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Shanghai Shang Shaft Bearing Quality Inspection Institute Co., Ltd.

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Address: 301 Shangxue Road, Jiading District, Shanghai

Sharing the first item inspection to three inspection system: self-inspection, mutual inspection, special inspection

2021-08-30 09:32

Definition of First Article and First Article Inspection

 

Process change





 

During the production process, any one or more production factors in 5M1E (human, machine, material, method, ring, test) change, such as personnel change, equipment adjustment and maintenance, material replacement and fixture replacement, design change, line stop, etc.

 

First Piece





 

The first or first few products processed by the production line at the beginning of each shift/production line or after a process change. For mass production, "first piece" often refers to a certain number of samples.

 

First-piece inspection  





 

Inspection of the first or first few products processed by the 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 3-5 products in continuous production need to be inspected, and subsequent products can be processed only after passing the inspection. The first article inspection shall be strictly carried out before any change of equipment or manufacturing process and before each work shift starts processing.

Purpose of First Article Inspection

 

  • The first inspection in the production process is mainly to prevent the product from being out of tolerance, repair and scrapped in batches. It is a means to control the production process in advance, an important method of product process quality control, and an effective and indispensable method for enterprises to ensure product quality and improve economic benefits.

     

  • The first article inspection is to identify the factors affecting product quality in the production process as early as possible and to prevent batch defects or obsolescence.

     

  • The first piece can only enter formal production after passing the inspection, mainly to prevent the occurrence of batch non-conforming products.

     

  • Long-term practical experience has proved that the first inspection system is an effective measure to find problems as soon as possible and prevent products from being scrapped in batches. Through the first article inspection, it can be found that there are systematic causes such as serious wear and tear of fixtures or installation and positioning errors, poor accuracy of measuring instruments, wrong drawings, wrong feeding or formula, etc., so as to take corrective or improvement measures to prevent the occurrence of batch nonconforming products.

 

03

Timing/occasion of first article inspection

 

  • Start of each work shift

     

  • Replace operator

     

  • Replacement or adjustment of equipment and process equipment (including tool replacement or sharpening)

     

  • Change technical conditions, process methods and process parameters (e. g. change of roughness requirements, change of inner hole reaming to boring, change of tool feed or speed in numerical control program, etc.)

     

  • After the use of new materials or material substitution (such as material changes during processing)

     

  • Replace or retest bath solution (e. g. phosphating, nitriding, etc.)

     

04

Process change






During the production process, any one or more production factors in 5M1E (human, machine, material, method, ring, test) change, such as personnel change, equipment adjustment and maintenance, material replacement and fixture replacement, design change, line stop, etc.


Requirements for first article inspection

 

The first article inspection adopts the three-inspection system:Self-inspection, mutual inspection and special inspection

 

The products submitted for inspection must be "self-inspected" by the operator first, then "mutual inspection" by the team leader or colleagues, and finally "special inspection" by the inspector, and the subsequent products can be processed only after being determined to be qualified.

 

Whether the first product is qualified after inspection shall be finally approved by the full-time inspector. The inspector shall mark the first product that has passed the inspection as specified and keep it until the shift or a batch of products are processed (all first product samples must be reserved for subsequent product comparison to see if the process changes, and mark "√" with a marker pen to show that the first product has passed the inspection).

 

If the first piece is unqualified in the inspection, it is necessary to find out the reason and take measures. After troubleshooting, it is processed again and three inspections are carried out. The first piece can not be determined until it is qualified.

 

05

Main items of first article inspection

 

  1. Is the drawing number consistent with the work order

  2. Whether the materials, blank or semi-finished products and the work task list are consistent

  3. Whether the surface treatment, installation and positioning of materials and blanks 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

First piece inspection specification process

 

Subject Content and Scope of Application





 

This document specifies the company's requirements and working 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 of the first article inspection and batch first article inspection of new products during the production process.

 

Duties





 

The production department is responsible for organizing and arranging the first piece inspection.

 

The directly responsible person shall be responsible for the quality accidents caused by the unauthorized production of products without the inspection of the first piece of new products, the first piece of batch or the first piece of unqualified inspection.

 

The inspector and the person in charge of the production line shall be responsible for the correctness of the first article inspection.

 

If the confirmation of the first article is not completed, the inspector starts to issue the quality certificate, and the inspector is responsible for the quality accident caused.

 

Control Requirements





 

The first completed semi-finished and finished products of the first continuous production of the production department must be inspected and confirmed.

 

For regular production products, first article inspection must be carried out by batch.

 

In case of shutdown due to equipment, process and other reasons, the first article inspection and confirmation shall be carried out when the shutdown is restarted.

 

The first article inspection and confirmation shall be carried out when the product materials and specifications are changed and put into production.

 

When inspecting the first article of the new product, the production unit shall be responsible for notifying the relevant inspection personnel according to the current effective drawings, lists (or samples provided by customers) and process documents. The inspector shall fill in the inspection records, sign on the first article card after passing the inspection, and hang the card on the first article product to make the first article mark; If the first article fails the inspection, it shall be returned immediately, and the first article shall be redone and recorded. Products that have not passed the first article inspection shall not be accepted.

 

The first piece, as a sample for mass production, is retained by the production department until the end of the full batch production before final delivery.

 

All raw and auxiliary materials used in the production process of the product shall be checked in the first article inspection, which must be consistent with the regulations.

 

Working procedure  





 

In the process of making the first piece, the person in charge of the production line and the inspectors shall go to the production site to supervise and inspect the actual producers to complete the first piece according to the production process according to the current effective production process documents, and supervise and inspect each production process, and correct and solve the problems found in time.

 

All production processes must be completed for the first production of conventional products and products that are stopped and started up again. After the producer passes the inspection and signs the first piece card, the first piece shall be inspected by inspectors. During the first article inspection, the inspector, together with the person in charge of the production line, shall carry out the inspection according to the current effective drawings, lists (or samples provided by customers), process documents and product requirements. After passing the inspection, the first article shall be marked (e. g. endorsement "first article qualified", etc.), and the manufacturer (or representative) and inspector shall countersign the first article card. For the first article inspection required due to major changes in the product, the relevant personnel and the inspection can sign for approval. If the first article fails the inspection, it will be returned immediately and the first article will be redone.

 

The first batch production of new products and the semi-finished products and finished products generated after the change of materials and specifications need to be inspected and confirmed.

 

During the first piece inspection, the first piece record shall be made in time and the first piece confirmation shall be filled in.

 

When quality problems are found in the production of the first article, they shall be reflected and dealt with in a timely manner, and the unqualified items shall be re-confirmed. Production can only be organized when the first article is inspected and the results are recorded on the first article card and the quality is approved by the inspector.