A First Article Inspection is the process of planning, manufacturing, and verifying a production process. A First Article inspection is often required during the new product introduction process to ensure that the manufacturing process is capable of consistently delivering products that meet specifications.

A First Article Inspection step in NPI FactoryLogix Office allows you to create an Inspection step where a single part or reference designator is assigned automatically to each activity created.

Info

Important

The only difference between a First Article Inspection step and a Guided Inspection step is that a First Article Inspection step is created with a Step Frequency of Start of Batch meaning that it will be presented to the shop floor users only once per batch.

Note

Activities do not appear in NPI FactoryLogix Office for a First Article Inspection step. Activities for this step type are generated dynamically when executed in Production after loading the batch and operation. The activities are controlled by the Activity Splitting tab in the Settings dialog for a First Article Inspection step after the part assignments are made.

To view the activities for a First Article Inspection step in NPIFactoryLogix Office, select the Show Shop Floor Show Shop Floor toolbar button button in the Process Definition window in NPIFactoryLogix Office.

Create a First Article Inspection step

Tip

Tip

You can also use a wizard to quickly create a First Article Inspection step for a new operation. See Create a step using a wizard for details.

Note

See Create an Active Work Instruction for more information about active work instructions.

Log into the NPIFactoryLogix Office client application.
Open a new process definition and create a new operation. (See Add a new operation to a process flow for more information.)
Double-click the operation to open it for editing.
Select the Add button under Step List in the Process tree, then select First Article Inspection Step.
Double-click the First Article Inspection step to open the Settings dialog.
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Use the following tables to make your selections for the step in the Settings dialog.
When you're finished making selections for the step, select OK to confirm your choices.

Settings dialog - Basics tab

Option	Description
Name	The name of the step. To apply a step template to the step, select the Apply a Template button, select a step template, then select OK. To save the step as a step template, select the Save as Template button, enter a name for the template, then select OK. For details about creating and saving step templates, see Create a process, step, or operation template.
Default Instruction	Enter the default instruction for this First Article Inspection step. For example, "Use the torque wrench to tighten 12 1-inch coarse bolts on the unit to 188 lb.-ft.)."
Operator Interface Template	The Operator Interface template to apply to the step. See Operator Interface templates for more information.
Assigned Workstation	The assigned workstation where the step and activities will be performed by a shop floor operator. See Create a factory and set up factory resources for more information.
Any Order Mode (Activities can be viewed in any order)	All the activities associated with the step may be viewed in any order.
Is Step Required?	The step cannot be skipped by a shop floor operator.
Activities may be executed without starting a unit	Any activities associated with the step may be executed by a shop floor operator without first scanning or entering a UID to start the unit in production.
Frequency	Frequency - The frequency with which activities associated with the step are displayed and performed. Every Item - Activities must be performed for every item. By Item Count - Displays activities for the step every n number of scans. For example, when you select 3, activities will display for every third item, (item 1, item 4, item 7, item 10, and so on). Batch Based - Displays activities using the specified condition: (Select All) - Displays activities for the first and last items in the batch. Start of Batch - Displays activities for the first item in the batch. End of Batch - Displays activities for the last item in the batch. Time Interval - Activities for the step must be performed using the specified conditions. For example, 1 product every 2 minutes for the current batch. At Certain Times of Day - Displays activities for the step at specific times during the day, for example when periodic maintenance is needed to keep a workstation or machine running smoothly. By % of Total - Displays activities (even distribution) for the step each time the specified percentage of the total batch is reached. For example, a value of 10 percent in a 50-piece batch will display the specified step and activities every tenth assembly (10 percent of 50 is 5 over the course of 50 assemblies). This condition might be useful for periodic inspection of items in a batch. Operation Session Based - Displays activities for the step each time an operator logs in to begin a new session.
Activity Completion Acknowledgement	Add Acknowledgement to: The shop floor operator must acknowledge completion of All Activities, the First Activity, or the Last Activity associated with the step.
Do you want to require credentials?	Yes - The shop floor operator is prompted to supply appropriate credentials before completing the step. No - The shop floor operator isn't required to provide credentials before completing the step.
Approval Process	Yes - An approval will be required for the specified activities before the step can be completed. Select an approval process from the Approval Process drop-down. Select the activities that the approval will be required for: First Activity, Last Activity, or All Activities. No - The shop floor operator won't be required to obtain an approval before completing the step and its activities.

Settings dialog - Color Coding tab

Option

Description

Color Palette

The color palette to use for color coding parts. Select a color palette from the Palette Chooser drop-down.

Tip

Tip

You can save custom color palettes for later use which can save you valuable time when creating future process definitions containing color coded steps.

Select the Edit Color Palettes button to open the color palette editor where you can specify custom colors for parts.
To add, edit, or delete a color in the selected palette, select a color, then use the Add Color , Edit Color , or Delete Color button to make the desired changes.
To change the name of a color palette, select the Change Palette Name button to the right of the Palette Chooser drop-down, enter a new name for the palette, then select OK.

Look Behind

The Look Behind feature is typically used in manual assembly operations where an assembler is shown the parts placed by the previous operator so that their work can be verified prior to performing their own tasks. Parts placed by the previous operator are color-coded/highlighted using a pre-selected Look Behind Color.

