Processes: First Article InspectionPerforming this process may sound a bit premature when still developing a working prototype and may in fact not be needed depending upon what the prototypes are being used for in Engineering. However, getting in the practice of validating functionality as well as dimensional accuracy will help yield a better product in a shorter amount of time.A First Article Inspection is much more than just inspecting the parts to the drawing from my perspective. It is a complete functional check of the product, which includes dimensional verification, electrical/electronic verification and performance within the system. This would apply to any part within a manufactured item. Performing this process and understanding these results early on will help alleviate possible issues when it comes time for production. A simple example of this would be that say a part is out of tolerance for a dimension on the drawing so it is technically ‘rejected’ on the FAI form. However, when this part is assembled into the system and subsequently tested, the out-of-tolerance dimension has no impact at this higher level. So what should be done? You could loosen up the tolerance or change the part dimensioning itself. In either case, you have options to correct the situation and in some cases make the part more manufacturable for the supplier. I would of course also notify the supplier that he did not meet the part specification. This can be done informally (email or phone call) or through the formal use of a CAR (Corrective Action Request) form. This process asks for why the CM did not meet the specification, what actions will be taken to meet the specification moving forward and a time on when this corrective action will be implemented.
The most important thing here is to validate as much as possible as early on as possible.
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