QP-8.6 First Article Inspection

Revision C · Effective 2026-05-18

1 Purpose

This procedure defines when a first article inspection (FAI) is required, how it is performed and documented to AS9102, who may approve it, and how the FAI package is provided to customers.

2 Scope

Applies to every part number and assembly produced at the Wichita plant for delivery to a customer. It does not replace first-piece approval at machine startup (WI-120), which is performed on every job setup.

3 Definitions

• FAI - a complete, independent and documented verification that the production process produces a part meeting every drawing and specification requirement.
• FAI Report - F-860-01, consisting of AS9102 Form 1 (part number accountability), Form 2 (product accountability: raw material, special processes, functional testing) and Form 3 (characteristic accountability, verification and compatibility evaluation).
• Ballooned drawing - the customer drawing with every characteristic numbered to match Form 3.
• Partial (delta) FAI - an FAI that re-verifies only the characteristics affected by a change.

4 Responsibilities

• Quality Engineer (Tomas Reyes) - determines FAI type, balloons the drawing, performs the second-person review and approves the FAI.
• Quality Manager - may approve an FAI in place of the Quality Engineer.
• Quality Technician / CMM programmer - measures characteristics per WI-210 using CMM programs released per WI-215. Contract CMM programmers may program and run the CMM but do not approve FAIs.
• Manufacturing Engineer - identifies process, tooling and NC program changes that may require a partial FAI.

5 Procedure

5.1 When a full FAI is required

A full FAI covering every characteristic is required for:

• a new part number;
• a part number made for a new customer;
• a change of manufacturing location (including moving the work to a different Tallgrass building or to an outside supplier);
• a lapse in production of the part number of 2 years or more, measured from the last shipment.

5.2 When a partial (delta) FAI is required

A partial FAI covering the affected characteristics is required for:

• a drawing revision change;
• a change of manufacturing process, tooling or NC program that affects a characteristic;
• a change of supplier for a special process (for example a new anodize or heat-treat source).

The Quality Engineer documents the reason and the characteristics included on Form 1. If in doubt, a full FAI is performed.

5.3 Performing the FAI

1. The Quality Engineer balloons the drawing and starts F-860-01 in the ERP.
2. The first part from the production process (not a part made by a special or prototype method) is identified with an FAI tag and held at the machine or in Bay 4.
3. Characteristics are measured; CMM measurement follows WI-210, including soak time and probe qualification. Non-CMM characteristics are measured with calibrated gages per QP-7.6.
4. Form 2 is completed with material certifications, special process certifications and any functional test results. Supplier certifications are checked against SQM-01 requirements.
5. Results are entered on Form 3, one line per balloon number, with the actual measured value.

5.4 Review and approval

The Quality Engineer performs a second-person review of the CMM report and Form 3 against the ballooned drawing before signing. Only Tallgrass Quality, meaning the Quality Engineer or the Quality Manager, may approve an FAI and sign AS9102 Form 3. Contractors, operators and production personnel may not sign Form 3. Approved FAI packages are saved as PDF in the Quality SharePoint site "FAI Records" library, filed by customer, part number and drawing revision.

5.5 Failed FAI

If any characteristic does not conform, the FAI is not approved. The part is tagged and an NCR is written per QP-7.5. After the cause is corrected, a new FAI is performed on a new part for the nonconforming characteristics and any characteristic affected by the correction. Production quantities beyond the first article are not shipped until an FAI is approved.

5.6 Customer submission

When the purchase order requires FAI submission, the Quality Engineer sends the approved FAI package (F-860-01 with the ballooned drawing and CMM reports) to the customer within 5 working days of approval, in the customer's required format or portal. The submission date is recorded on Form 1. Customer FAI approval, where required, is received before the first production shipment.

5.7 Supplier FAI

Suppliers that make parts or perform processes for Tallgrass provide FAIs as required by SQM-01; supplier FAIs are checked at receiving inspection (SHP-01), and discrepancies are referred to the Supplier Quality Engineer.

6 Records

FAI Reports (F-860-01), ballooned drawings, CMM reports and customer submission evidence are quality records retained 10 years from creation, or longer where the customer contract requires, per QP-4.2.

7 Revision history

Rev	Date	Change	Approved by
A	2018-03-05	Initial release, AS9102 Rev B.	Ruth Okafor
B	2021-06-14	Updated to AS9102 Rev C; added 2-year production lapse trigger.	Ruth Okafor
C	2026-05-18	Aligned with WI-210 rev G: only Tallgrass Quality (Quality Engineer or Quality Manager) may approve an FAI and sign Form 3; added second-person review; FAI records moved to SharePoint "FAI Records" library; customer submission within 5 working days of approval.	Ruth Okafor