Use the Look Behind drop-down to select the completed steps or activities the operator should review before performing this step.

Look Behind Color

Use the Look Behind Color drop-down the specify the color to use for the selected Look Behind steps and activities.

Show Look Behind

Use the Show Look Behind drop-down to select the activities that will display the selected Look Behind Color:
- First Activity - The selected Look Behind Color displays only for the first activity.
- Last Activity - The selected Look Behind Color displays only for the last activity.
- All Activities - The selected Look Behind Color displays for all activities.

Settings dialog - Activity Splitting tab

The Activity Splitting tab of the Settings dialog for a Guided Inspection step allows you to define or limit the number of color-coded parts to be displayed on each page. (Since the human eye can typically discern about 10 different colors at any given time, it is best to limit the Max Number of Items per Activity to no more than 10.) On this tab of the Settings dialog, you can also define the ordering and sorting of parts listed for each activity to help focus operator attention on a specific area of a PCB for placing or inspecting parts.

Option

Description

Group by

Side - (electronics) Specifies the side of the board to group activities by for color coding:
- Mixed - Activities are grouped by both the top and bottom sides of the board.
- Top Bottom - Activities are grouped first by the top side of the board then by the bottom side of the board.
- Bottom Top - Activities are grouped first by the bottom side of the board then by the top side of the board.
Type - Specifies that activities are grouped by either Part Number or Reference designator for color coding.
All Items on one Activity - Creates a single activity with all assigned parts listed.
Max Items per Activity - Facilitates large numbers of items (for example, groups of like part numbers or references based on the grouping method) by setting the maximum quantity of items per activity. The smaller the number, the more activities are created. As the number increases, activities are created automatically. (The number of activities created depends on the total number of parts assigned to this operation divided by the Max Items per Activity setting.)

Sorting

Side - (electronics) Sorts activities by the selected side of the board for color coding:
- Mixed - Activities are sorted by both the top and bottom sides of the board.
- Top Bottom - Activities are sorted first by the top side of the board then by the bottom side of the board.
- Bottom Top - Activities are sorted first by the bottom side of the board then by the top side of the board.
Region - Auto-generates activities based on either the whole board/panel or by dividing the whole board/panel into a customer-defined number of regions using a custom window size.
- Entire Board/Panel - Sorts activities for the entire board or panel.
- Custom Window Size - Sorts activities based on a custom window size you specify using X-axis and Y-axis coordinates. For complex PCBs, using a custom window size and serpentine pattern helps focus operator attention on specific areas of a PCB. You can also specify the Start Corner and Direction in which activities are sorted. Us the Adjust Independently check box if you want to adjust the X and Y axes measurements independently of each other.
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- Zoom To Region - When selected, zooms the window automatically to the region you specified for the activity.
Sort - Specifies the sorting order for the color-coded parts listed for each activity:
- Alphanumeric - Footprint Name - Sorts parts alphabetically by footprint name.
- Alphanumeric - Part Number - Sorts parts alphabetically by part number.
- BOM Line Item - Sorts parts by BOM line items.
- Customer Part Number - Sorts parts by customer part numbers.
- Footprint Size - Sorts parts by the size of the footprint.
- Manual - Allows you to sort parts manually.
- Manufacturer Part Number - Sorts parts by manufacturer part number.
- Polarity - Sorts parts by polarity: positive (+) and negative (−).
- Quantity - Sorts parts by quantity.
- References - Sorts parts by reference designator.
- Socket - Sorts parts by socket type.
- X - Sorts parts by X-axis location.
- XY - Sorts parts by X-axis location, then Y-axis location.
- Y - Sorts parts by Y-axis location.
Use the ASC (Ascending) and DSC (Descending) buttons under Sorting to select the sort order for the parts listed for each activity. Select More Sort Options (...) to the right of the Sort drop-down to display two additional levels of sorting options. (These options also have ASC and DSC sort order options.)
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Settings dialog - Part Assignments tab

Option	Description
Color Assignments by	Part Number - Colors parts automatically by part number. Reference - Colors parts automatically by reference. Line Item - Colors parts automatically by BOM line item. Image Removed Image Added
Use Operation Assignments	Uses global operation assignments to add activities to a Color Coded step.
Use Custom Step Assignments	Uses the current activity splitting rules (on the Activity Splitting tab of the Settings dialog) to add activities automatically to a Guided Inspection step. Each activity has its own part assignments.
Show Entire BOM	When you select the Show Entire BOM button, the BOM associated with the process definition is displayed where you can select/deselect parts for color coding. Image Modified

Settings dialog - Option Codes tab

Option

Description

Option Codes

Displays a list of available option codes.

Note

Option codes are only used with configurable (CTO) assemblies.

Use the Apply Option Codes button to move selected option code(s) to the Assigned Option Codes column.
Use the Remove Option Codes button on the right side of the window to move selected assigned option code(s) back to the Option Codes list.

Note

For details about option codes, see Option codes for configurable assemblies.

Assigned Option Codes

Displays the option codes assigned to this step.

Use Logical Expression

Select the Use Logical Expression Use Logical Expression button button on the right side of the dialog to define option codes for a step in the form of a logical expression (comprised of available option codes plus the logical operators: AND, OR, and NOT, and brackets to identify precedence).