Product Development Process: The Evolution of the Fist Article Inspection Report (FAIR)
The manufacturing industry is trending towards digital first article inspection reports in order to cope with increasing complexity and product variety as well as the need for more comprehensive coordination between customers and suppliers.
From development to series production
In the automotive sector, stringent requirements for quality and safety are placed on the products and thus on the processes of the tier suppliers. Why is this so?
Increasingly close cooperation in the supply chain, shorter development times, higher product variety and increasing complexity require more comprehensive coordination between the customer and supplier. The production process and product release are documented using a standardized procedure to ensure the agreed upon quality, at the planned time and in the required quantity. The trend is moving away from a document-led implementation (via pdf forms, Excel, etc.) to a digital first article inspection report (FAIR). This article outlines the details.
Definition of a First Article Inspection Report
First articles are initial samples (parts, assemblies, units, systems, modules and components) of a trial production that have been manufactured under series conditions using series-production tools. These components are tested, for example, for dimensional accuracy, mechanical and optical properties, to name just a few of the many critical features that must be checked. The first article inspection report, usually abbreviated as FAI or FAIR, is created from the customer's specified nominal values and the test results.
The test samples are subject to the standardizing requirements of quality assurance:
Production at the site of series production
Use of series tooling and devices
Use of series material
Manufacture by employees designated for series production.
Purpose of the FAIR
The FAIR represents an important element of quality assurance. In the course of development, the customer usually has only received prototypes and technical samples. If development advances to series production, adjustments to the changing conditions await the manufacturer. Through the initial samples, the supplier proves that the requirements for series production and the product have been met. At the same time, the FAIR serves important purposes from the point of view of both the customer and the manufacturer:
Granting delivery release
Establishing a common understanding of the specification by the manufacturer and the OEM
Control and specification of the quality of series production
Assurance of the supplier to the customer about the acceptance of the quality criteria
Security for the customer about the quality of his goods
Relevant data for the FAIR
By the time the customer has placed the order and before a component, assembly or software is developed, the requirements must be discussed in detail between the OEM suppliers and the customer. This can take the form of a specification sheet. Usually, the coordination meeting is based on design drawings or the CAD model. This allows for timely clarification of misunderstandings, feasibility challenges or incorrect assumptions.
The requirements in the specifications usually contain the following information:
approved specifications (including legal requirements), spec sheets, drawings, standards, packaging instructions, change status, color sample boards
Dates and timelines
Determination of the number of products to be tested and delivered
Scope of the customer release
Delivery locations for samples
Product scope
Proof for software
Handling of standard parts
Measurement and test methods
Product and process characteristics for capability studies
Implementation of the PPAP process at the production site
Determination of performance test or process validation
Documentation requirements
Dealing with deviations
Re-qualification exams
Defective part analysis process
Claims processing
Reasons for First Article Inspection (FAI)
Most frequently, FAIRs are created when a new component has been developed for a customer and is advancing to series production. However, there are several additional reasons for a first article inspection.
The production of a new part or a new product group
Change in the manufacturing process, for example due to alternate materials, new or modified tooling or other production equipment
Modification of the design data
Change of supplier
Re-release after correcting errors
Relocation of production to another site
Depending on the industry, re-qualification is necessary even during series production. According to ISO 9001, quality controls and approvals are sufficient to ensure series production. For the automotive sector, regular re-qualification, similar to first article inspection, is necessary according to IATF 16949. The requirements for verification are based on the FAIR. The requirements from the standards are are considered implemented only if the following scopes are checked:
Complete dimensional and functional test
Factory certificate for material and function.
The FAIR forms are used for re-qualification. Only the changed data must be rechecked. In case of production relocation or extended downtime, all parameters must be checked.
Contents of the inspection report
With the FAIR, the supplier proves the quality of his products in series production. Therefore, all quality criteria agreed upon between customer and supplier are included. In the report, the NOMINAL and ACTUAL values of the individual parameters are compared against each other. Depending on the complexity, supplementary information is required, such as documentation of the individual parts, labels or the assembly process. FMEA's and the implementation of these measures can also be part of an inspection report.
