FAIRCHILD CONTROLS CORPORATION PROPRIETARY
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TABLE OF CONTENTS
PARAGRAPH
PAGE
1.0
SCOPE
3
1.1
PURPOSE
3
1.2
POLICY
3
1.3
APPLICABILITY
3
2.0
DEFINITIONS
3
3.0
APPLICABLE DOCUMENTS
5
4.0
GENERAL REQUIREMENTS
5
4.1
Classification of Characteristics
5
4.2
Supplier’s Inspection Personnel and Records
5
4.3
Qualification Criteria for Sampling
5
5.0
PROCEDURES FOR ACCEPTANCE SAMPLING
6
5.1
Sample Size and AAQL Values
6
5.2
Acceptance Number
6
5.3
Selection of Samples
6
5.4
Inspection of Samples
6
5.5
Lots Not Accepted
7
6.0
TRAINING
7
7.0
AUDITS
8
QUALITY PARAMETERS
8
Appendix “A”
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1.0
1.1
SCOPE
PURPOSE
This procedure defines the accepted methods for Fairchild Controls Corporation (Fairchild)
suppliers to perform statistical sampling inspection of parts and assemblies produced to Fairchild
drawings and specifications. This procedure is compliant with the requirements of SAE ARP9013
and ARP9013/2 as issued October 2005.
1.2
POLICY
The supplier may elect to perform 100% screening of all characteristics specified on the Fairchild
drawing/specification or perform attribute acceptance sampling of the Fairchild drawing and/or
specification characteristics in accordance with this document. Any deviation from this procedure
requires prior written approval from Fairchild Supplier Quality Assurance or the cognizant
Fairchild Program Quality Engineer. The Fairchild Director of QA or his/her designee is
responsible for the administration of statistical product acceptance plans.
1.3
APPLICABILITY
This procedure is applicable when inspection code V15 is specified on the Fairchild Purchase
Order, unless otherwise directed by the drawing or specification.
2.0
DEFINITIONS
2.1
AAQL
Associated AQL – a quality parameter developed by N.L. Squeglia which is associated with the
AQLs of ANSI Z1.4 and which affords consumer protection equal to or greater than the ANSI
Z1.4 plans.
2.2
Acceptance Sampling
Inspection in which decisions are made to accept or not accept a lot based on the results of a
sample selected from that lot.
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2.3
Attribute Data
Attribute data is the result of determining a characteristic to be either conforming or
nonconforming (pass or fail) when evaluated against the requirements. The evaluation method
may include actual dimensional measurements, inspection fixtures, go/no-go gages, optical and/or
mechanical comparators, etc.
2.4
Characteristic
Each distinguishing feature (dimension, pressure, flow, weight, etc.) indicated on the Fairchild
drawing/specification. (Classification of characteristics as Critical, Major, or Minor, shall be
provided by Fairchild as defined herein.)
2.5
Inspection Lot
All items manufactured to the Fairchild drawing/specification under essentially the same
conditions, at essentially the same time, and presented for inspection. The number of items in the
lot (lot size) is abbreviated “N”. The lot shall be clearly identified and segregated throughout the
process of sampling inspection.
2.6
Quality Parameter
An index that defines, in whole or in part, what is needed to determine how much to inspect. The
purpose of any assigned value for a quality parameter is to define what it takes to determine and
ensure conformance for each accepted unit of product. Examples of quality parameters include
AAQL, AOQL, AQL, ERP, IRR, and LQ.
2.7
Random Sampling
Selecting a sample of one or more items at random from the inspection lot or batch without regard
to the quality and whereby each item in the inspection lot/batch is assumed to have an equal
chance of being selected.
2.8
Sampling Plan
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Indicates the number of items to be selected from each inspection lot/batch to be inspected for
each characteristic (sample size), and the criteria for determining the acceptability of the
inspection lot/batch (acceptance and rejection numbers).
3.0
APPLICABLE DOCUMENTS
- SAE ARP9013, Statistical Product Acceptance Requirements
- SAE ARP9013/2, Statistical Product Acceptance Requirements Using Attribute or Variable Lot
Acceptance Sampling Plans
- SAE AS9100, Quality Management Systems – Requirements for Aviation, Space, and Defense
Organizations
- Zero Acceptance Number Sampling Plans, Fifth Edition, by N.L. Squeglia, ASQ Quality Press ©
2008 ASQ American Society for Quality
- GEN-QAI0412, Design Control (Fairchild document)
4.0
GENERAL REQUIREMENTS
4.1
Classification of Characteristics
As per GEN-QAI0412, Fairchild will classify characteristics as Critical, Major, or Minor on the
drawing and/or SIDR (Supplier Inspection Data Record). The characteristics shall be considered
“Minor” if not otherwise indicated on the drawing or SIDR.
4.2
Supplier’s Inspection Personnel and Records
When statistical sampling is utilized, the supplier’s inspection personnel shall select and inspect
samples as defined herein. Sampling plans and instructions shall be available to applicable
personnel in all areas where sampling is to be performed. Records shall be maintained that indicate
the sampling plans used, lot size, sample size, and results of sampling, including documentation of
any nonconformance. No sampling is authorized for Critical characteristics. Critical
Characteristics must be inspected 100%.
4.3
Qualification Criteria for Sampling
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Prior to the use of statistical sampling inspection the supplier shall ensure that the processes used
to manufacture the product demonstrate the ability to produce conforming product.
5.0
PROCEDURES FOR STATISTICAL SAMPLING
In order to avoid excessive lot rejections, suppliers need to maintain a process average as least as
good as the specified AAQL. Regardless of the use of this procedure, the supplier is responsible
to ensure that each part conforms to all specification requirements.
