Defence & Military II (EN)
What is a First Article Inspection (FAI) — and what does AS9102 require?
A First Article Inspection is a documented verification that a new or changed production process actually produces parts conforming to the drawing and specification. The supplier performs it and the customer reviews the report. AS9102 is the aerospace and defense standard for this, structured around three forms covering part accountability, product accountability and characteristic verification.
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Purpose and scope
An FAI is not a one-off measurement of a single part. It verifies the whole production route: that the drawing has been interpreted correctly, that tooling and fixtures can hold the required characteristics, that the sequence of operations is reproducible and that all specified requirements — dimensions, materials, processes, markings — have actually been met.
Normally the supplier carries out the inspection on the first part produced or on a sample from the first batch, and the customer reviews the report. Where the necessary capability is not available in house, dimensional work can be placed with an accredited measurement laboratory.
What AS9102 asks for
The standard organises the report around three forms:
- Form 1 — part number accountability: identification of the part, drawing revision, assembly relationship and a summary of the inspection result.
- Form 2 — product accountability: materials, special processes and functional testing, together with the certificates and approvals behind them.
- Form 3 — characteristic accountability: every characteristic on the drawing, uniquely numbered, with the requirement, the measured result and the method used.
Form 3 relies on a ballooned drawing or an annotated 3D model in which each characteristic carries a unique number, so that requirement and measurement can always be matched. European and Japanese equivalents of the standard exist under the EN and SJAC numbering, and the FAI itself forms part of the wider advanced product quality planning and part approval framework.
When an FAI is required
Typical triggers are a new part, a design change affecting form, fit or function, a change of manufacturing process, tooling or numerical control programme, a change of the manufacturing location or of a sub-supplier for a special process, and a lapse in production — often defined as two years unless the customer specifies otherwise.
Where only part of the process changes, a partial FAI covering the affected characteristics is usually acceptable. In practice, two points cause most of the delay: characteristics that are missed because the ballooning was incomplete, and results recorded without stating the measuring equipment used. Both are avoidable by preparing the ballooned drawing and the measurement plan before the first part is cut.
Key points
- An FAI verifies the production process, not just one measured part.
- AS9102 uses three forms: part accountability, product accountability, characteristic accountability.
- Every drawing characteristic is uniquely numbered on a ballooned drawing or annotated model.
- Design, process, tooling or location changes and long production gaps trigger a new FAI.
Related questions
Who performs the First Article Inspection?
Normally the supplier, with the customer reviewing and approving the report. If the supplier lacks the necessary metrology capability, or the customer requires independence, the dimensional inspection can be placed with an accredited measurement laboratory.
What is the difference between a full and a partial FAI?
A full FAI covers every characteristic of the part. A partial FAI covers only those characteristics affected by a specific change, such as a modified feature or a new machine. The customer decides which is acceptable, and the reason is recorded in the report.
Does an FAI replace ongoing inspection?
No. It qualifies the process at a point in time. Series production still requires its own inspection plan with defined sampling, calibrated equipment and records. An approved FAI is the entry ticket to series, not a substitute for controlling it.
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