How to Populate AS9102 First Article Inspection Forms From ERP Data
how to populate AS9102 FAI forms from ERP data
Also searched as
- AS9102 Form 1 Form 2 Form 3 ERP data source
- when is a new first article required AS9102 ERP trigger
- FAI raw material special process traceability ERP
- delta FAI after engineering change ERP
Short answer
Roughly half of an AS9102 package is data your ERP already holds: part number, revision, drawing, serial or lot, PO, raw material and special process records on Forms 1 and 2. Form 3 characteristics come from the ballooned drawing and the inspection results, not the ERP. The ERP's best contribution is deciding when an FAI is required and keeping the evidence linked.
Applies to: AS9102 Revision C (aerospace first article inspection requirement), AS9100 suppliers, any ERP with item revision control, routings and lot receipts; FAI tools such as InspectionXpert, Net-Inspect, Camio-class or QMS-native modules, or spreadsheets
Connecting ERP data to an FAI package
- 1Map Form 1 (Part Number Accountability) fields to ERP item master: part number, part name, drawing number and revision, and the organization and customer details, plus the serial or lot number and the PO or job being inspected.
- 2Map Form 2 (Product Accountability) rows for raw material, specifications, special processes and functional testing to the bill of materials, receipt records and routing operations flagged as special process.
- 3Pull raw material evidence from lot receipts: supplier, supplier lot or heat number, certificate of conformance reference and specification.
- 4Pull special process evidence from routing operations performed by approved processors, such as heat treat, plating, NDT or anodize, with the process spec and the processor's cert linked to the job or PO.
- 5Leave Form 3 characteristics to the ballooned drawing and the measured results, entered in the FAI tool or QMS, and link the gauge IDs used to the calibration records.
- 6Configure triggers in the ERP so a new FAI task is raised on defined events instead of someone remembering.
- 7Store the FAI report number on the part revision and job in the ERP, and hold release of the production lot to the customer until approval where the contract requires it.
Which form fields the ERP can feed
AS9102 has three forms. Form 1 identifies the part and the reason for the inspection. Form 2 accounts for the materials, specifications, special processes and functional tests that went into the part, including who supplied them and what certification backs them. Form 3 lists every characteristic from the drawing with the requirement, the measured result and the tool used.
The ERP is a strong source for Forms 1 and 2 because it already records revisions, receipts and routings. It is a weak source for Form 3, because the characteristics live on the engineering drawing and the results come from the inspector. Do not try to force Form 3 out of the ERP. Feed it from the drawing balloons and the measuring equipment, and use the ERP only for reference data such as the gauge list.
Form 1 Part number, name, drawing rev, serial/lot, PO/job ERP item master, job Form 2 Raw material, supplier lot, cert, specification ERP receipt, BOM, cert attachment Form 2 Special process, processor, spec, cert ERP routing op, PO to processor Form 3 Characteristic, requirement, result, gauge Drawing balloons, inspection data
When a new or partial FAI is required
AS9102 requires a full FAI for a new part, and a full or partial one (a delta FAI covering the affected characteristics) after events such as a change to the design affecting form, fit or function, a change in manufacturing source, process, location, tooling or inspection method, a change in numerical control program or translation to another media, a natural or man-made event that may affect manufacturing, and a lapse in production, for which AS9102 gives two years as the period. Customer flowdowns can tighten these rules, so read the purchase order.
Most of those triggers are visible in the ERP: a new item revision, a changed routing or work center, a new approved supplier or processor on the PO, a new tool or program revision, or no production receipt for the item in 24 months. A scheduled check for each is far more reliable than relying on engineers to notify quality. Create the FAI task from the event and link it to the item revision.
Keeping the evidence connected
A package fails review most often because the raw material cert does not match the lot actually used, or the special process cert is for the wrong revision of the spec. If the ERP job issues the specific lot and the PO to the processor carries the process spec revision, the FAI can cite them directly and a reviewer can follow the chain in minutes.
Keep the signed FAI report as an attachment to the item revision and job, and record the approval status as a field that the shipping step can check. For customers who require approval before shipping production quantity, a shipment hold keyed to FAI status closes the gap between the quality system and the dock.
Common pitfalls
- !Treating the FAI as a one-time event per part number instead of per revision and per change trigger.
- !Citing a raw material cert for the part's general spec instead of the lot actually issued to the job.
- !Forgetting that a change of special process supplier is a trigger, even if the process spec is unchanged.
- !Entering characteristics manually from a marked-up print when the same drawing revision already has a ballooned file.
- !Letting the FAI report number sit only in the quality tool, so shipping cannot see approval status.
- !Assuming the ERP part revision always matches the customer's drawing revision without a check.
How an ERP-grounded AI assistant handles this
A grounded assistant can assemble the ERP-sourced part of the package: for a given job, list the item revision, issued material lots with supplier lots, special process operations and processors, and attached certs, and flag mismatches such as a cert for a different revision. It can also scan for FAI triggers, such as items with a new revision or no production in two years. Form 3 content and the final accept or reject remain with the inspector and quality engineer.
Frequently asked questions
Does AS9102 require the ERP to produce the forms?
No. AS9102 specifies what the forms must contain, not which system produces them. Many suppliers use dedicated FAI software or spreadsheets. The ERP matters because it is the authoritative source for part revision, material lots and routing, and a package that matches the ERP is easier to defend.
What is a delta or partial FAI?
It is an FAI limited to the characteristics and accountability rows affected by a change, instead of re-inspecting everything. AS9102 allows it where the change is understood and bounded. You need to document which characteristics were affected and why the rest are not.
Can I auto-generate Form 3 from the drawing?
Ballooning tools can extract characteristics from a PDF or CAD model and prefill the requirement and tolerance columns, which saves time. Someone still has to verify the extraction against the drawing, because OCR and model extraction miss notes, general tolerances and flagged characteristics.
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