First Article Inspection (FAI) is a formal quality control process used in manufacturing to verify that a production method can consistently yield a part conforming to all specified requirements. This rigorous procedure is performed before full-scale production begins, acting as a mandatory checkpoint to minimize risk. This article explains the core concepts of FAI, detailing the steps involved and the reporting standards that govern the process.
What Defines First Article Inspection
First Article Inspection is a complete, independent, and documented verification process confirming that a production method has accurately produced an item conforming to all engineering drawings and specifications. It is not simply a check of a finished product but an audit of the manufacturing process itself to ensure capability and repeatability. FAI is mandated by specific triggers in the production lifecycle, preventing the use of unverified components.
The process is always required for the first production run of a new part, establishing a baseline for quality. FAI is also necessary following a change in the manufacturing location, the introduction of new or modified tooling, or a significant change in the process sequence. A lapse in production exceeding a specified period, often 12 to 24 months depending on industry standards, also requires a new inspection to revalidate the dormant process.
Why FAI is Essential for Quality Assurance
Performing FAI is a proactive measure for mitigating significant financial and operational risks associated with non-conforming parts. By validating the process at the earliest stage, manufacturers prevent costly scrap, rework, and potential delays that can halt a full production line later on. FAI establishes a definitive quality baseline, providing objective evidence that the manufacturer possesses the technical competence to meet complex design requirements.
This verification confirms the supplier’s capability to execute the defined production plan reliably and repeatedly. The successful completion of FAI provides the necessary confidence to scale up production volumes. It acts as a formal gate, ensuring that the design intent has been fully translated into a repeatable physical reality.
Navigating the FAI Process
The FAI process begins with meticulous planning, involving the selection of a representative sample part from the first production run using finalized tooling and methods. The central activity is the physical measurement phase, where inspectors perform 100% verification of every dimension, tolerance, and feature called out on the engineering drawing. This comprehensive check ensures no requirement is overlooked, capturing measured values for future analysis.
Beyond dimensional checks, the process requires verifying all material requirements, including certifications for chemical composition and physical properties. Inspectors must also confirm that all necessary special processes have been applied correctly and documented according to specifications, such as plating, heat treatment, or non-destructive testing (NDT). The inspection also mandates the verification of tool calibration records to ensure all measuring equipment used was accurate and traceable to national standards.
Required Documentation and Reporting
The value of the FAI process is captured within its documentation package, which serves as the objective proof of conformity and process capability. Without these records, the inspection holds limited regulatory or contractual weight. Reporting is standardized across many high-specification industries, often utilizing the AS9102 form or an equivalent industry-specific template.
This standard report is divided into three distinct sections. Section One details Part Number Accountability, identifying the part, the revision level, and the organization that performed the FAI. Section Two covers Product Accountability, confirming all materials, special processes, and functional tests used are compliant with the design requirements. The final section, Characteristic Accountability, is the most extensive, detailing the measurement results for every design feature. To facilitate this detailed reporting, the engineering drawing is typically “ballooned,” linking sequential numbers next to each characteristic directly to a corresponding line item on the AS9102 form.
Industries Reliant on FAI
First Article Inspection is a mandatory requirement in sectors where component failure carries extreme consequences, making it a standard gate in high-stakes manufacturing. The Aerospace and Defense industries are the primary drivers of FAI standards due to the absolute requirement for zero-defect components in safety-critical applications. These sectors operate under stringent regulatory oversight where parts must function reliably over extremely long operational lifecycles.
Similarly, the Medical Device industry relies heavily on FAI for components used in surgical tools and implantable devices, where precision and material compliance directly impact patient safety. The high-precision Automotive sector, particularly for powertrain and safety systems, also utilizes FAI to validate complex components before mass production begins.
FAI vs. Standard Quality Control
It is important to distinguish First Article Inspection from the routine activities of standard Quality Control (QC) or in-process inspection. Standard QC focuses on ensuring adherence to specifications during the production run, typically through sampling or statistical process control, confirming that the validated process remains stable over time.
In contrast, FAI is a one-time, comprehensive validation event that proves the manufacturing process is capable of producing a conforming part before mass production begins. FAI is a milestone event confirming initial design conformity and process capability, whereas standard QC ensures the continuity of that established capability throughout the production cycle.