What is First Article Inspection?
First Article Inspection (FAI) is a quality assurance process that verifies the first production part meets all customer specifications before full production begins. It confirms that the manufacturing process is capable of producing parts that meet requirements.
FAI is typically required for new parts, design changes, process changes, or after extended production pauses.
FAI is often required by AS9102 standards for aerospace applications and is increasingly common in medical and automotive industries.
Why FAI matters
- Quality verification — confirms the part meets all specifications
- Process validation — verifies the manufacturing process is capable
- Risk reduction — identifies issues before full production
- Customer confidence — provides documented evidence of quality
- Compliance — meets regulatory and industry requirements
Always request FAI reports from your supplier for the first production batch. This builds confidence in their quality system.
What is included in an FAI report?
- Part identification — part number, revision, drawing number
- Material verification — material grade and certificate
- Dimensional inspection — all dimensions and tolerances verified
- Surface finish inspection — measured against specification
- Visual inspection — surface defects, burrs, finish quality
- Test results — if any functional testing is required
- Inspection equipment — list of equipment used
- Sign-off — supplier and customer approvals
FAI process steps
- Step 1 — Manufacturer produces the first production part
- Step 2 — Complete dimensional inspection is performed
- Step 3 — FAI report is compiled with results
- Step 4 — Report is sent to customer for review
- Step 5 — Customer approves or requests corrective action
- Step 6 — Full production begins after approval
Delaying FAI until after full production. FAI should be completed on the first article before scaling to full production.
When is FAI required?
- New part production
- Design changes
- Process changes
- Supplier changes
- Extended production pauses
- Customer requirements
Frequently Asked Questions
What is the difference between FAI and standard inspection?
FAI is a comprehensive inspection of the first production part against all drawing requirements. Standard inspection checks samples during production.
How long does an FAI take?
Typical FAI takes 1-3 days depending on part complexity and number of dimensions to be inspected.
Is FAI required for every part?
Not always. FAI is typically required for new parts, design changes, or when specified by the customer.
What if a part fails FAI?
Corrective action is taken to address the issue. A revised FAI is submitted after correction.