5.1
Sample Size and AAQL Values
The sample size “n” shall be determined using Table 1 based upon the inspection lot size “N” and
whether the characteristic is Minor or Major. The AAQL for Minor characteristics shall be 4.0%
and the AAQL for Major characteristics shall be 1.0%. Critical characteristics must be inspected
100%.
5.2
Acceptance Number
The acceptance number shall be zero (C=0) and the rejection number is one (1) for all sampling
plans, i.e. if any defect is found in the sample, the lot must be rejected, see paragraph 5.5, Lots Not
Accepted, below.
5.3
Selection of Samples
Samples shall be drawn at random from the total production lot and the method for selecting the
sample must provide that each item in the lot has an equal chance of being selected. Use of a
random number table is recommended. If random sampling is impractical, stratified sampling
may be utilized in accordance with these guidelines:
5.4
a.
Divide into sub lots and select sub-samples proportional to the size of the sub-lot.
b.
Draw sample items from all parts of each sub-lot.
c.
Draw sample items as randomly as practicable.
Inspection of Samples
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Once the sample items have been selected, the characteristic requirements (dimensions, weight,
pressure, etc.) are evaluated for compliance. Measuring devices used for product acceptance shall
be controlled as per AS9100. Verification must be performed on all articles in the sample for all
required characteristics. Inspector’s discretion is not permitted – any deviation from the
specification shall be reported and handled as nonconforming.
5.5
Lots Not Accepted
If there are 1 or more nonconforming characteristics in the sample the lot is considered rejected.
Rejected lots shall be documented and handled according to the supplier’s nonconforming material
procedures. Rejected lots may be scrapped, sorted, or reworked and reinspected.
TABLE 1*
Lot Size "N"
2 to 8
9 to 15
16 to 25
26 to 50
51 to 90
91 to 150
151 to 280
281 to 500
501 to 1200
1201 to 3200
3201 to 10000
10001 to 35000
35001 to 150000
Sample Size "n" for 4.0% AAQL
(For Minor Characteristics)
3
3
3
5
6
7
10
11
15
18
22
29
29
Sample Size "n" for 1.0% AAQL
(For Major Characteristics)
ALL
13
13
13
13
13
20
29
34
42
50
60
74
Note: The acceptance number in all cases is zero.
* The information contained within Table 1 was reprinted with permission from Zero Acceptance Number
Sampling Plans, Fifth Edition, by N.L. Squeglia, ASQ Quality Press © 2008 ASQ American Society for Quality.
No further distribution allowed without permission.
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6.0
TRAINING
All personnel engaged in statistical sampling are subject to the training requirements of AS9100.
7.0
AUDITS
Statistical techniques used for product acceptance shall be reviewed as part of periodic internal
audits conducted in accordance with AS9100. Fairchild may elect to periodically audit the
supplier’s implementation of this procedure.
APPENDIX A – Appendix A shows the quality parameters for each sampling plan as required by
ARP9013. Appendix A is not intended for routine use by the supplier in determining sample quantities
for inspection. See Table 1 for that purpose.
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APPENDIX A
QUALITY PARAMETERS FOR FAIRCHILD C=0 ACCEPTANCE SAMPLING PLANS
For Acceptance Sampling Conducted by Fairchild's Suppliers Per GEN-IP1001
Lot Size
2 to 8
9 to 15
16 to 25
26 to 50
51 to 90
91 to 150
151 to 280
281 to 500
501 to 1200
1201 to 3200
3201 to 10000
10001 to 35000
35001 to 150000
n @ 4.0%
AAQL1
3
3
3
7
8
9
10
11
15
18
22
29
29
2
AOQL%
7.7
9.8
10.8
4.5
4.2
3.8
3.5
3.3
2.4
2.0
1.7
1.3
1.3
3
LQ%
46.7
50.0
51.4
27.3
24.0
23.5
20.2
18.7
15.0
12.7
10.8
7.6
7.9
4
ERP%
18.3
19.2
19.8
9.3
8.0
7.8
6.6
6.0
4.8
4.1
3.4
2.3
2.4
n @ 1.0%
AAQL1
ALL
13
13
13
13
19
29
29
34
42
50
60
74
AOQL%2
0.4
1.4
2.1
2.4
1.7
1.2
1.2
1.1
0.9
0.7
0.6
0.5
LQ%3
8.5
11.9
14.2
15.1
11.0
7.5
7.4
6.9
5.3
4.5
3.9
3.3
ERP%4
3.9
3.9
4.6
4.9
3.4
2.3
2.3
2.1
1.6
1.4
1.2
1.0
The information contained within Appendix A was derived or reprinted with permission from Zero Acceptance Number
Sampling Plans, Fifth Edition, by N.L. Squeglia, ASQ Quality Press © 2008 ASQ American Society for Quality. No
further distribution allowed without permission.
1. Associated AQLs.
2. Average Outgoing Quality Limit as defined by SAE ARP9013; the maximum AOQ over all possible values of incoming
product quality level for a given acceptance sampling plan, expressed in terms of the % of nonconforming product.
3. Limiting Quality as defined by SAE ARP9013; a quality parameter where there is a small chance that a lot will be
accepted when acceptance sampling is employed. (Established at Pa = 0.10, this is the % defective that the sampling
plan will reject 90% of the time.)
4. Equal Risk Point as defined by SAE ARP9013; the fraction nonconforming at which the probability of rejecting a lot is
fifty percent (also noted as p.50). At this fraction nonconforming, the risk to the producer and consumer are the same.
(Also, ERP ≈ 1 - IRR where IRR is an estimate of the probability of conformance for each unit of product accepted
through the associated sampling plan.)
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