IA9100 FOD and Planning Check

Foreign objects in the PFMEA and control plan, phased planning with gates, measurement behind your capability, and process verification beyond the first part.

Free to use, change and copy inside your own organization. Editable Excel, plus a fillable PDF you can complete on screen.

IA9100 draft: based on the IAQG's published changes; IA9100 is not yet final, and the final text may change these topics and clause numbers.

The problem it solves

A customer finds a curl of aluminum in a blind hydraulic port. The part passed every dimension, and its first article was signed off two years ago. Since then the deburr moved bench, the wash cycle was shortened, and nobody re-verified anything, because the part had not changed. The process had. The IA9100 draft strengthens foreign object prevention, phased planning, statistical techniques, measurement systems analysis and production process verification. This workbook checks the four records that carry them: the PFMEA and control plan, the process change log, the program gates and the gauge and capability studies.

Who uses it, and when

Quality and manufacturing engineers, production supervisors and program leads, with the quality manager. When a PFMEA is reviewed; whenever a machine, fixture, program, cycle, bench or special-process operator changes; at each gate of a new part or program; when a key characteristic gets a new gauge or study; and at management review.

Part of

IA9100 Transition Package.

Companion to

The AS9100 Transition File, issue 5: The chip in the bore.

Clause references: IA9100 draft 8.1 (k, the b note and the planning note), 7.1.5.1, 8.3.2.1, 8.5.1.3. Clause numbers only; the standards text is not reproduced, use your own licensed copy.

A management aid, not certification or a registrar audit. Using it does not by itself show conformity to AS9100D or any other standard.

Page 1 of the PDF. Every resource includes a worked example.