The kit has eight tools that follow a part from the order to steady production, and it leans on eight related tools from other collections. Each is a working file you can use on its own; together they form one system, with the same part, the same balloons and the same record numbers running through all of them.
| AQL | Tool | Format | Use it when |
|---|---|---|---|
| D07 | First Article Inspection Planning Checklist | Excel, PDF | At order review and at every change: does the job need a first article, full or partial, and is it planned |
| E11 | Inspection Planning Worksheet | Excel, PDF | Planning how every ballooned characteristic is verified, with which gauge, how often |
| D16 | Key Characteristics Monitoring Register | Excel, PDF | Recording key characteristic values and capability from the first part on |
| E07 | Control Plan Template | Excel, PDF | The controls and reaction plans for each operation in production |
| E09 | Production Traveler Review Checklist | Word, PDF | Releasing a traveler to the floor, and closing it before the certificate of conformance |
| D09 | Production Readiness Review Checklist | Excel, PDF | Deciding, before the first article, whether the launch is ready to make product |
| E12 | First-Piece Inspection Checklist | Excel, PDF | Releasing every setup on evidence, and logging what it took |
| D08 | AS9102 FAI Package Completeness Checklist | Excel, PDF | Reviewing the first article package before it is signed and submitted |
Related tools
| AQL | Tool | What it adds to the kit |
|---|---|---|
| E10 | Tooling and Equipment Maintenance Register | Validating and maintaining fixtures, machines, customer tooling and NC programs |
| E01 | Calibration and Measurement Risk Register | Keeping every gauge in the inspection plan calibrated, and knowing what a failed gauge measured |
| E04 | Gage R&R Study Data Sheet | Measurement studies on the gauges that check key characteristics |
| E06 | Process Capability (Cp/Cpk) Calculator | Capability from the key characteristic values |
| D11 | Engineering Change Impact Assessment | Assessing a drawing change, including its first article trigger |
| E13 | Manufacturing Process Change Assessment | Assessing a process change, including its first article trigger |
| D19 | Nonconformance Management Log | Recording the nonconformances found during a first article |
| G02 | Operator Qualification and Authorization Record | Qualifying setup people and first article inspectors |
The thread that ties them together
Three things run through every tool in the kit, and keeping them consistent is most of the discipline:
- The balloon number. The ballooned drawing numbers every requirement once. The inspection plan (E11) has one line per balloon, in the same order. Form 3 of the first article has one line per balloon. The first piece (E12) and the key characteristic register (D16) use the same numbers. When the drawing changes, all of them change line for line.
- The revision. The order, the drawing, the traveler, the programs and the first article record all name the revision they apply to. Most rejected packages and most escapes after a change come from two of these disagreeing.
- The record number. The first article number goes on the plan log (D07), the traveler (E09), the validation record for new tooling (E10), the package review (D08) and the certificate of conformance where the customer asks. Anyone can follow the thread from any one of them.
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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.