(ASAP Checklist)
Reference Standard:
Aerospace Supplier Assurance Program
AS9100
Fairchild Controls Auditor(s)
Audit Started (MM/DD/YY)
CAR No. (When Applicable)
Audit Completed (MM/DD/YY)
Product Assessment
This Product Audit has been conducted by Fairchild Controls to determine the extent of product conformity demonstrated by the supplier
based on criteria selected from the SAE Aerospace Standard, AS9100. Fairchild Controls has assessed the capability and readiness of
the Supplier’s Production Management Process and its ability to ensure compliant product in accordance with Purchase Order
requirements. We have evaluated the effectiveness of the manufacturing processes and their ability to meet these specified objectives.
During this audit we have reviewed the Quality Management System, Process Documentation, Manufacturing Processes and Process
Controls directly related to Fairchild Controls product. The following audit results have been reviewed with the supplier’s authorized
representative.
Audit Participants
Names & Titles
General Information
Supplier ID No.
Supplier Name
Last QMS Audit (MM/DD/YY)
Street Address
City
Phone
Active P/O No.
State
Email
Fax
Active P/N
Zip Code
Description
Inspection Codes
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(ASAP Checklist)
Dynamics Reviewed:
Significant/Applicable Revisions to the Supplier’s Process Management System
Comment:
Prior ASAP Audit Results
Comment:
Prior Corrective Actions
Comment:
Open Corrective Actions
Comment:
Summary Results:
-
- Opportunities for Improvement
-
- Observations
-
- Major Audit Findings
-
- Minor Audit Findings
Statement of Overall Effectiveness:
(C)
Fully Compliant – Process Performance Meets Expectations
(PC)
Partially Compliant – A significant number of process indicators are compliant, however some indicators
fail to meet expectations
(NC)
Not Compliant – A significant number of process indicators are not compliant and no appropriate actions are
being taken or planned. Overall process controls fail to meet expectations.
(N/A)
The noted process indicator is not applicable to the product manufactured for Fairchild Controls
Audit Findings:
Strengths
Opportunities for Improvement
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(ASAP Checklist)
Nonconformance:
When, during the audit, conditions are identified that indicate the requirements of the Standard are not fully compliant, the nonconforming condition
shall be included in this report and documented on a Corrective Action Request (CAR) in accordance with GEN-QAI1401. The nonconformance will
be classified according to risk, as Major or Minor. Observations will be documented in this report for follow-up at a later date.
Major Nonconformance:
The requirement has not been met. Evidence indicates one or more of the following:
a. Systemic failure of the Management System
b. Condition could result in the delivery of nonconforming product
c. Condition could result in the failure or reduced usability of product or service
Major Findings
Minor Nonconformance:
The requirement has not been fully met. Evidence indicates one or more of the following:
a. Non-Systemic, not likely to result in the failure of the Management System
b. Condition is an isolated occurrence
Minor Findings
Observations:
The requirement has been marginally met. No corrective action is required at this time. Follow-up in this specific area is required during the next audit period or as indicated in this section
of the report to ensure stability of the process.
Observations
Supplier’s Authorized Representative:
I have reviewed and concur with the audit results contained herein.
____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Print – Name & Title
Signature & Date
Comments:
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C
Not Applicable
Description
Do Not Comply
Clause
Partially Compliant
Aerospace Supplier Assurance
Program
ASAP - Product Audit
Fully Compliant
(ASAP Checklist)
PC
NC
N/A
Comments
Work Instructions
General
Info
General
Info
4.2.3
4.2.3
4.2.3
4.2.3
Which of the following did the supplier indicate on their last Fairchild
Quality Management System Survey:
Perform Acceptance Sampling IAW ANSI Z1.4, Level II,
Single Sampling Plan for Normal Inspection, with AQL not
greater than 4.0 for Minor
and 1.0 for Major Characteristics
Maintain a unique sampling plan approved by Fairchild
Performs 100% product verification, - Inspecting each part
& each drawing characteristic in the lot/order
Does Fairchild Controls Configuration Management maintain:
An approved copy of the vendor’s drawing
N/A
An approved copy of the vendor’s ATP
N/A
1. How do Fairchild PO requirements flow down and assure
requirements are verified on each order (part config, inspection codes,
dwg req.)
