First Article Inspection (FAI)

First Article Inspection (FAI) is a planned and documented inspection process used to verify whether the first production item or a representative item from the initial production run meets the specified design, material, dimensional, functional, and other applicable requirements.

The purpose of FAI is not simply to check whether one product is acceptable. It is also to provide objective evidence that the manufacturing process, production documentation, tooling, and inspection methods can produce items that conform to the defined requirements.^[1]

FAI is commonly used in industries where product specifications and manufacturing consistency require detailed verification. In aerospace and defense, AS9102 establishes specific requirements for performing and documenting FAI.^[2]

Why Is FAI Important?

A product may look correct while still differing from its approved drawings, specifications, or material requirements. If these differences are not identified before regular production continues, the same issue may be repeated across a larger quantity.

FAI helps manufacturers and buyers:

• Verify design conformity: Check whether the first production item meets the approved drawings, specifications, purchase order, and other applicable requirements.
• Confirm manufacturing readiness: Assess whether the intended production process and tooling can produce the specified product.
• Identify discrepancies early: Detect dimensional, material, functional, or workmanship issues before they are repeated in subsequent production.
• Establish inspection records: Create documented evidence of the inspection results and supporting verification activities.

FAI provides evidence about the initial production process and representative product. It does not, by itself, guarantee that every subsequent unit will conform.

When Should First Article Inspection Be Conducted?

FAI is generally planned before or at the beginning of the first production run, using one or more items representative of the intended production process.

Typical situations in which FAI may be required include:

• A new product or part number enters production.
• A new manufacturing process or production setup is introduced.
• Significant changes are made to product design, materials, tooling, or manufacturing methods.
• A customer or purchase agreement specifically requires FAI.

Whether a full or partial FAI is necessary after a change depends on the applicable standard, customer requirements, and the nature of the change. For example, Boeing's supplier guidance identifies engineering, process, and tooling changes as factors that may invalidate previous FAI results and require review.^[3]

FAI requirements should therefore be agreed upon before production begins rather than assumed to apply identically to every order.

What Does First Article Inspection Cover?

The inspection scope should be based on the product's approved requirements and the agreed FAI plan. Depending on the product, it may include:

Not every product requires every item in this table. The inspection scope should reflect the actual design characteristics, product specifications, and customer acceptance requirements.

How Is First Article Inspection Performed?

A typical FAI process includes the following steps:

1. Review product requirements

Collect and review the latest approved drawings, product specifications, purchase order, bill of materials (BOM), and applicable testing or inspection requirements.

2. Prepare the FAI plan

Identify the product characteristics to be verified, the inspection methods, responsible personnel, measuring equipment, and required supporting records.

3. Select representative production items

Use items produced through the intended manufacturing process. A prototype made using a different process may not provide representative evidence of normal production capability.[1]

4. Inspect and verify product characteristics

Measure dimensions, examine materials and workmanship, and conduct functional or other specified tests. Record the actual results against the relevant requirements.

5. Document inspection results

Compile the inspection results and supporting evidence into a First Article Inspection Report (FAIR), where required.

6. Review discrepancies and follow-up actions

Document any nonconformities, agree on corrective actions, and determine whether another inspection or updated FAI record is necessary before proceeding.

What Is a First Article Inspection Report (FAIR)?

A First Article Inspection Report (FAIR) is the documented record of an FAI. It presents the inspection results and supporting evidence used to demonstrate whether the inspected item meets the applicable requirements.

Depending on the applicable standard and customer requirements, a FAIR may contain:

• Product identification, part number, and drawing revision
• Applicable drawings and specifications
• Identification of individual design characteristics
• Actual measurement and inspection results
• Material and process certifications, where applicable
• Functional or laboratory test results, where required
• Nonconformity records and related dispositions
• Inspection personnel, dates, and approval information

For aerospace applications, AS9102 specifies a structured FAI documentation approach, including the use of defined report forms and supporting records.^[2]

For other industries, the FAIR format and level of detail may vary according to the buyer's requirements and the product's complexity.

First Article Inspection vs. Other Product Inspections

FAI and routine product inspections serve different purposes. FAI focuses on verifying the initial production item and the manufacturing process's ability to meet defined requirements. Other inspections may take place at different stages or use different sampling approaches.

FAI does not replace ongoing production monitoring or final inspection. A satisfactory first article is evidence about the inspected item and the process represented by it; continued quality control is still needed throughout production.

Frequently Asked Questions

1. Is First Article Inspection the same as sample approval?

Not necessarily. Sample approval may confirm that a sample's appearance, design, or function is acceptable to the buyer. FAI is a more structured verification process that checks specified product characteristics and, depending on the applicable requirements, provides evidence that the intended production process can produce conforming items.

2. Does FAI mean inspecting only one product?

No. FAI may use one or more representative items from the first production run. The number of items and inspection scope depend on the applicable standard, product requirements, and customer agreement.[1]

3. Is FAI mandatory for every product?

No. FAI is not a universal requirement for all products or industries. It may be required by a customer, contract, industry standard, or internal quality procedure. AS9102 specifically addresses FAI requirements in the aerospace and defense supply chain.[2]

4. Does passing FAI mean the entire production order is acceptable?

No. FAI verifies the inspected item and provides evidence about the production process represented by that item. It does not replace ongoing process control, in-process inspection, or final product acceptance.

Sources & References

[1] International Aerospace Quality Group (IAQG). 9102 First Article Inspection Requirement. https://iaqg.org/standard/9102-first-article-inspection-requirement/

[2] SAE International. AS9102C: Aerospace Series — First Article Inspection Requirements. Revised June 28, 2023. https://saemobilus.sae.org/standards/as9102c-aerospace-series-first-article-inspection-requirements

[3] The Boeing Company. First Article Inspection (FAI). Supplier quality guidance. https://www.boeingsuppliers.com/become/quality/fai