FAI Results Reconciler — Balloon List vs Inspection Results Screen. Catch the mismatches before the package goes out.

What it checks

The tool compares each measured value with the limits in your balloon list and reports what it could and could not evaluate. It does not decide that a first article is acceptable.

Verdict: PASS only when every non-REF characteristic is matched and within limits with no flag of any kind; any REVIEW line gives REVIEW; any FAIL line gives FAIL. An empty or ambiguous input is never a PASS. Exit codes for scripts: 0 PASS, 3 REVIEW, 4 FAIL.

Inputs it reads

• Balloon list or characteristics list: CSV, TSV or XLSX. Nominal with bilateral, asymmetric or unilateral tolerance, explicit upper and lower limits, or a single-limit feature tolerance such as position ≤ 0.05.
• Results: generic CSV or XLSX, Calypso-style CSV (including semicolon delimiters and decimal commas) and PC-DMIS text reports.
• Column names are matched by common synonyms; a column map file covers unusual exports. Unrecognised lines are listed, never silently dropped.
• PC-DMIS and Calypso are trademarks of their respective owners. This tool only reads exported files and is not affiliated with or endorsed by them.

Example card (EXAMPLE DATA)

EXAMPLE DATA. Synthetic balloon list and results generated for this page, not a real part, customer or program.

FAI RESULTS RECONCILER  ·  EXAMPLE DATA (synthetic, not a real part)
VERDICT: FAIL: flagged for human review  |  1 out of tolerance, 1 missing of 24 characteristics
subject: FAI-4155af30d6fa (hash of the part number; the number itself is never sent)

FLAGGED
  FAIL    FAI-TOL-01   char 7   measured 40.1193 outside [39.95, 40.05]   [balloons.csv row 10, cmm.csv row 8]
  REVIEW  FAI-MISS-01  char 9   no inspection result for this characteristic   [balloons.csv row 12]
  REVIEW  FAI-UNM-01   char 99  result has no matching characteristic   [cmm.csv row 30]
  INFO    FAI-UNIT-01  *        declared units: 22 result(s) in in converted to mm per row with the exact factor 25.4; limits stay in mm
  REVIEW  FAI-REV-01   -        revision differs: 'B' in balloons.csv, 'C' in cmm.csv   [balloons.csv row 3, cmm.csv row 3]

NOT EVALUATED
  REF     FAI-REF-01   char 24  (88.900) reference dimension

CHECKED (example rows)
  PASS  char 1  Overall length   120.034  in [119.9, 120.1]
  PASS  char 2  Overall width     59.968  in [59.9, 60.1]
  PASS  char 3  Thickness         25.412  in [25.35, 25.45]

Receipt: UNVERIFIED-LOCAL (offline run, not server-signed)
Screening aid that flags issues for human review. Not a quality sign-off or AS9102 approval.

Failure cases (EXAMPLE DATA)

EXAMPLE DATA: FAIL (units cannot be resolved)
  FAIL    FAI-UNIT-01  char 4  units differ (characteristic mm, result in) and cannot be resolved; not evaluated
                               (not the same as out of tolerance)

EXAMPLE DATA: REVIEW (bonus tolerance not evaluated)
  REVIEW  FAI-GDT-01   char 12  outside the base tolerance, but a material-condition modifier is present

EXAMPLE DATA: REVIEW (formula without a saved value)
  REVIEW  FAI-ATTR-01  char 5   formula cell has no cached value in the workbook

Screening aid that flags issues for human review. Not a quality sign-off or AS9102 approval.

Privacy

• Balloon lists, drawings and inspection data are read on your computer and are never uploaded. They may be export-controlled; keep them local.
• With --offline the tool makes no network call at all and still produces the full card.
• When you choose a signed receipt, only an audit hash, a hash of the part number and a one-line metric are sent to the signing endpoint. Measurements, characteristic descriptions, part numbers and file names are not.
• Use --no-excerpts to keep source row text out of the local card as well.

Limits

• Single-limit feature tolerances are supported; there is no bonus-tolerance maths. A material-condition modifier that puts a reading outside the base tolerance is a REVIEW, not a FAIL.
• XLSX values are read as saved; a formula with no saved value is flagged. Legacy .xls, .xlsm and encrypted files are not read: save as .xlsx or .csv.
• Report layouts vary and are often customised. Only the formats above are recognised, and only synthetic samples have been used to test them; lines it cannot read are listed.
• Declared inch/mm units always convert exactly per row. Undeclared units are never converted into a PASS: a row that only fits a 25.4 scale is REVIEW, so declare the units.
• It does not approve a first article and makes no statement about AS9102 or any other standard.

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