a. Does the supplier know how to check Fairchild inspection codes on
our website
b. Does the supplier verify inspection code detail after receiving every
PO or change notice (Inspection code and/or text description may
change)
2. Are work instruction materials adequately controlled and do they
match the Master File
4.2.1d
3. Are ESD controls implemented where applicable
4.2.1d
4. Do work instructions reference the applicable process specification
and/or include written process instructions for the following:
Yes
N/A
Soldering per J-STD-001
Yes
N/A
Welding per AMS-STD-2219
Yes
N/A
Helicoil Installation
Yes
N/A
Riveting per MIL-STD-403
Yes
N/A
Control of ESD
Yes
N/A
Safety Wire Installations per MS33540
Yes
N/A
Ctrl & Application of Adhesives
Yes
N/A
Ctrl & Application of Primer & Paint
Other:
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4.2.1
Best
Practice
b. Are special tools specified in the instruction
4.2.1d
7.5.1k
c. Is acceptance criteria clearly defined (standards, pictures, samples)
4.2.3a,
b, &
5.5.1
6. Are work instructions and changes to work instructions approved by a
specified authority
4.2.1c,
7.5.1a &
b
7. Has the supplier provided Fairchild with a copy of their most current
drawing
8. Do work instructions include or refer to all applicable procedures,
drawings, or other documents needed to produce the item
7.2.1
9. Are all Fairchild dwg requirements, dwg notes, and specs incorporated
correctly into the supplier’s work instructions
7.5.1b
10. Are the work instructions available to the person performing the task
7.5.1g
11. Is an adequate explanation documented when quantities change
during the work flow, splits, attrition, etc.
8.3
12. Do dispositions of N/C product require Fairchild approval when C/A
would result in any deviation from the Source Controlled Dwg
8.3
13. Do reworked/repaired parts required re-inspection and re-enter the
work sequence at the same point where the N/C was identified
7.4.2
7.4.3
7.4.3a
Purchased Materials
14. Does the supplier’s PO capture and flow down all applicable Fairchild
requirements to sub-tier suppliers, including inspection codes, and
M&TE
15. Does the supplier provide applicable PO requirements to R/I and
does objective evidence indicate sub-tier supplier’s product is compliant
16. Does the supplier maintain objective evidence of the quality of
product from sub-tier suppliers, i.e., documentation, C of C, test reports,
etc.
Outside Processes
7.4.1
17. Are work instructions provided for subcontracted work
7.4.2
18. Are Fairchild drawings and inspection code requirements accurately
and contractually flowed down to sub-tier suppliers
7.4.3 &
8.2.4
Comments
a. Internal procedures implement government and industry specification
(MIL specs are converted into internal procedures)
4.2.1d
7.5.1b
4.2.3
N/A
5. Do the documented instructions provide sufficient direction to
implement customer, industry, and/or regulatory requirements
19. Does the supplier maintain objective evidence that their outside
processor’s services meet all applicable requirements
Special Processes
6.2.2,
7.5.2, &
7.5.3
20. Are personnel trained and, when required, certified
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6.2.2,
7.5.2, &
7.5.3
21. How are personnel trained and/or certified
7.5.2 &
7.5.3
22. Are specific process materials, tools, and equipment stated in the
process instructions and are they used by the operator
7.5.2 &
7.5.3
23. Are specific process sequences stated in the process instructions
and are they followed by the operator
7.5.2 &
7.5.3
24. Is acceptance criteria (standards, pictures, samples) clearly defined
in the process instructions and are they followed by the operator
4.2.3,
7.5.2, &
7.5.3
4.2.3,
7.5.2, &
7.5.3
4.2.3,
7.5.2, &
7.5.3
4.2.3,
7.5.2, &
7.5.3
25. Is all documentation under change control, approved, and at the
correct revision level
N/A
Comments
26. Is the application of adhesives correctly documented
a. Is the manufacturer’s instruction referenced and available to the
operator or a special procedure details how to mix and cure
b. Does a method exist in the work instructions to document when the
material is fully cured and processing can continue
7.5.2 &
7.5.3
27. Is the application of paint correctly documented
7.5.2 &
7.5.3
a. Is the manufacturer’s instruction referenced and available to the
operator or a special procedure details how to mix and cure
7.5.2 &
7.5.3
