First article inspection (8.5.1.3, AS9102)
| When | Full FAI on the first production run; partial or full FAI after a change in design, process, tooling, location, source, NC program, or a lapse in production (typically 2 years) |
|---|---|
| Content | Ballooned drawing; Form 1 part accountability, Form 2 materials, special processes and functional tests (with certificates), Form 3 every characteristic with actual results |
| Pass | Every characteristic conforming; nonconformities resolved before the FAI is complete |
Configuration management (8.1.2)
Configuration identification (part numbers, revisions, effectivity), change control (who approves which class of change; customer approval for major changes), status accounting (as-designed vs as-built), configuration audits. Evidence: change board records, as-built lists, drawing revision on traveller matches the PO.
Counterfeit prevention (8.1.4)
| Element | Evidence |
|---|---|
| Policy and training | Training records for buyers, receiving, stores |
| Sourcing | Buy from OEMs or authorized distributors; risk assessment for others; flow-down to suppliers |
| Verification | Certificates of conformance with traceability to the OEM; inspection / testing for higher-risk sources |
| Control | Quarantine and report suspect parts (GIDEP, ERAI, customer); never return suspect parts to the supply chain |
FOD prevention (8.5.1, 8.5.4)
FOD-critical areas defined; tool control (shadow boards, tool counts); housekeeping and "clean as you go"; inspection points for foreign objects; FOD awareness training; FOD incident reporting and trending. NAS 412 / AS9146 give the structure.
Special processes (8.5.1.2)
Qualified procedures, qualified equipment, qualified personnel, process parameter records, periodic revalidation, and customer or NADCAP approval where required. Outsourced special processes must use approved sources and their certificates are verified.
Operational risk and product safety (8.1.1, 8.1.3)
Risk register at operations level (schedule, capacity, single sources, key characteristics, new processes) with mitigations and acceptance decisions; product safety process with critical items list, safety-related events reporting, and safety culture training.
On-time delivery
Measured against the customer's required date, reported monthly, reviewed at management review (9.3.2), with actions for misses. Many primes rate suppliers on OTD and quality in their scorecards; low scores trigger corrective action or probation.
8d-problem-solving-report-writer
Write and review 8D problem-solving reports for customer complaints and serious nonconformities (automotive and aerospace practice: Ford Global 8D, VDA, GM, Stellantis formats): D0 emergency response, D1 cross-functional team and champion, D2 problem description with 5W2H and is / is-not and no cause in the statement, D3 interim containment within 24 hours with verification and clean point, D4 verified occurrence and escape (non-detection) root causes plus systemic cause, D5 permanent corrective actions for each cause verified before implementation, D6 implementation, validation with production data and removal of containment, D7 PFMEA, control plan and read-across to similar products, D8 closure and recognition. Checks an 8D discipline by discipline for missing content, human-error root causes, missing escape cause or action, late containment and dates out of order.
acceptance-sampling-plan-selector
Select and evaluate acceptance sampling plans for incoming, in-process and final inspection: ANSI/ASQ Z1.4 / ISO 2859-1 single sampling under normal inspection (code letter from lot size and inspection level I, II, III, S-1 to S-4; sample size, Ac and Re from AQL, following the table's arrows to the correct plan; 100% when n reaches the lot size; AQLs above 10 per 100 units), operating characteristic curves (Pa at any quality, producer's quality level, indifference point, LTPD, AOQ and AOQL, binomial or hypergeometric), plans designed from producer and consumer risk, and c = 0 zero-acceptance plans. Covers AQL choice by defect class, switching rules between normal, tightened and reduced inspection, when sampling is not appropriate, and random sampling.
approved-supplier-list-manager
Manage and audit an approved supplier list (ASL) / external provider register for ISO 9001 8.4.1, IATF 16949 8.4 and AS9100 8.4.1: supplier status (approved, conditional, probation, pending, disqualified), scope of approval by commodity and process, risk class, certification and expiry, re-evaluation intervals by risk, conditions with end dates, single-source contingency, approver and customer-directed sources. Audits the list for expired or expiring certificates, overdue re-evaluations, conditional or probation status past its decision date, high-risk suppliers without the required certification, single-source suppliers without backup and missing approvers, and checks purchase orders for suppliers that are off-list, disqualified or pending, or buying outside the approved scope. Covers ERP blocks, PO requirements, off-list and emergency purchases.
apqp-phase-planner
Plan and track Advanced Product Quality Planning (AIAG APQP 3rd edition, IATF 16949) for a new or changed automotive part: back-schedule the five phases (plan and define, product design, process design, product and process validation, launch and feedback) from the start-of-production date by program complexity, with overlap, PPAP lead and safe-launch period; list the deliverables and gate for each phase (DFMEA, DVP&R, feasibility, process flow, PFMEA, control plans, MSA, Ppk, run at rate, PPAP, safe launch, lessons learned); adjust for build-to-print suppliers; flag compressed timelines and late or untracked deliverables against a status list. Covers gate reviews, red/yellow/green status reporting, run at rate and safe-launch exit criteria.
audit-report-writer
Write internal, supplier and pre-certification audit reports with the content ISO 19011:2018 6.5 expects: audit objectives, scope, criteria with revisions, dates, team and auditees, method and sampling statement, specific strengths, findings table and three-part finding details (requirement, evidence, statement), conclusion on the degree of fulfilment of criteria, diverging opinions, follow-up deadlines and distribution. Builds a Markdown report from a JSON audit record, generates the conclusion from the findings (major / minor / none) and flags reports missing required content or findings without clause or evidence. Covers conclusion wording, closing meetings, response expectations and verifying corrective actions.
capa-effectiveness-checker
Verify whether a corrective action actually worked (ISO 9001 10.2.1 d, IATF 16949, 8D D6) with statistics instead of 'no complaints so far': before/after defect-rate comparison with an exact conditional binomial test for Poisson counts and a minimum practical reduction, zero-defect demonstration size (n = ln(1-C)/ln(1-p), rule of three) with progress so far, and exact Clopper-Pearson upper bounds on the post-action defect rate. Returns effective, not yet demonstrated (with the units still needed) or not effective. Covers setting effectiveness criteria when the CAPA is opened, choosing the window by problem frequency, leading indicators for rare failures (Cpk, SPC stability, error-proofing checks, LPA), and traps such as volume changes, detection changes and containment masking.