A first article inspection (FAI) is a documented check that your process can make a part to every requirement on the drawing and in the specification. You measure the first parts from the real production process, record the actual results against each requirement, and give the customer the evidence. In aerospace it follows the AS9102 standard and its three forms. It is repeated when something important changes, such as the design, the process, the tooling, the location or a long gap in production.
What an FAI proves
It proves two things. First, that you read the drawing and the specification correctly. Second, that the production process, not a one-off sample, actually produces a part that meets all of it. A customer who buys a first article inspection is buying evidence that production will start from a good place.
When one is required
The purchase order or contract usually spells it out. The usual triggers are these:
- A new part. The first production run of a new product.
- A design change. A revision that affects the part.
- A change of material or source. A different material, or a new supplier of it.
- A process, tooling or location change. New tools, a new method, or production moved to another site.
- A long gap in production. AS9102 treats more than two years since the part was last made as a trigger.
Where only part of the part is affected, an FAI of the changed features may be enough. Check with your customer.
The three AS9102 forms
| Form | Name | What it covers |
|---|---|---|
| Form 1 | Part number accountability | The part being inspected, and any assemblies or detail parts it contains |
| Form 2 | Product accountability | Materials, special processes and functional testing the design requires, with who did them and the supporting certificates |
| Form 3 | Characteristic accountability | Every dimension, tolerance and note on the drawing, each with a balloon number, the requirement and the measured result |
The balloon numbers on the drawing must match the characteristic numbers on Form 3. That is where many reports go wrong.
How to do one
Get the requirements
Confirm with the customer that an FAI is required, which standard or format they want and what the submission looks like.
Balloon the drawing
Put a number on every dimension, tolerance, note and specification, so that nothing is left out. Keep the numbering consistent from here on.
Make the part on the real process
Use production tooling, production methods and the people who will make it. A hand-finished sample from the tool room does not prove the process.
Check the gauges
Calibration current and the measurement method able to do the job. See Gage R&R explained.
Measure every balloon
Record the actual value, not “OK.” Where the requirement is a note, record how you verified it.
Fill in Forms 1, 2 and 3
Check them against the drawing line by line. Attach the material and special process certificates and test reports.
Review before it goes out
Someone other than the person who filled it in checks the balloons, the values and the revision level.
Keep a copy and record the result
Note any nonconformance and how it was dispositioned. Save the file with the part’s revision.
FAI, PPAP and first-off: not the same
| First article inspection | PPAP | Setup first-off | |
|---|---|---|---|
| Where it is common | Aerospace and other industries | Automotive | Any plant, any shop |
| What it covers | The part against the drawing, plus materials, processes and testing | The whole production process: documents, measurements, capability and samples | The first part after a setup or change |
| When | New part or major change | New part, change or customer request | Every setup, shift or tool change |
| Output | AS9102 forms or customer format | A submission package with a signed warrant | A recorded pass before running |
A setup first-off checks that this setup is right today. An FAI proves the part and process are right in the first place. See PPAP: the 18 elements for the automotive approval package.
Mistakes that get an FAI rejected
- Balloons that do not match the report. A missing or duplicated number is the first thing a reviewer finds.
- Writing “OK” instead of the value. The customer wants to see what you measured.
- Skipping notes and specifications. Every requirement counts, not just dimensions.
- The wrong drawing revision. A report against an old revision is a report against the wrong part.
- Gauges out of calibration. The measurements stop counting.
- Not repeating after a change. A new process or tool means a new FAI.
The First Article Inspection workbook lays out the forms, and the Setup & First-Off Inspection Report covers the per-setup check.
Questions people ask
What is AS9102?
An aerospace standard that defines how a first article inspection is planned, performed and reported, including the three forms.
Is a first article inspection the same as PPAP?
No. FAI centers on measuring the first parts against the drawing. PPAP is an automotive process covering the whole production process, with documents, capability and samples.
How many parts do I inspect for an FAI?
Follow your customer’s requirement. Often it is one part or a small number, from a single production run, and it may need one per cavity or line.
When do I repeat an FAI?
After a change to the design, material or source, process, tooling or location, or a long lapse in production. Often a partial FAI of the affected features is enough, if the customer agrees.
Do I need an FAI if I am not in aerospace?
Only if your customer asks for one. Many do, in a similar format, even outside aerospace.