First Article Inspection Explained: Importance, Process and Benefits

Prevents Mass Production Errors

Without FAI, undetected issues in the initial production stage could lead to thousands of defective products. The FAI checks for compliance at the earliest stage, allowing for corrections before mass production.

Ensures Compliance with Specifications

The FAI verifies every feature against the design documents and standards. It assures both manufacturers and customers that the products will perform as expected.

Reduces Costly Rework and Waste

By catching errors early, the FAI minimizes the risk of expensive rework or scrapping large volumes of parts.

Enhances Supplier and Customer Confidence

Documented FAI results demonstrate a supplier’s commitment to quality and reliability and build trust with customers.

Required by Industry Standards

Many industries, especially aerospace, automotive, electronics, and medical devices, mandate documented FAIs as part of their quality assurance processes.

Supports Process Improvement

FAI provides manufacturers with valuable data on their processes under real production conditions, offering opportunities to optimize methods or equipment.

Related article: Detailed explanation of third-party inspections: FAI

When Should FAI Be Conducted?

FAI is not a one-time activity for every production run; instead, it should be performed whenever there is a significant change that could affect part conformity. Common triggers include:

• New Product Introduction: When manufacturing a product for the first time.
• Change of Supplier or Manufacturing Location: Different facilities might use unique processes or materials.
• Design Changes: Any modification to drawings, specifications, or materials.
• Process or Tooling Changes: Modifications in manufacturing methods, machinery, or equipment.
• Material/Sub-supplier Changes: Introduction of new materials or sub-suppliers.
• Prolonged Production Gaps: Restarting production after an extended pause may require FAI to confirm continued conformity.

Each situation may require either a full FAI or a partial (delta) FAI, depending on the scope and impact of the change.

Related article: The Importance of Third-Party Quality Inspection

Types of First Article Inspection

FAI generally comes in two forms:

1. Standard/Full FAI

A complete inspection covering all drawings, dimensions, requirements, material certifications, and performance criteria for every feature of a part or assembly. This is required when:

• Producing a new part for the first time
• There are significant design or process changes

2. Partial/Delta FAI

Focused only on the features affected by specific changes, such as new tooling, minor design updates, or material changes, while referencing previous FAI records for unchanged features.

Summary Table

The FAI Process Flow

A successful First Article Inspection involves several well-documented steps:

Step 1: Preparation

Gather Documentation:

• Engineering drawings (with all dimensions and tolerances)
• Digital product data sets (2D/3D models)
• Bill of Materials (BOM)
• Material certifications
• Process specifications
• Work orders and production routing sheets
• Supplier/sub-supplier information

Purpose: To ensure everyone understands the requirements and expectations for both product and process.

Step 2: Create an Inspection Plan

Tasks:

• Identify all features to be inspected
• Assign unique identifiers to each requirement on the drawing (“ballooning”)
• Complete standardized forms (e.g. AS9102 )
• Define measurement tools and test methods
• Categorize features by criticality

Purpose: To ensure systematic coverage and traceability of each requirement.

Step 3: Manufacture the First Article

Tasks:

• Produce initial sample using standard production processes
• Document any deviations or non-standard practices
• Record batch numbers and operator information
• Optionally involve third-party inspectors for objectivity

Step 4: Inspection and Data Collection

Tasks:

• Measure every identified feature with calibrated equipment
• Record results for each characteristic on the inspection report
• Note any non-conformities immediately
• Attach relevant certificates (material COC, test reports)

Step 5: Compile and Review the FAI Report

Tasks:

• Fill out all required forms (usually based on AS9102 standard)
  • Form 1: Part number accountability
  • Form 2: Product accountability (material & processes)
  • Form 3: Characteristic accountability (measurement results)
• Attach supporting documents (drawings, photos, certificates)
• Submit report for customer review and approval

Purpose: Provides transparent evidence that all requirements have been met before authorizing full productio