AS9102

AS9102 is an aerospace industry standard that defines requirements and documentation formats for conducting First Article Inspection (FAI) on production parts and assemblies. It is used by organizations in the aerospace and defense supply chain to objectively verify that manufacturing processes can consistently produce parts that conform to engineering drawings, specifications, and purchase order requirements.

What AS9102 Includes

AS9102 commonly refers to:

• A structured First Article Inspection process that verifies that a new or changed production process can make a part that meets all design requirements.
• Standardized FAI forms (often referred to as Form 1, Form 2, and Form 3) used to record part information, material and process data, and measurement results for all design characteristics.
• Requirements for when an FAI is required, such as for first production runs, significant design changes, significant process changes, or changes in manufacturing location, tooling, or supplier.
• Expectations for retaining and controlling FAI records so they are available for customers and audits.

In production environments, AS9102 shows up in workflows as ballooned drawings or models with numbered characteristics, inspection plans linked to those characteristics, and completed FAI reports that tie each measured result back to the requirement.

What AS9102 Does Not Cover

AS9102 does not:

• Define general quality management system requirements for an organization (this is covered more broadly by standards such as AS9100).
• Replace ongoing in-process or final inspection plans; it focuses on a representative part at a specific point in the lifecycle, not continuous inspection.
• Specify particular measurement methods or equipment, although it expects that appropriate, capable methods are used.

Operational Use in Manufacturing Systems

In industrial and regulated environments, AS9102 FAI is often managed using a combination of CAD, PLM, MES, QMS, and supplier portals. Common operational elements include:

• Ballooning drawings or models so every dimension, note, and requirement is assigned a unique characteristic number.
• Creating AS9102 inspection plans that link each characteristic to an inspection method and result field.
• Collecting measurement data, often directly at the machine or inspection station, and recording it on AS9102 Form 3.
• Capturing process, material, and special process information (such as heat treat or plating) on Forms 1 and 2.
• Storing FAI packages, including forms, measurement data, and supporting records, in controlled document or QMS repositories.

Common Confusion

• AS9102 vs AS9100: AS9100 is a broader aerospace quality management system standard. AS9102 is focused specifically on First Article Inspection requirements and documentation.
• AS9102 vs FAI: First Article Inspection is a generic practice used in many industries. AS9102 refers to a specific aerospace FAI standard and report format. Some organizations use the term FAI loosely, but AS9102 has defined forms and rules.
• AS9102 vs ongoing inspection: AS9102 verifies the capability of the process at defined events. It does not replace routine inspection, SPC, or control plans used in daily production.

Context in Regulated Aerospace Manufacturing

In aerospace and defense operations, AS9102 FAI reports are often required by customers for new part introductions, supplier approvals, and significant changes. They are used as part of audit evidence to demonstrate traceability of design characteristics to measured results and to show that manufacturing and inspection processes are defined, repeatable, and controlled within the wider quality system.