In the design and production process of any product, activities such as design changes, process changes, process adjustments, unplanned line stoppages, production changes, and line changes often occur. So, how to ensure that these activities will not affect the quality of subsequent production? This requires first article inspection in the stages of job readiness verification and post-shutdown verification.
01
Definition of first article and first article inspection
process change
During the production process, any one or more of the production elements in 5M1E (people, machine, material, method, environment, and test) changes, such as personnel changes, equipment adjustment and maintenance, material and fixture changes, design changes, Stop the line and so on.
The first product or products processed by the production line at the beginning of each shift/line production input or after a process change. For high-volume production, "first article" often refers to a certain number of samples.
First Article Inspection
An inspection performed on the first or first few units processed on a production line at the beginning of each shift or after a process change. The number of inspections can be formulated according to the requirements of different enterprises or customers. Generally speaking, at least 3 to 5 products in continuous production need to be inspected, and subsequent products can be processed after passing the test. First article inspection is rigorously performed before any changes to equipment or manufacturing processes, and before each work shift begins processing.
02
Purpose of first article inspection
The first article inspection in the production process is mainly to prevent batches of products from being out of tolerance, repaired and scrapped. It is a means of pre-controlling the production process of products, an important method of product process quality control, and an enterprise to ensure product quality. An effective and indispensable method to improve economic efficiency.
The first article inspection is to find out the factors affecting product quality in the production process as early as possible, and prevent batch failure or scrap.
The official production can only be started after the first piece of inspection is passed, mainly to prevent the occurrence of unqualified products in batches.
Long-term practical experience has proved that the first inspection system is an effective measure to find problems as early as possible and prevent products from being scrapped in batches. Through the first article inspection, it can be found that there are systematic reasons such as severe wear of fixtures or installation and positioning errors, poor accuracy of measuring instruments, misreading drawings, wrong feeding or formulas, etc., so that corrective or improvement measures can be taken to prevent batch failure. Goods happen.
03
Timing/occasion for first article inspection
1) Each work class starts;
2) Change the operator;
3) Replacement or adjustment of equipment and process equipment (including tool replacement or sharpening);
4) Changes in technical conditions, process methods and process parameters (such as changes in roughness requirements, changes in inner hole reaming to boring; changes in the amount of cutting or rotation speed in holes, CNC programs, etc.);
5) After adopting new materials or material substitutions (such as material changes during processing, etc.);
6) Replace or re-test the bath solution, etc. (such as phosphating, nitriding, etc.).
04
First Article Inspection Requirements
The first article inspection adopts a three-inspection system: self-inspection, mutual inspection and special inspection.
The products submitted for inspection must first be "self-inspected" by the operator, then "mutually inspected" by the team leader or colleagues, and finally "specially inspected" by the inspector, and the subsequent products can only be processed after confirming that they are qualified.
Whether the first piece is qualified after the inspection shall be finally approved by the full-time inspector. The inspector shall mark the first product that passes the inspection and keep it until the class or a batch of products are processed (all first products must be Reserve samples for subsequent product comparison to see if the process has changed, and mark "√" with a marker pen to indicate passing the first article inspection).
If the first piece fails to pass the inspection, it is necessary to find out the reason, take measures, and re-process after troubleshooting, and carry out three inspections. It can only be determined as the first piece after passing the inspection.
05
Main items of first article inspection
1) Whether the drawing number matches the work order;
2) Whether the materials, blanks or semi-finished products are consistent with the work order;
3) Whether the surface treatment and installation positioning of the material and blank are consistent;
4) Whether the formula ingredients meet the specified requirements;
5) Whether the actual quality characteristics of the first product after processing meet the requirements specified in the drawings or technical documents.
06
Standardized process for first article inspection
Subject content and scope of application
This document stipulates the company's requirements and work procedures for the first article inspection and batch first article inspection of new products during the production process.
This provision applies to the company's control over the first article inspection and batch first article inspection of new products during the production process.
responsibility
The production department is responsible for organizing and arranging the first article inspection.
The person directly responsible shall be responsible for the quality accidents caused by the unauthorized production of products without the first piece of new product, the first piece of batch inspection or the failure of the first piece of inspection.
The inspector and the person in charge of the production line are responsible for the correctness of the first article inspection.
If the confirmation work of the first piece is not completed, the inspector begins to issue the quality certificate, and the quality accident caused by it shall be the responsibility of the inspector.
Control requirements
1) For the first completed semi-finished product and finished product continuously produced by the production department for the first time, it must pass the first article inspection and confirmation;
2) For conventional production products, the first article inspection must be carried out according to the batch;
3) In case of shutdown due to equipment, process, etc., the first article inspection and confirmation shall be carried out when the shutdown is restarted;
4) The first article inspection and confirmation shall be carried out when the product materials and specifications are changed and put into production;
5) When inspecting the first piece of a new product, the production unit shall be responsible for notifying the relevant personnel of the inspection, and conduct it according to the currently valid drawings, checklists (or samples provided by the customer), and process documents. The inspector shall fill in the inspection records. Sign on the card, and hang the card on the first product to make the first product mark; if the first product fails to pass the inspection, it should be returned immediately, and the first product should be redone, and a record should be made. Products that have not passed the first article inspection shall not be accepted;
6) The first piece is a sample for mass production, and the production department is responsible for keeping it until the end of the batch production before delivering it;
7) In the first article inspection, all raw and auxiliary materials used in the production process of the product should be checked, and they must comply with the regulations.
Work program
During the production process of the first piece, the person in charge of the production line and the inspection personnel should go to the production site to supervise and inspect the actual producer to complete the first piece by himself according to the production process flow and the current effective production process documents, and supervise and inspect each production process. Issues were corrected and resolved in a timely manner.
The production of the first piece of conventional production products and products produced after shutdown and restarting must complete all production processes, and after the manufacturer passes the inspection and signs on the first piece plate, it will be handed over to the inspector for first piece inspection. During the inspection of the first article, the inspector shall, together with the person in charge of the production line, conduct the inspection according to the currently valid drawings, lists (or samples provided by the customer), process documents, and product requirements, and mark the first article after passing the inspection (such as endorsement " The first article is qualified, etc.), and the first article card shall be countersigned by the producer (or representative) and the inspector. For the first piece inspection required due to major changes in the product, it can be approved by the relevant personnel and the inspection signature; if the first piece inspection fails, it will be returned immediately and the first piece will be redone.
The first mass production of new products and semi-finished products and finished products produced after changes in materials and specifications need to undergo first article inspection and confirmation.
During the first article inspection, the first article record shall be made in time, and the first article confirmation form shall be filled out.
When the quality problem is found in the production of the first piece, it should be reported and dealt with in time, and the unqualified items should be re-confirmed. Production can only be organized after the qualified first piece is inspected and the result is recorded on the first piece card, and the quality is approved by the inspector.
Only after the first piece is confirmed, the inspector can start the normal delivery inspection.
