A material change usually requires FAI resubmission when it changes the approved design baseline, material specification, grade, form, treatment, or any condition that could affect fit, form, function, or required characteristics. A new lot alone usually does not trigger FAI unless customer or program rules say otherwise.

Out-of-tolerance results during FAI are normally treated as nonconformances, not as paperwork issues. The part is contained, the measurement is verified, the result is recorded, and disposition follows the approved quality process, often involving MRB, engineering, and customer notification when required.

Teams should choose full FAI when there is no valid prior baseline for the current part configuration and production method. Partial FAI is appropriate only when an existing FAI remains valid and the team can clearly define which characteristics, operations, materials, tools, or sources were affected by a change.

In most aerospace plants, Quality owns the FAI process, but day-to-day coordination is often handled by a quality engineer, FAI coordinator, or program quality role. Manufacturing engineering, planning, inspection, supply chain, and document control usually contribute evidence and approvals.

During a partial FAI, resubmit the FAI records needed to prove the changed or affected characteristics, not the entire original package by default. At minimum, identify the reason for the partial FAI, reference the prior accepted FAI, and provide objective evidence for the affected requirements. Customer flowdowns may require more.

FAI performance should be measured with a balanced set of cycle-time, quality, documentation, review, and change-impact KPIs. Speed alone is a weak measure; in AS9102 and regulated environments, traceability, completeness, and controlled disposition matter as much as throughput.

Nonconformances found during FAI should be controlled through the normal nonconforming material and quality system process, not informally corrected to make the FAIR pass. The FAIR should reflect the actual result, with disposition, approvals, corrective action, and any required partial or full FAI rerun handled under contract and QMS controls.