WI-210 CMM First Article Inspection

Revision F · Effective 2024-09-09

1 Purpose

This instruction describes how first articles are measured on the coordinate measuring machines (CMM-01 and CMM-02) in the Bay 4 metrology lab and how results are reported on F-860-01 for First Article Inspection (FAI).

2 Scope

Applies to all CMM measurements performed for full or partial (delta) FAIs required by QP-8.6. Program creation and release are covered by WI-215.

3 Definitions

• Ballooned drawing: a copy of the customer drawing with every characteristic numbered in a balloon; the numbers match the characteristic numbers on AS9102 Form 3.
• Reference sphere RS-0412: the calibrated sphere used to qualify CMM probes.
• Form 3: the AS9102 Characteristic Accountability, Verification and Compatibility Evaluation, part of F-860-01.

4 Responsibilities

• CMM operator: prepares the part, qualifies the probe, runs the released program, completes the report and signs Form 3.
• Quality Engineer: prepares the ballooned drawing and supports the CMM operator on alignment and measurement questions.
• Quality Manager: owns the FAI process and resolves disputes about results.

5 Procedure

5.1 Preparation

1. Confirm the FAI type (full or partial) and the drawing revision against the traveler and the ERP job.
2. Obtain the ballooned drawing from the Quality Engineer. Every dimension, tolerance, note and flag note must carry a balloon. Number balloons sequentially starting at the top-left of sheet 1 and moving clockwise.
3. Confirm the program loaded on the CMM is the released version per WI-215.

5.2 Thermal soak

1. Place the part in the Bay 4 lab (20 +/- 1 C) before measurement.
2. Minimum soak: 2 hours for aluminum; 4 hours for steel, titanium, and any part over 20 kg.
3. Record the soak start time and lab temperature on the traveler. If the lab is outside 20 +/- 1 C, do not measure; notify the Quality Engineer.

5.3 Probe qualification

1. Qualify every stylus to be used on reference sphere RS-0412 at the start of each shift, after any crash, and after any stylus change.
2. The qualification standard deviation must be 0.002 mm or less. If it is higher, clean the stylus and sphere and requalify. If it still fails, tag the CMM out of service and notify the Quality Engineer; see QP-7.6.

5.4 Alignment and datum setup

1. Fixture the part so it is fully supported without clamping distortion.
2. Build the alignment from the drawing's datum reference frame (primary, secondary, tertiary datums). Never align to a convenient non-datum surface.
3. After alignment, re-probe the primary datum and confirm its form error is consistent with the drawing before running the full program.

5.5 Measurement and reporting

1. Run the program and measure every ballooned characteristic. Characteristics the CMM cannot measure (thread gages, surface finish, visual notes) are measured with calibrated gages and entered manually.
2. Enter results on F-860-01 Forms 1, 2 and 3, with Form 3 balloon numbers matching the ballooned drawing.
3. Save the CMM report and the completed F-860-01 to the network share Q:\CMM\Reports, in a folder named for the part number.

5.6 Sign-off

1. The CMM operator checks that every balloon has a recorded result and that every result is within tolerance.
2. The CMM operator signs Form 3 and notifies Production that the FAI is complete. No second-person review is required.

5.7 Out-of-tolerance characteristic

1. If a characteristic is out of tolerance, check the probe qualification and alignment and re-measure once. Do not re-measure repeatedly to obtain a passing value.
2. If the result is confirmed, red-tag the part per WI-610 and enter an NCR per QP-7.5.
3. The FAI is not approved. After the cause is corrected, a new part is measured for the nonconforming characteristics and any characteristic affected by the correction, per QP-8.6.

6 Records

CMM reports and F-860-01 records are retained 10 years from creation, or longer if the customer contract requires (QP-4.2).

7 Revision history