FAI, stands for First Article Inspection, which is a complete, independent, and documented physical and functional inspection process. The first article assembly process in whole printed circuit board (PCB) assembly is a very important step. FAI is carried out on the first completed assembly board prior to run mass production for ensuring no assembly errors. If found any defects, we can immediately stop run, and modify the machine program and other set-up. For simple PCB design, we sometimes assemble one or two PCB boards on tape and to do the inspection.
Free PCB DFM Check applied to circuit boards assembly, possible design and board fabrication issues might occur can be prevented. Before assembly, double-check, including Incoming materials, components uploading, SMT program, machine setup, oven profiling and speed and etc., can promise every component soldered on the PCB in correct polarity and accurate position.
As a Turnkey PCB Assembly Provider, Fuchuangke Technology knows any small error in machine setup, especially the machine program, can cause multiple errors when circuit boards are fabricated in a current work flow. Thus, it is required to use stringent quality inspection techniques for assembling the first article PCBA. Our engineers and technicians are highly trained to solder a printed circuit board (PCB) providing evidence of concept validation. Our QC team uses statistical process control methods to demonstrate the techniques we use for supervising the PCB board assembly process.
Who to Do First Article Inspection?
Once first article is completed by us, the corresponding inspection report for FAI circuit board will be issued quickly by our engineers, and they will propose suggestions on how to modify the errors if found. We support 2 ways to check the first article. One is by us, which can save time and one shipping freight. Another is by you, which will spend more 3-7 days in delivery and one more shipping freight. But sometimes, FAI done by customers is preferred. For example, the order doesn’t require us to do IC programming and functional testing. In this case, if done by us, we can only check whether our placement meets the drawing and requirements, but can’t find other potential issues may related to programming and testing. But no matter which one you choose, we will adjust the setup upon the FAI feedbacks.
Free First Article Inspection
It’s our obligation to provide qualified assembled boards to customer. So, we do not charge our customer any extra on first assembled PCBs or any modification of services, even if they ask shipping first article PCBA to them for inspection. For leadless and BGA component assembly, visual inspection is not applicable, and we inspect the first article PCBA with modern techniques such as automated X-ray inspection (AXI) to check soldering on the joints. Excepts for visual inspection on most joints visible components, we also check the PCBA board with automatic optical inspection (AOI) for verifying other solder joints, component polarity and placement. If FAI done by customers themselves, they test and feedback us of any changes necessary. We take actions to do modifications in programming of our machines and other set-up for PCB assembly line at no extra cost to our customers.
Why First Article Inspection?
The intention is to verify the processing methods used by the PCB and Assembly manufacturer have produced an acceptable circuit board as specified by the CAM data, specifications and requirements from the customers. The purpose of a PCBA first article inspection is to provide evidence that all design and specification requirements are exhaustively verified and recorded. Sometimes, suppliers are unaware of the purpose and importance of first article inspection and this ultimately results in loss of customers’ money and time, creating big problem in both design and production.
The fist article inspection is a standard process to ensure the design characteristics of a PCB board forwarded to the manufacturer actually meet design intent when the PCB is actually produced. The customer may repeat the first article inspection entirely or in part if there are some changes such as:
- Change in the source or location where the PCB is produced.
- If the design change significantly affects the form, fit, or functioning of the PCB.
- If have significant change in the processes related to fabrication, assembly, inspection, or testing.
- If any manufacturing equipment has undergone a significant change.
- If a natural or man-made occurrence adversely affects the manufacturing processes.
- The production process has been interrupted for a significant amount of time.
- Significant degradation is test yields.
- Any change in manufacturing and/or test personnel on the product line.
- Any change in a vendor supplied item with an age factor or revision factor.
If without first article inspection and modifications when problems occurred, it is likely that other PCBs assembled will also not conform. For this reason, we ensure that prior to shipping, our final QC reviews the first PCBA article inspection in detail in detail to verify items have passed, and no steps skipped or any other mistakes made. We also validate that all the requirements mentioned, such as fab notes on a drawing, are given a careful review to ensure the PCB assembled in SMT house meeting all design requirements. FAI is vital prior to high volume production. We prefer spending more time on it, which is better than rework on PCB assemblies with problems when found afterwards.
For more information about SMT PCBA FAI, please check our PCB Blog
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