A Focus on Quality – Initial Sample Inspections: The Gateway to Serial Production
From the idea to serial production. Find out how our EMP.Net software facilitates the creation of a standard-compliant initial sample inspection report and thus paves the way towards serial production and the associated fulfilment of customer requirements.
The initial sample inspection or FAI (First Article Inspection) is a process with which suppliers provide evidence, that their products meet the quality requirements stipulated by the customer. Initial samples hereby generally undergo a full inspection in order to identify possible faults prior to the serial production process and to verify whether or not applicable agreements have been adhered to. Serial production may only commence after the customer has made a positive verdict regarding the initial sample. All necessary information is documented in the initial sample inspection report.
Standard Compliant Initial Sampling
There are various standardized requirements and formats for initial sample reports. The automotive industry, for instance, created guidelines like QS 9000, ISO/TS (IATF) 16949 or the VDA volumes which provide methods such as PPAP (Production Part Approval Process) and documents like PSW (Part Submission Warrant) or ISIR (Initial Sample Inspection Report) and the German PPF/EMPB (Erstmusterprüfbericht). The aim of these guidelines is to simplify and streamline all aspects and interactions that relate to the creation and communication of initial sample inspection reports.
These range from design records to the analyses of applied measurement processes. Within the actual sampling process, a specific number of products must be manufactured in sequence under realistic conditions in order to e.g. meet the requirements of the AIAG (Automotive Industry Action Group). True to our motto of conformity to standards, all necessary documents and templates are available in EMP.Net in a standard-compliant format.
Increase in Efficiency and Precision
Due to the complexity of the tasks involved and the variety of different information sources that need to be combined, there are considerable risks involved in the manual creation of paper-based initial sampling reports - the time expenditure required for the manual creation of an ISIR is, of course, also immense. The usage of a software solution like EMP.Net provides a great number of advantages that facilitate a considerable improvement in both efficiency and precision. In the EMP.Net software, you work directly in a dedicated initial sample tree structure in which you simply select the respective supplier or customer and assign the relevant inspection plans and characteristic structures to them at the push of a button. The software then systematically guides you through the creation of a standard-compliant ISIR and provides you with all systemwide information right at the point where you require it.
Inspection Planning and Inspection Data Acquisition
After the inspection planning, in which you precisely define how many parts and which characteristics are to be inspected with which action limits, the assistant-driven examination of the manufactured test-parts commences. You will then receive the finished test report as a PDF file including all relevant accompanying documentation.
This documentation proves to your customer that the underlying sample was manufactured in a process that complies with the respective guideline and defined production rate. All along the process from inspection planning and data acquisition to the generation of the inspection report, EMP.Net ensures full referential integrity and thus eliminates the likelihood of data transmission errors.
Direct Data Exchange and Integrated CAD
The direct exchange of systemwide information is one of the main drawcards of EMP.Net, as data from a variety of areas such as gauge management, risk analysis, or control plan can be brought together in a single document. It is, for instance, possible to exchange characteristics between the control plan and EMP.Net and vice versa.
The software also allows you to easily include and stamp CAD-drawings in a variety of import formats such as DXF, DWG, or IGES. The graphic inspection planning tool CAD-Link.Net can be fully integrated into the software and allows you to retrieve inspection characteristics including specifications (sizes, shapes, tolerances, symbols, and comments) and many additional parameters from directly within your CAD drawings.
Always Keep an Eye on Your Deadlines and Workflows
The due-date monitoring functions in EMP.Net allow you to always keep an eye on your requalification inspections and related deadlines. This means you can prepare yourself for upcoming product requalifications well in advance and include your suppliers in the process as well. You also won’t need to reassemble the necessary data, as EMP.Net lets you call up the most current version of the ISIR and easily modify its content in order to correspond to the requirements of the requalification. Because EMP.Net can act as a dynamic element of your approval workflow, it seamlessly integrates into your project management or APQP-workflows. This facilitates a sophisticated cross-modular information management, which is distinguished by extraordinary levels of data transparency and the consistent availability of up-to-date information.
Industry-Ready File Formats
Apart from the intelligent internal linkage of the modules, EMP.Net also provides direct linkage to a variety of external platforms such as SupplyOn or MyCAQ.Net as well as other portals that communicate e.g. via the QDX XML data exchange format. The QDX (Quality Data eXchange) format was developed by the VDA and allows different management systems to easily exchange quality-related information with one another.
The high degree of integratability lastly also encompasses peripheral devices. Hence, the comprehensive integration of gauges via online interface boxes, the implementation of protocol-capable measuring devices, and the usage of complex multi-point measurement machines is, of course, possible in EMP.Net as it is in all other CAQ.Net® modules.