Limit Defects in production of valued product


15th, March, 2019
Limit Defects in production of valued product

During production, inspections can help you to verify product quality. The evaluation method consists of comparing outcomes from measuring the properties and geometry of an initial sample item against given specifications. Along with other inspection methods, first article inspection (FAI) is one of the key stages to limiting product defects in finished products.

First article inspection (FAI)

FAI involves a complete review of all part characteristics, it involves manufacturing engineers and quality engineers reviewing the Technical Data Package (TDP ā€“ part drawings, specifications). First Article ensures that the production process reliably produces the first part. It is design verification and a formal method of providing a reported measurement for a given manufacturing process.

Both Supplier and Client can perform the First Article. The evaluation method consists of comparing finished product from measuring the properties and geometry of an initial sample item against given specifications,

Importance of the first article inspection

Any product that contains expensive components or materials which are difficult to rework might also require first article inspection. These products often have strict dimensional tolerances and are made by using processes that are more vulnerable to calibration error than human error.

Balloon drawing

From quality inspection perspective, a bubble drawing is created and used to locate all designed dimension values such as linear dimensions, Hole dimension, angular dimensions, Chamfer, Radius dimensions, GD&T, Note, Material, surface roughness and Treatment on an engineering drawing. Each dimension value is indicated by a unique numbered bubble (balloon). If there is a similar instance then it consider as a multiple Balloons.

Balloon Drawing and FAI report are Critical part of the Inspection procedure.

  • Comparing all dimensions and characteristics in the approved drawings: –
    This ensures that the Engineer understands and can follow the exact design requirements.
  • Verifying production output to meet requirements and to properly calibrate tooling: –
    It can help to identify any weak step in the production process that could cause defects in mass production and manufacturer need to modify tooling or processes if finished components don’t match specifications.

First Article inspection report

This report restricts the use of a single part in a single application; if a part has many parent applications then each application shall have a First Article Inspection (FAI) Report. Any deviations from drawings shall be highlighted in First Article Inspection report. During the inspection process, the physical and functional characteristics of the product should be verified against drawings, purchase order, specifications, and/or other design documents. The verification must be documented on what is most commonly called a first article inspection report (FAIR).

Each specification dimension is measured on the physical part, compared against the print, First article inspection report might look something like the following:

  • To verify the accuracy of drawings and ensure that they reflect any changes made to parts design during the prototype design.
  • To verify the production process in every parameter, rather than just concentrating on “critical” dimensions.
  • To verify all tooling used to produce a part, to ensure that it is capable of producing parts to specifications.
  • To verify the ability of the manufacturer to meet the needs of production.

Key Advantages of Bubble Drawing and First article inspection report:

  • Automates inspection planning process
  • Eliminates data entry mistakes
  • Saves time
  • Provides easy mechanism for drawing revision
  • It is fast, accurate and reliable.

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