Glossary

Characteristic Ballooning

Characteristic ballooning is the numbering of drawing requirements so each feature can be inspected and traced.

AS9102 First Article Inspection and Net-Inspect AS9102 / FAI

Characteristic ballooning is the practice of marking each inspectable requirement on an engineering drawing or model-based definition with a unique identifier, often shown as a numbered balloon or bubble. The identifier links the requirement to inspection records, measurement results, and quality documentation.

In manufacturing, characteristic ballooning is commonly used for first article inspection, in-process inspection planning, source inspection, and supplier quality review. A balloon may identify a dimension, tolerance, note, material requirement, finish callout, process requirement, or other verifiable characteristic.

The purpose is to create a clear cross-reference between the design requirement and the evidence that it was checked. For example, a numbered dimension on a drawing may correspond to the same characteristic number in an AS9102 Form 3 or an inspection report.

Characteristic ballooning should not be confused with measurement itself. Ballooning identifies and organizes the characteristics to be verified; it does not prove conformity unless it is linked to accepted inspection results and supporting records.

They need to be detailed enough to unambiguously trace what was actually used and to support review against the drawing, specification, and purchase or processing records. In practice, that usually means exact material and process identifiers, revision status where applicable, and supplier or source linkage. More detail than needed can add noise, but vague entries create traceability and validation risk.

Do OEM-specific quality clauses override the standard AS9102 triggers?

Usually, no. OEM-specific quality clauses generally add to, clarify, or tighten AS9102 expectations rather than erase the baseline triggers. In practice, you must review the contract, drawing notes, PO clauses, and flowed-down customer requirements together, because conflicts, exceptions, and approval paths are often site- and program-specific.

Can FAI requirements be triggered automatically from ERP or MES?

Yes, FAI (e.g., AS9102) requirements can be triggered automatically from ERP or MES, but only when business rules, master data, and integrations are well defined and validated. In most brownfield plants this requires careful mapping of part/rev status, routing changes, and supplier data, plus change control, testing, and clear ownership of FAI logic.

Does moving production to a different machine always trigger a delta FAI?

No. Moving production to a different machine does not always trigger a delta FAI by itself. The key question is whether the change can affect fit, form, function, safety, reliability, process capability, or the approved manufacturing process. The answer depends on your customer requirements, internal change control, process similarity, tooling, programming, qualification status, and objective evidence.

Related Glossary

FAI rejection

FAI rejection is the disposition of a first article inspection submission as not accepted due to missing, incorrect, or nonconforming evidence.

FAI

FAI (First Article Inspection) is a formal process to verify that initial production parts meet all engineering, specification, and documentation requirements.

FAI performance metrics

Measures used to track the timeliness, quality, completeness, and closure performance of first article inspection activities.