b. Do work instructions provide a place to record paint thickness,
adhesion test results, application and cure times
7.5.2 &
7.5.3
28. Is the installation of screw fasteners correctly documented
7.5.2 &
7.5.3
a. Is torque value and, if required, locking method stated in the work
instructions
7.5.2 &
7.5.3
b. Is verification of torque and locking method required
7.5.2 &
7.5.3
c. Do work instructions add the running torque of the locking device to
the applicable fastener torque, where required
Inspection Methods
7.2.1 &
8.4.2
29. Are inspection records maintained to support compliance to PO
requirements and are Actual Measurements or Pass/Fail recorded
30. Does the supplier perform 100% verification or is acceptance
sampling used and does this agree with what the supplier stated on their
Survey
31. If acceptance sampling is authorized is it clearly defined in
procedures - Is there objective evidence that procedures are followed by
the operator
a. Are Fairchild dwg characteristic classification deployed in work
instructions (Critical, Major and Minor)
7.2.1 &
8.4.2
b. Do sampling records indicate lot size, sample size (AQL or IRR as
applicable) for the characteristic classification, and the inspection results
8.2.4
8.2.4
7.2.1 &
8.4.2
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7.2.1 &
8.4.2
c. If one (1) reject is found in a lot is the entire lot inspected for that
defect
7.2.1 &
8.4.2
d. Are switching rules employed and sample quantities are increased in
the next lot when rejects are found in a sample
8.2.4.2
32. Are inspection records maintained for FAI to validate new parts or
following any subsequent change that invalidates the previous FAI result
N/A
Comments
Measurement & Special Tools
7.5.1c,
d, e,
7.5.1.1
& 7.6
7.5.1c,
d, e,
7.5.1.1
& 7.6
7.5.1c,
d, e,
7.5.1.1
& 7.6
7.5.1c,
d, e,
7.5.1.1
& 7.6
7.5.1c,
d, e,
7.5.1.1
& 7.6
7.2.1 &
7.6
7.5.1c,
d, e,
7.5.1.1
& 7.6
7.5.1c,
d, e,
7.5.1.1
& 7.6
7.5.1c,
d, e,
7.5.1.1
& 7.6
7.5.1c,
d, e,
7.5.1.1
& 7.6
33. Are all tools used for measuring the acceptance of product calibrated
a. If calibrated tools are being used, are they specified in the work
instructions
b. Are calibrated tools available when they are specified in the work
instructions
c. Are calibrated tools properly labeled or marked so they can be
identified
d. Does an adequate calibration recall system exist
34. Does the accuracy of measurement tools conform to Fairchild PO
requirements.
(Measurement error can be significant if the M&TE is less than 4 times
as accurate as the parameter tolerance zone)
35. Are all special tools controlled
a. If special tools are being used, are they specified in the work
instructions
b. Are special tools available when they are specified in the work
instructions
c. Are special tools properly labeled or marked so they can be identified
7.5.1 &
7.6
36. Are procedures in place to ensure Special Tooling is properly stored,
maintained, and fit for use
6.4,
7.5.5,
7.6
37. Are cleaning processes sequenced for optimum benefit and are they
effective
6.4 &
7.6
38. Is lighting adequate to perform work and inspection operations
Cleanliness & Environmental Conditions - FOD Prevention
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Best
Practice
N/A
Comments
39. Is plant safety promoted and evident within the facility
7.5.1i
40. Is the environment designed to prevent foreign objects and
contamination
7.5.1i
a. Are there previsions for the prevention, detection and removal of
foreign objects (i.e., FOD Control Program)
Product Controls
4.2.3g
4.3
7.5.1.2
4.2.3g
4.3
7.5.1.2
4.2.3g
4.3
7.5.1.2
4.2.3g
4.3
7.5.1.2
4.2.3c
4.2.3g
4.3
7.5.1.2
7.5.3
Best
Practice
41. Does the supplier have an implementation method that provides for
product effectivity of configuration changes
a. Do change notices describe how to implement the change into
production
b. Do change notices describe how to implement the change for work-inprocess (WIP), and how is it handled
c. Do change notices describe how to implement the change to material
in stock, and how is it handled
42. Are work instructions updated to reflect configuration revision
changes
43. Do serialization methods have mistake proofing features to prevent
duplication of serial numbers
a. Is serialization verified by final inspection
7.5.3
b. Does a data base exist (Electronic or Manual)
7.5.3
c. How are serial numbers issued
7.1c &
7.5.1a
8.2.4
44. Is acceptance criteria clearly defined (work instructions, standards,
