First article inspection (FAI)
First article inspection is a formal verification process that confirms a supplier can produce parts meeting all specifications before proceeding with production quantities. FAI documents the complete measurement and testing of one or more initial production units against design requirements, providing objective evidence of manufacturing capability.
Examples
Machined component FAI: Before approving volume production of a precision housing, FAI measures all dimensions called out on the drawing, verifies material certification, confirms surface finish requirements, and documents all results against specifications. Any deviations require engineering disposition.
Electronics assembly FAI: FAI for a new PCB assembly includes verifying component placement accuracy, solder joint quality, electrical test results, label accuracy, and workmanship against IPC standards. The FAI package documents all inspections with objective evidence.
Aerospace FAI (AS9102): An aerospace supplier completes FAI per AS9102 standard, including Forms 1-3 documenting part accountability, product verification, and design characteristics. All characteristics require measurement results regardless of capability history.
Definition
FAI serves as a final quality gate before committing to production, catching specification interpretation issues, process problems, and capability gaps before they cause widespread quality failures. The investment in thorough FAI is minor compared to the cost of production quality problems.
FAI requirements vary by industry and product risk. Aerospace and defense follow AS9102 with specific documentation requirements. Medical devices require FAI as part of design verification. Commercial products may have less formal requirements but still benefit from supplier capability verification.
Triggers for FAI include new product introduction, new supplier qualification, production transfers, significant process or specification changes, and production restarts after extended dormancy. Any change that could affect whether the supplier can meet requirements may warrant FAI.
FAI responsibility is typically shared: the supplier performs measurements and compiles documentation, while the buyer reviews, may witness key inspections, and formally approves the FAI before authorizing production. Incomplete or unsatisfactory FAI should block production release.
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