First Article Inspection (FAI): What It Is, When It Is Required, and How to Complete One

What Is a First Article Inspection?

A First Article Inspection (FAI) is a complete, independent verification that a production process is capable of making parts that conform to all design requirements. It involves measuring every dimension, testing every specification, and documenting every result on the first parts produced using production tooling and production processes.

The term “first article” refers to the first part (or set of parts) produced from a new or modified manufacturing process. The “inspection” is a full layout inspection, meaning every dimension on the engineering drawing is measured and recorded, not just the critical or key characteristics.

FAI is used across multiple industries, including aerospace, defense, automotive, and medical device manufacturing. In aerospace, the requirements are formalized in AS9102 (Aerospace First Article Inspection Requirement). In automotive, FAI concepts are incorporated into the PPAP (Production Part Approval Process).

When Is FAI Required?

FAI is typically required in the following situations:

• New part number: The first time a part is produced.
• Engineering change: When the design is revised and the change affects form, fit, or function.
• Process change: When a manufacturing process, tooling, or material is changed in a way that could affect the product.
• New manufacturing location: When production moves to a new facility.
• Lapse in production: When a part has not been produced for an extended period (often defined as 2 years or more).
• Customer request: When the customer specifically requires an FAI due to quality concerns or as part of their supplier qualification process.

The specific triggers for FAI are usually defined by the applicable standard (AS9102 for aerospace) or by customer requirements. Always verify the trigger criteria with your customer before assuming an FAI is or is not required.

FAI vs. PPAP: What Is the Difference?

FAI and PPAP (Production Part Approval Process) are related but different:

FAI focuses on verifying that the product meets all drawing and specification requirements. It is primarily a measurement and verification activity. The output is a documented report showing every dimension, material test, and functional test result.

PPAP is broader. It includes dimensional verification (similar to FAI) but also encompasses process documentation (FMEA, control plan, process flow), capability studies (Cpk/Ppk), measurement system analysis, and customer approval via the Part Submission Warrant (PSW). PPAP proves both the product and the process.

In automotive, the dimensional results element of a PPAP submission effectively serves the same purpose as an FAI. In aerospace, AS9102 FAI is a standalone requirement with its own forms and documentation standards.

How to Complete a First Article Inspection

Step 1: Gather the Documentation

Collect all applicable documents: the engineering drawing (latest revision), material specifications, performance specifications, customer requirements, and any applicable industry standards. Verify that you are working from the current revision of every document.

Step 2: Create a Ballooned Drawing

Create a ballooned drawing by numbering every dimension, note, specification, and requirement on the engineering drawing. Each balloon number corresponds to a line item on the FAI report. This ensures nothing is missed during inspection.

Step 3: Produce the First Articles

Produce the parts using production tooling, production equipment, and production processes. Parts made on prototype tooling or under non-production conditions do not qualify for FAI. The parts must represent what will be delivered to the customer in regular production.

Step 4: Perform the Inspection

Measure every ballooned dimension using calibrated equipment. Record the actual measured value for each dimension, not just pass/fail. Test material properties, surface finishes, plating thicknesses, and any other specified requirements. Functional tests (pressure tests, leak tests, performance tests) are also included.

Step 5: Document the Results

Record all results in the FAI report. For aerospace suppliers following AS9102, the report uses three standard forms:

• Form 1 (Part Number Accountability): Identifies the part, drawing revision, and FAI reason.
• Form 2 (Product Accountability for Raw Material, Processes, and Specifications): Documents material certifications, special processes, and specification compliance.
• Form 3 (Characteristic Accountability, Verification, and Compatibility): Lists every dimension with the drawing requirement, actual measurement, and pass/fail status.

For non-aerospace applications, the report format varies by customer. Some customers accept a simple dimensional report with the ballooned drawing. Others have specific templates.

Step 6: Review and Approve

The FAI report should be reviewed internally for completeness and accuracy before submission to the customer. Verify that every balloon has a corresponding result, all results are within specification, and all supporting documents (material certifications, test reports) are attached.

Step 7: Handle Nonconformances

If any characteristic does not meet the specification, it must be documented as a nonconformance. Depending on the customer and industry, you may need a deviation approval, a corrective action plan, or a new FAI after the issue is resolved. An FAI with nonconforming characteristics is typically not accepted without customer disposition.

Common FAI Mistakes

• Missing dimensions: Not ballooning every dimension on the drawing. If it is on the drawing, it must be in the FAI.
• Wrong drawing revision: Inspecting to an obsolete drawing revision. Always verify the current revision before starting.
• Uncalibrated equipment: Using measurement equipment that is not calibrated or is beyond its calibration due date.
• Recording pass/fail instead of actuals: Most customers require the actual measured value, not just whether it passed.
• Non-production parts: Using prototype or pre-production parts for the FAI instead of parts from production tooling and processes.
• Incomplete material documentation: Missing material certifications, heat treat records, or special process certifications.

Frequently Asked Questions

How many parts need to be inspected for an FAI?

Typically one part, unless the customer or applicable standard specifies otherwise. AS9102 requires FAI on at least one part. Some customers require multiple samples, especially for multi-cavity tools where each cavity must be verified.

Is FAI the same as a layout inspection?

They are closely related. A layout inspection measures every dimension on the drawing, which is the core activity of an FAI. However, FAI also includes material verification, process verification, and formal documentation that a simple layout inspection may not include.

Who performs the FAI?

The supplier performs the FAI. It should be conducted by qualified inspection personnel using calibrated equipment. Some customers require that the inspection be performed by an independent function (not the operator who produced the part). Third-party inspection services can also perform FAI.

What is a partial FAI?

A partial FAI (also called a delta FAI) is performed when only certain aspects of the part or process have changed. Instead of re-inspecting every dimension, you only inspect the characteristics affected by the change plus any characteristics that the change could reasonably impact. AS9102 permits partial FAI under specific conditions.

Does FAI need to be repeated periodically?

FAI is typically a one-time event for each configuration. It does not need to be repeated unless a trigger event occurs (engineering change, process change, lapse in production). Ongoing inspection during production is governed by the control plan, not the FAI.

What software is used for FAI?

Options include Net-Inspect, Discus, InspectionXpert, QualityXpert, and 1Factory. These tools automate ballooning, create FAI forms, and link to measurement equipment. For smaller operations, Excel templates with the AS9102 forms are commonly used.