We have been discussing one of the requirements when a First Article Inspection (FAI) is needed as stated per AS9102, Rev A, Per 5.3.5 "A lapse in production for two years or as specified by the Customer." The customer requires us to follow AS 9102 for FAI.
It is evident that one explanation is when the product was not manufactured for two years or more, than a full FAI is required when manufactured the next time.
The question is: If the product been manufactured and in inventory for more than 2 years, is a FAI required? The customer has not changed the part number or the revision level since it was made several years ago."
We are a small injection molding company that operates one shift and less than 50 employees. The storage area is clean and periodic checks are performed by the supervisor per ISO 9100, Rev B, par 7.5.1.3
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Comments
bobdoering 4/15/2004
The best way to get a lock on frequency is to plot the data on a variable chart. With 4 heads, I would plot data from each head individually to collect enough data to understand how each had affects the process. Then, I like to use the 7 point rule as the rule of thumb for frequency. There should be 5 to 7 sample points of data between the need for ANY adjustment of ANY of the heads. All adjustments should be driven from the SPC data approaching a control limit. The only adjustments that may have to occur in a machining process not based on the control limits is tool change from surface finish indications. If the needs fro adjustment from the control charts is once per week, then you might want to check parts more frequently to find evidence of special causes, before you fill the dumpster with scrap. Otherwise, your sampling frequency will now have some statistical merit.
That is my short version of how I would handle determining frequency.
Bob Doering