Glossary

Dimensional Report

A dimensional report documents measured dimensions of a part or assembly against specified tolerances, typically for inspection and quality records.

Nonconformance, MRB and CAPA (NCR)AS9102, FAI, and Aerospace Compliance

A dimensional report is a formal record that documents the measured dimensions of a part or assembly and compares them to the design or specification requirements. It is commonly generated after an inspection activity and is used as objective evidence that the manufactured item meets, or does not meet, defined dimensional tolerances.

What a dimensional report typically includes

While formats vary by organization and customer, a dimensional report commonly contains:

Part and drawing identifiers (part number, revision, drawing number)
Inspection lot, work order, or serial number references
List of characteristics or features to be measured (often ballooned from the drawing)
Nominal dimension and tolerance for each characteristic
Actual measured values from inspection equipment
Pass/fail or in-tolerance/out-of-tolerance indication for each dimension
Measurement method and equipment identifiers, when required
Inspector identification and date, and sometimes approval signatures

In regulated and aerospace environments, the dimensional report may be tied to first article inspection (FAI) packages, manufacturing records, or supplier deliverables.

Operational use in manufacturing and quality systems

In industrial operations, dimensional reports are used to:

Provide traceable evidence that critical dimensions meet design and customer requirements
Support first article inspection and qualification builds
Document results of in-process, final, or receiving inspection activities
Feed nonconformance, CAPA, or MRB workflows when dimensions are out of tolerance
Support audits and customer reviews of inspection and quality records

Digital MES, QMS, or inspection systems often generate dimensional reports automatically from captured measurement data, linking them to work orders, inspection plans, and device history or as-built records.

Relationship to standards and FAI

In aerospace, dimensional reports are often part of AS9102 first article inspection documentation. The report lists drawing characteristics, their requirements, and the measured results that demonstrate conformity. Similar reporting approaches are used in other regulated sectors, even when different standards apply.

What a dimensional report is not

It is not the same as a full device history record or manufacturing history, which includes process steps, materials, and other data, not only dimensions.
It is not a process capability study, although dimensional report data may be used as input to capability analysis.
It is not limited to first articles; it can be used for routine inspection, sample inspection, or special measurement studies.

Common confusion

Dimensional report vs. inspection report: An inspection report is a broader term that may include visual checks, functional tests, and other attributes. A dimensional report focuses specifically on measured dimensions and tolerances.
Dimensional report vs. CMM report: A CMM report is a type of dimensional report generated from a coordinate measuring machine. Not all dimensional reports come from CMMs; they may use calipers, micrometers, optical systems, or manual gauges.

Choose the method based on risk, complexity, recurrence, evidence quality, and cross-functional impact, not by habit. A simple 5 Whys may be enough for an isolated issue with clear facts, while 8D, fault tree analysis, or a structured RCCA is more appropriate when the non-conformance is repeated, systemic, supplier-related, or poorly understood. The method must fit your evidence trail, validation burden, and existing QMS workflows.

What criteria should drive a scrap decision for aerospace structural parts?

A scrap decision for aerospace structural parts should be driven first by engineering disposition limits and traceable evidence, not by cost or schedule pressure. The practical test is whether the part can still be shown to meet drawing, material, process, and airworthiness-related requirements after any allowed rework or repair, with approved records and clear authority.

What does NCR mean in an audit?

In an audit, NCR stands for Nonconformity (or Nonconformance) Report. It is a formal record that a requirement was not met, based on objective evidence. An NCR by itself is not a regulatory failure or certificate loss, but it usually triggers documented corrective actions, follow-up, and potential re-audit. Impact depends on severity and recurrence.

What is the difference between a major and minor nonconformity?

In regulated manufacturing, "major" vs "minor" nonconformities are risk-based classifications, not universal legal terms. A major nonconformity typically indicates a systemic, repeated, or high‑risk failure that can impact product conformity or the QMS’s effectiveness. A minor is limited in scope or risk. Exact criteria depend on your QMS procedures, standards (e.g., AS9100, ISO 9001), auditor guidance, and evidence. Clear definitions, traceability, and consistent use across NCR, CAPA, and audit workflows are essential to avoid misclassification and unintended regulatory or customer impacts.

Related Glossary

FMEA (Failure Modes and Effects Analysis)

A structured method for identifying potential failures, their effects, causes, and relative risk in products or processes.