The contents at a glance:
Cover sheet with article master sheet
Self-assessment on product, production process and, if applicable, software
Proof of product and production process development (i.e. process flow diagrams, production control plans, parts lists and material data)
Evidence for verification of the product (i.e. test results and release documents)
Evidence for validation of the production process (for example laboratory qualification)
General proof (i.e. proofs of compliance with legal requirements or assembly prints)
Proof for software
Proof that sampling has been carried out in accordance with VDA Volume 2 and that the IMDS data set has been created.
The sample parts must be submitted together with the inspection report. The number of samples are typically determined in the quotation phase.
Excerpt from a standard FAI report. Documents are still exchanged in pdf, Word or Excel format in many cases
Number of test samples
The number of test samples should already be determined during then quotation phase. It is usually based on the scope of the tests to be performed. Components from non-destructive tests can subsequently be used in the series. A few points must be considered when determining the number of initial samples:
In molding processes for high volumes, several molds or one mold with several cavities are often used. In these cases, at least one test specimen for each mold or cavity must be inspected.
If there are several variants of a component, the customer decides how many samples of each version he needs. In most cases, these variants can be combined in one FAIR. For example, this applies to different colors, different decorative fabrics or software versions. However, if different technical requirements are placed on the variants, these should be verified with separate FAIRs.
Test production is independent of the planned number of pieces for production. Test production must also be performed for small and medium-sized series. In such cases, customers typically require smaller quantities for these test runs. Nevertheless, quality and technical features must be verified.
Evaluating the initial samples
The initial samples and the FAIR are checked internally at the supplier after they have been created. If the quality assurance department approves the documents and samples, they are made available to the customer. After inspection by the customer, the samples are evaluated in three different release stages:
Full release: authorization for series production without conditions
Conditional release: series production only with conditions and the subsequent correction of problems
Rejected: No series production due to defects in the product or documentation.
Only with full release can production be started without further restrictions. In the case of minor errors that do not affect the function, a conditional release is usually given. A time period or a maximum number of units is agreed for the necessary changes. If the change has not been implemented by this point, production must be stopped.
First Article Inspection not Passed
The first article inspection is not always passed immediately. In the event of deviations above the tolerance limits, corrective actions must be implemented and documented. After implementing the changes, a test production is carried out again under series conditions. Initial samples are again taken from this new production and tested. This cycle continues until the test samples can be released.
Digital FAI
A first article inspection report contains a lot of data, which takes a lot of effort to compile. Components made of several materials, complex assemblies or different requirements for variations increase the inspection and processing time further. Additionally, manual data transfer can lead to errors. Therefore, digital processing of FAIR is becoming more and more mainstream. The advantages lie in:
Time savings as a result of automatic data transfer from drawings
Digital data transfer and thus a paperless process
Error-free and standardized and thus independent of the person who compiles the data
Direct transfer of measurement values from digital measuring equipment into the test report
Time saving for subsequent testing, for re-qualification, due to rejected reports or due to changes
Transfer of nominal values directly from the customer's drawings.
By digitizing the inspection report, at least 50% of professionals' working time can be saved. At the same time, it saves the company time in forwarding manual reports and approval by the customer. Thanks to clear assignment of data, drawings and test results, series production can start faster.
Advantages of digital FAI with the supply chain collaboration platform material.one
Further facilitation for manufacturers is provided by material.one's Supplier Network Collaboration Platform. In this platform use case, this cloud-based solution connects manufacturers and testing laboratories to digitize the complete testing process. Based on the 3D data of the component as well as legal standards and test specifications of the customer, a proposal for a test plan is created. Requests to available laboratories and the posting of results to the FAIR are handled independently by material.one's software. The Supplier Network Collaboration Platform provides further saving of valuable working time, another distinct advantage. The process takes place in the following steps:
The customer provides the 3D data with the requirements via the platform
The platform creates a draft test plan and requests quotations from test institutes and laboratories
The test labs test the product and post the results themselves in the cloud
An FAIR is created from the data and then checked
The customer receives the test report and decides on the release according to specifications
The FAIR is archived.
Figure: Example of a digital FAI generated via material.one. You can download this digitally generated FAI here (pdf Plastic Enclosure).
In addition to the standard requirements for the tests, the platform has interfaces to various databases. This allows information on material and material sampling, recycled content and certificates to be automatically included in the report. In this way, the product's CO₂ footprint can be provided to the customer.
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