pictures, samples, etc.) and recorded
4.2.3
7.2.1a
45. Is the ATP in use approved in writing by Fairchild and is it on file with
Fairchild
Test Procedures
Best
Practice
4.2.3
Best
Practice
46. Does the supplier have a standard method for preparing test
procedures and is it utilized
47. Is there a method of review, approval, and config control for test
procedures, changes to test procedures, and is the method utilized
48. Does the supplier’s Quality and Manufacturing organization
participate in the review and approval of test procedures
6.2.2
49. Does the supplier have training and, when required, certification and
re-certification program for test personnel
6.2.2
50. Are ATP’s performed only by trained and, when required, certified
test personnel
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7.5.1a &
b
7.5.1c
4.3
7.2.1a
7.1c &
8.2.4
8.3
7.5.3 &
8.2.4
4.2.1
N/A
Comments
51. Are test procedures available to test personnel
52. Does the test procedure specify all the equipment, special tools
and/or computers to be used
53. Is test software revision controlled and both the revision and name
are specified in the ATP
54. Does the test procedure specify the equipment accuracy for generic
M&TE, and meet Fairchild’s PO requirement.
(Measurement error can be significant if the M&TE is less than 4 times
as accurate as the parameter tolerance zone.)
55. Do test procedures have clear acceptance criteria for each
parameter or function tested and is it mapped from the document to the
data sheet
56. Does the test procedure include direction for documenting test
failures
57. Do test data sheets contain the ATP #, Rev, P/N, S/N, test date,
testers stamp or signature, results of each parameter or functions tested,
and failure report #, if applicable
58. Do test procedures include or refer to all procedures, dwgs, or other
documents needed to test the item and are they available to test
operators
Best
Practice
59. Does the test data sheet format utilize mistake proofing
Best
Practice
a. Are entries organized for easy and quick review
Best
Practice
b. Are ranges specified rather than +/- tolerances
Best
Practice
c. Are units of measured values stated
Best
Practice
d. Are actual values recorded, not simply pass/fail
Manufacturing (CNC) Software
4.2.3
60. Does the supplier protect the master CNC program, is a backup copy
maintained, and is access limited to only authorized personnel
7.5.1b
61. Are set-up sheets and instructions present
7.5.1b
62. Are set-up sheets and instructions controlled
7.5.1b
63. Are set-up sheets and instructions backed up
7.5.1c
64. Are required programs identified in the set-up requirements or within
the work instructions
7.5.1.3
65. Does a method exist to show the program is approved to produce a
specific revision level of the part
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N/A
Comments
Inspection (CMM) Software
4.2.3
66. Does the supplier protect the master CMM program, is a backup
copy maintained, and is access limited to only authorized personnel
7.5.1b
67. Are set-up sheets and instructions present
7.5.1b
68. Are set-up sheets and instructions controlled
7.5.1b
69. Are set-up sheets and instructions backed up
7.5.1c
70. Are required programs identified in the set-up requirements or within
the work instructions
7.5.1.3
71. Does a method exist to show the program is approved to produce a
specific revision level of the part
Test Software
4.2.3
72. Does the supplier protect the master Test program, is a backup copy
maintained, and is access limited to only authorized personnel
7.5.1b
73. Are set-up sheets and instructions present
7.5.1b
74. Are set-up sheets and instructions controlled
7.5.1b
75. Are set-up sheets and instructions backed up
7.5.1c
76. Are required programs identified in the set-up requirements or within
the work instructions
7.5.1c
77. Does a method exist to show the program is approved to test a
specific revision level of the part
Corrective Action & Preventive Action
8.5.2
8.5.3
78. Does evidence exist indicating Corrective Action and Preventive
Actions are identified
5.2.2d
8.5.2
8.5.3
5.2.2d
8.5.2
8.5.3
79. Does evidence exist indicating Corrective Action and Preventive
Actions are tracked
80. Does evidence exist indicating Corrective Action and Preventive
Actions are effectively addressed and responded to in a timely fashion
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