Free quality tools from Aegis: templates, kits and guides you can use today →
Aegis Technologies Inc.

The FAI and Production Readiness Kit HandbookChapter 3 of 22

The workflow

Every new or changed part moves through the same stages. The shaded boxes are gates: Yes continues down, No goes to the note on the right.

  1. Order review: read the drawing, the order and the quality clauses. Screen for first article triggers (D07).
  2. Decision: Does the job need a first article (new part, change, lapse, customer request)? If yes, continue to the next step.
    No:Record the reason on the trigger screen. Every setup still gets a first piece (E12).
  3. Plan it: balloon the drawing, plan inspection for every balloon (E11), set key characteristic controls (D16, E07).
  4. Build the process: traveler (E09), programs, fixtures and tooling validated (E10), gauges calibrated and studied.
  5. Decision: Production readiness review: is every part of the launch ready to make product (D09)? If yes, continue to the next step.
    No:Close the Not ready items, then a short re-review. No first article on an unready process.
  6. First piece at every setup, released on evidence (E12).
  7. Run the first article on the production process; measure every balloon; record values.
  8. Decision: Does every characteristic conform? If yes, continue to the next step.
    No:NCR; fix the cause; re-verify the affected characteristics on a corrected part (D19).
  9. Decision: Package review before signing (D08). Complete, with every count reconciled? If yes, continue to the next step.
    No:Fix each finding, look again, then sign.
  10. Submit; hold shipment where approval is required. Then into production: key characteristics monitored (D16), control plan (E07), triggers watched (D07).
Process flowchart. Shaded boxes are decisions: Yes continues down, No goes to the note. Open the flowchart as an image (as it appears in the handbook).
StagePurposeToolsOutputAS9100D
Order reviewKnow what the order requires and whether it triggers a first articleD07Trigger screen, scope decision8.2.3
PlanPlan the first article and the inspection of every characteristicD07, E11, D16, E07Planning checks, inspection plan, KC controls8.1, 8.6
Build the processMake the process able to make the partE09, E10, E01Released traveler, validated tooling and programs8.5.1, 8.5.1.1
Readiness reviewDecide, on evidence, whether to proceedD09Go, Go with conditions, or No go8.1
SetupsRelease each setup on evidenceE12First-piece records, setup log8.5.1
First articleProve the production processD07, D19Completed AS9102 record8.5.1.3
Package reviewSend a package that is complete and rightD08Reviewed, signed package8.5.1.3, 8.6
ProductionKeep the process where the first article proved itD16, E07, E12, D07KC data, capability, trigger watch8.5.1, 8.5.6

Need more than one resource, or not sure where to start? Book a complimentary 30-minute Aegis Quality Guidance Call. We'll find the tools that fit your situation and a sensible place to start. No sales pressure, no obligation.

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.