What should be resubmitted during a partial FAI?

During a partial FAI, resubmit the records needed to prove the changed or affected characteristics comply with the current design and process requirements. That usually means an updated FAI cover record identifying the partial FAI, the reason for it, a reference to the prior accepted FAI, and objective evidence for each affected characteristic. It does not normally mean resubmitting the entire original FAI package unless the customer, contract, internal procedure, or scope of change requires it.

What is commonly included

In an AS9102-style FAI package, the resubmission typically includes:

• Updated Form 1 information showing that the submission is partial, why it is being performed, and what prior FAI it is based on.
• Updated Form 3 entries for the affected design characteristics, including inspection results, balloon references, acceptance status, and supporting measurement evidence where required.
• Updated Form 2 information only when the change affects material, special processes, functional testing, specifications, or related certifications.
• Revised drawing, model, specification, or change reference that explains what changed and which characteristics are affected.
• Supporting records such as material certificates, special process certificates, test reports, inspection reports, or CMM output when they are relevant to the affected scope.
• Clear linkage to the original FAI so unchanged characteristics are not treated as newly verified without traceability.

The practical rule is simple: resubmit enough of the FAI package to make the affected scope independently understandable and reviewable. A reviewer should be able to see what changed, why a partial FAI was triggered, which characteristics were reverified, what evidence supports acceptance, and what prior FAI remains in effect.

What usually does not need to be resubmitted

Unchanged characteristics, unchanged material records, unchanged special process records, and unchanged functional test evidence are usually referenced rather than fully resubmitted. That boundary only works if the prior FAI is approved, retrievable, and still applicable to the current part number, revision, configuration, manufacturing process, and supplier source.

If the prior FAI cannot be located, was not accepted, is tied to an obsolete configuration, or lacks sufficient traceability, a partial submission may not be defensible. In that case, the organization may need to perform a broader partial FAI or a full FAI, depending on the gap and customer requirements.

Where partial FAI submissions fail

Partial FAIs commonly fail review when the organization only submits dimensional results and does not explain the trigger, scope, or baseline FAI. They also fail when the change appears narrow but actually affects material, tooling, CNC program revision, special processes, supplier source, inspection method, or functional performance.

Another common failure is weak system linkage. In brownfield environments, the change may originate in PLM, the routing may live in ERP or MES, inspection evidence may sit in a quality system, and the FAI package may be managed in a customer portal or standalone file structure. If those records do not agree on revision, effectivity, lot, serial number, or process route, the partial FAI can become difficult to defend even when the inspection results are acceptable.

Customer and procedure requirements still control

AS9102 provides a common structure, but customer flowdowns and internal quality procedures often add requirements. Some customers require all three forms to be resubmitted for every partial FAI. Others require only the changed forms and supporting evidence. Some portals enforce a specific upload structure regardless of what is technically unchanged.

Do not treat a partial FAI as a shortcut around change control. The organization still needs documented rationale, configuration control, objective evidence, and approval through the required quality process. A partial FAI reduces unnecessary repetition only when the affected scope is clear and the unchanged baseline is traceable.