool setting, sharpening, adjustment; a new FAI will be required.
8.0 The FAI shall not be considered complete until all relating non-conformances are closed and corrective actions – implemented.
9.0 The documents attached can be used as templates to complete the FAI.