Resource Library/Process Control and Measurement/Inspection Planning Worksheet
Inspection Planning Worksheet
Plan the inspection of every ballooned characteristic before the first part is made: where it is verified, by which method and gauge, how often, what gets recorded and what happens when it is out, with a check that every gauge can resolve its tolerance.
- Excel
- fillable PDF
- Worked example
- Your logo on it
- Aegis Insights
Page 1 of the PDF. Every resource includes a fully worked example.
The problem it solves
Inspection gets planned from habit: the operation checks what that machine usually checks, the final inspector checks what the last revision needed, and nobody can say where note 6 or the second position tolerance on the lug is verified. Gauges are chosen from the crib on the day, sometimes too coarse for the tolerance. Key characteristics are recorded as 'OK', so there is no data to show capability. The plan exists, if at all, in the inspector's head. This worksheet makes the plan once, from the ballooned drawing: one line per characteristic, the method, the gauge and its resolution against the tolerance, the frequency and its basis, the record, and the reaction when a part is out.
Who uses it
Quality engineers who write inspection plans; manufacturing engineers and inspectors who use them; planners who carry the inspection points onto the traveler.
When
When a new part is planned, before the production readiness review (AQL-D09) and the first article (AQL-D07); whenever the drawing, the process or a gauge changes; and after 30 parts, to set production frequencies from real capability.
Free to use, change and copy, in your own organization or with your clients; add your own logo, keep the Aegis credit. Part of: FAI and Production Readiness Kit. Clause references: 8.6; also 7.1.5, 8.1, 8.5.1, 8.5.1.3 (numbers only; use your own licensed copy of the standard).
A management aid, not certification or a registrar audit. Using it does not by itself show conformity to AS9100D or any other standard.
How to put it to work
Chapters of our free guides that use this tool.
- The kit and how the tools connectThe FAI and Production Readiness Kit Handbook, chapter 2
- The workflowThe FAI and Production Readiness Kit Handbook, chapter 3
- Inspection planning and key characteristics (E11, D16, E07)The FAI and Production Readiness Kit Handbook, chapter 7
- The traveler (E09)The FAI and Production Readiness Kit Handbook, chapter 8
- Setting it up in thirty daysThe FAI and Production Readiness Kit Handbook, chapter 17
- Quick referenceThe FAI and Production Readiness Kit Handbook, chapter 20
Related resources
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Checklist
First Article Inspection Planning Checklist
Decide whether a job needs a first article and how much of one, then plan it before the part is made: requirements, the production process, the ballooned characteristics, gauges, materials, special processes, people and records, with a shop-wide log from trigger to customer approval.
Excel · PDFFree download -
Checklist
AS9102 FAI Package Completeness Checklist
Review a first article package before it is signed and sent: the part record, materials, special processes and tests, every characteristic, the ballooned drawing and the records behind it, with count reconciliations that find the missing line in minutes.
Excel · PDFFree by email -
Checklist
Production Readiness Review Checklist
Decide, on evidence, whether a new or changed part is ready to make product: thirty-eight readiness checks across thirteen areas, a record of the decision and its conditions, and a summary that shows what is blocking the launch.
Excel · PDFFree download -
Checklist
Production Traveler Review Checklist
Two reviews of the document that carries a job through the shop: one before the traveler is released to the floor, so it says what the drawing and the order require, and one when the job is complete, so the record shows every operation done, every part accounted for and every exception authorized.
Word · PDFFree download -
Checklist
First-Piece Inspection Checklist
Release every setup on evidence: nineteen setup checks, the first piece measured characteristic by characteristic with fail and near-limit flags, a suggested decision, and a shop-wide log that shows which setups keep needing a second try.
Excel · PDFFree download -
Workbook
Key Characteristics Monitoring Register
Every key characteristic with its limits, control method and reaction plan; every measured value; and capability worked out from the values, so you know which KCs are capable, which are not, and which have too little data to say.
Excel · PDFFree download
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