2. Inspection Steps
2.1 Incoming Material Check
Verify material certification (grade, thickness, hardness) matches the purchase order.
Inspect raw material for surface defects (scratches, rust, dents).
2.2 First Article Inspection (FAI)
Inspect the first batch of stamped parts after tool setup.
Use CMM or optical comparator to validate critical dimensions against CAD drawings.
Check for burrs, cracks, or deformation using visual inspection.
Confirm proper functionality (e.g., fit with mating parts).
2.3 In-Process Inspection
Frequency: Every 1-2 hours or per production lot (define based on risk).
Key Checks:
Dimensional accuracy (e.g., hole diameter, flange length).
Surface finish (free of scratches, dings, or tool marks).
Burr height (must not exceed 0.1mm unless specified).
Hardness testing (if heat-treated).
Record results in inspection reports.
2.4 Final Inspection
100% Inspection (for critical parts) or AQL Sampling (e.g., Level II per ISO 2859-1).
Checklist:
Conformance to engineering drawings (all dimensions).
Functional testing (e.g., assembly trial, springback verification).
Cosmetic standards (no visible defects in Class A surfaces).
Packaging integrity (no damage during handling).
2.5 Non-Conformance Handling
Tag and isolate defective parts.
Document defects (photos, measurements) for root cause analysis.
Initiate corrective actions (e.g., tool adjustment, process review).
3. Acceptance Criteria
Dimensions: Within ±0.05mm tolerance (or as per drawing).
Surface defects: No cracks, wrinkles, or tears.
Material properties: Hardness, thickness, and coating (if any) meet specifications.
4. Documentation
Records:
First Article Inspection Report (FAIR)
In-process inspection logs
Final Inspection Certificate
Material Test Certificates (MTCs)
Sign-off: Approved by QA Supervisor before release.
5. Continuous Improvement
Review inspection data monthly to identify trends (e.g., recurring defects).
Update tooling or processes as needed to enhance quality.
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