How to Create a First Article Inspection Report

5 Steps to Create a First Article Inspection Report

A First Article Inspection Report is a document certifying that every sample produced was created and inspected with regard to customer specifications. First Article Inspection revolves around planning, producing and verifying a manufacturing process. 

What Is a First Article Inspection?

According to https://www.3d-engineering.net/first-article-inspection, a first article isn’t actually the very first unit that is produced in the production line. First articles are those units that are produced in bulk during the first production run. Prototypes or pre-production articles or samples are not included in the first articles list. This is because they are produced using processes that may not be used during mass production. First article inspection involves the inspection of a random sample chosen from the first production run. 

Inspection is conducted at this early stage of the production process to check if the production staff has incorporated your requirements into the articles and processes. If the inspection meets your standards, then you can be relieved that the factory will be able to mass produce the products according to your standards. 

Majority of the companies conduct the AS9102 first article inspections. However, this inspection can vary from company to company. The AS9102 is the SAE requirement that governs the first article inspection, especially in America. Here are 5 steps to create a first article inspection report. 

Step 1 – Pre-planning

The first step is pre-planning. There are a bunch of documents required to conduct your inspection. This documentation will help you identify all those factors that you need to monitor and keep your eye on. Here are a few documents required to pre-plan the inspection. 

• Digital product definition data sets
• Raw Material list
• Manufacturing planning
• Work order
• Supplier information
• Engineering drawings
• Specifications

Step 2 – Create an Inspection Plan

The second step involves the development of an inspection plan. It consists of the following process. 

• Identify the requirement that will undergo inspection with a balloon number. 
• Fill in the AS9102 forms – form number one is about number accountability and form two is about product accountability. You will get the information to fill the form from the Bill of Materials and Specifications list. 
• List the reference location of the balloon.
• List the requirements comprising of the measuring units and other requirements that vary according to tolerances. 
• Lastly, list the classifications including critical, major and key factors. 

Step 3 – Manufacture the Part

The third step is manufacturing the product. 

• Develop the product and make sure that you properly document and record the entire process and inspection result
• Remember that the first article isn’t necessarily the first good produced; it is a randomly selected item from the first production run. 
• Keep certified inspection tools in check so that they can be traced back to the person who used the tool to measure the manufacturing process accurately. 

Step 4 – Collect Data

The fourth step consists of gathering the data from the entire process. 

Step 5 – Create Report

The fifth step involves the creation of the report. 

• Enter the measurement data result in the form. 
• Make sure you use qualified tooling.
• Ensure that the information is non-conforming.
• Draw up a Functional Test Report. 

The first article inspection report is extremely important for maintaining the quality of the products. Ensure that you conduct this report when starting a manufacturing process.