With the drawing ballooned, the inspection plan (E11) gets one line per balloon: the requirement as the drawing states it, the class of characteristic, the operation that produces it, where it is verified, the method and gauge, the gauge's resolution against the tolerance band, the frequency, what is recorded, and what happens when a part is out. Its Plan check column stays crimson until the line is fully planned, and its Summary counts lines against the balloon count on the plan header.
Choosing gauges
We start with a gauge whose resolution is no more than a tenth of the tolerance band, and the worksheet checks it on every line. Resolution is necessary, not sufficient: a gauge that checks a key characteristic also needs a measurement study (E04) before its readings are trusted. Every gauge on the plan is on the calibration register (E01).
Key characteristics
Key characteristics are the few characteristics whose variation most affects fit, function or life. The customer may designate them on the drawing; you may add your own from the process risk review. For each, the plan records actual values from the first part on, the key characteristic register (D16) holds the data and the capability, and the control plan (E07) states the control and the reaction plan at the operation that produces it.
Method, frequency and record by class
| Class | Method we reach for | Starting frequency | Record |
|---|---|---|---|
| Key characteristic | Variable gauge at the machine with a measurement study; CMM for positions | Every part until capability is shown | Actual values |
| Critical item feature | As for a key characteristic, or as the customer specifies | Every part | Actual values |
| Major | Variable gauge where the tolerance allows; attribute gauge otherwise | First and last piece, plus a frequency from the process's history | Values, or pass or fail for attributes |
| Minor | Standard hand gauges | First and last piece | Values or pass or fail |
| Notes and process requirements | Visual against a standard; certificate review; receiving checks such as coating thickness | Every part for visual notes; every lot for certificates | Pass or fail; certificate number |
Frequencies and the sampling basis
Initial frequencies are high on purpose: key characteristics every part until capability is shown, major characteristics first and last piece plus a frequency, notes every part at final. The plan header records the basis. AS9100D expects sampling used for acceptance to rest on recognized statistical principles and to suit the product's criticality; many aerospace customers also restrict sampling on their own terms, and their rules come first.
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A management aid, not certification or a registrar audit. Using it does not by itself show conformity to AS9100D or any other standard, and your customers' requirements may add to it.
Clause numbers refer to AS9100D (SAE AS9100 Rev D) unless another document is named. The standards' text is not reproduced here: use your own licensed copy.
Aegis Insights are our own guidance, labeled wherever they appear: how we approach this work, not a requirement of any standard or customer.