In the aerospace and defense industries, precision and compliance are paramount. Whether a part is going on a SpaceX Starship rocket, or a Lockheed F35 fighter jet, or a US Navy submarine, quality is key. When it comes to introducing a new or revised part, the First Article Inspection (FAI) process is the gold standard for ensuring every requirement is met. AS9102, part of the broader AS9100 quality management system, is the standard that governs this crucial process. But what’s changed in the latest revision, AS9102 Rev C, and how does it impact your work? Let’s dive in.
AS9102 outlines the requirements for conducting and documenting FAIs. These inspections are necessary whenever a new part is produced or an existing part is revised, ensuring that the part meets all specified requirements before full-scale production begins. The goal? To provide confidence that the production process is capable of delivering a product that conforms to design specifications. The standard is divided into three main forms:
• Form 1: Part Number Accountability – Tracks the parts being inspected.
• Form 2: Product Accountability – Focuses on materials, processes, and functional testing.
• Form 3: Characteristic Accountability – Documents inspection results for each design characteristic.
Since its inception in 2000, AS9102 has seen several revisions, each aimed at refining the FAI process:
• Original AS9102 (2000): Established standardized FAI requirements and became the industry benchmark for supplier documentation.
• AS9102 Rev A (2004): Clarified when to perform an FAI and improved the standard’s layout for better usability.
• AS9102 Rev B (2014): Emphasized the value of FAI, separated planning and evaluation activities, and addressed the growing importance of Digital Product Definition (DPD).
What’s New in AS9102 Rev C?
Released in 2023, AS9102 Rev C introduces several key updates to align more closely with the AS9100 standard and enhance the overall FAI process:
• Rev C has been updated to better align with the production process verification section of AS9100, ensuring a more cohesive approach to quality management across the board.
• The new revision places greater emphasis on planning and executing FAIs, ensuring that each step is meticulously documented and evaluated. This change aims to improve the accuracy and reliability of the FAI process.
• Form 1 now requires more detailed information, such as specifying the reason for conducting a Full or Partial FAI (Field 14). The form also clarifies that all parts within a Bill of Materials (BOM), including COTS items, must be listed.
• Form 2 has seen the removal of the signature field, streamlining the process. The language regarding Special Processors has been strengthened, making it clear that suppliers performing special processes must either create a FAIR or document the results on a detailed Certificate of Conformance (CoC).
• Form 3 also sees a simplification with the removal of the signature field, allowing for a more straightforward documentation process.
The transition from Rev B to Rev C includes several subtle yet significant changes:
• Form 1: The updates to field names and the mandatory inclusion of COTS parts in the BOM section ensure greater clarity and accountability.
• Form 2: With the signature field removed, the focus shifts to ensuring that special processes are adequately documented, whether through a FAIR or a CoC.
• Form 3: The removal of the signature field simplifies the process, reflecting an ongoing effort to streamline documentation without compromising on thoroughness.
At GroundControl, we’re committed to helping you navigate these updates with ease. Our AS9102 report generation software is designed to fully support the latest Rev C requirements, enabling you to complete error-free FAI reports up to 10x faster. Whether you’re dealing with complex assemblies or managing digital product definitions, GroundControl automates the process, ensuring compliance and efficiency every step of the way.
Ready to enhance your FAI process? Discover how GroundControl can help you achieve faster, error-free compliance with AS9102 Rev C.
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