5.2 The Engineering Query (EQ) & FAI Handoff

The transition from "Digital" to "Physical" is gated by the Engineering Query (EQ) process and the First Article Inspection (FAI). This protocol defines the responsiveness required to maintain the production schedule and the criteria for mass production release.

The Pre-Flight Checklist

Before uploading the Golden Data Pack, the engineer must verify:

• [ ] DRC (Design Rule Check) Clean.
• [ ] Gerber/ODB++ vs. Drill File alignment verified.
• [ ] BOM validated against AVL.
• [ ] Pick & Place rotation verified.

Engineering Query (EQ) Protocol

If the manufacturer identifies a discrepancy (e.g., Pad on Via, Missing MPN), an EQ is raised.

• EQ Hold: Production clock stops. The line is idle.
• SLA: The engineering team must respond to critical EQs within 24 hours. Failure to respond typically results in the production slot being reassigned, causing multi-week delays.
• Resolution: EQ responses must be formally documented. "Just fix it" is not a valid instruction; the specific correction must be detailed.

First Article Inspection (FAI)

The first unit off the line is the "Golden Sample."

• Digital FAI: High-resolution images of the first placement and reflow are sent for approval. This gates the completion of the batch.
• Physical FAI: For new NPIs, the physical unit is shipped for functional verification.
• Approval: Written sign-off on the FAI report freezes the process parameters. No changes to the machine program or oven profile are allowed after this point without a new FAI.

Final Checklist