FAI (First Article Inspection)

First Article Inspection (FAI) is a formal, documented process used to verify that the first production run of a part or assembly meets all specified design, drawing, and process requirements. It is most commonly associated with aerospace and other highly regulated manufacturing sectors, but the concept is used across many industries.

What FAI includes

In a regulated manufacturing context, an FAI typically involves:

• Inspecting a representative production part (or parts) produced using normal production tools, methods, and conditions
• Verifying all defined characteristics, such as dimensions, tolerances, materials, finishes, and notes from the engineering drawing or model
• Documenting inspection results in a structured report, often linked to ballooned drawings or characteristic lists
• Capturing evidence of process controls, tooling, and key manufacturing steps used to produce the inspected article
• Reviewing and signing off the results by appropriate quality and engineering personnel

In aerospace, FAIs are commonly performed in accordance with the AS9102 standard, which defines a specific format and content for First Article Inspection Reports (FAIRs). Digital FAI solutions often integrate with MES, PLM, or QMS systems to pull design data, manage revisions, and store inspection evidence.

When FAI is typically performed

Although timing can vary by customer or internal procedure, an FAI is commonly required when:

• Producing a new part number for the first time
• Moving production to a new facility, line, or supplier
• Making significant design or process changes that may affect form, fit, or function
• Restarting production after a long interruption, if required by contract or procedure

FAI is generally performed on production-intent hardware, not prototypes, and is distinct from routine in-process or final inspection. It serves as an initial validation that the manufacturing process, as set up, can consistently produce conforming parts.

Operational use in manufacturing systems

In industrial operations, FAI information may be:

• Linked to work orders, routings, and travelers within an MES
• Associated with specific part revisions in PLM or engineering systems
• Managed in QMS or dedicated FAI software for document control and audit trails
• Shared with customers or suppliers as part of qualification and source approval workflows

Digital workflows can help control which lots or serial numbers require FAI, ensure the correct revision of drawings is inspected, and retain evidence for audits or customer reviews.

Common confusion

• FAI vs. FAIR: FAI refers to the inspection process itself. FAIR (First Article Inspection Report) is the resulting documented record of that inspection.
• FAI vs. production inspection: FAI is a one-time or event-driven verification tied to initial production or significant change, while in-process and final inspections are ongoing checks during regular manufacturing.
• FAI vs. PPAP: In automotive and some other sectors, Production Part Approval Process (PPAP) serves a similar qualification purpose but uses a different structured set of documents and requirements. FAI in aerospace is often governed by AS9102.

Relation to AS9102 and aerospace

In aerospace manufacturing, FAI commonly refers to the AS9102-defined process and forms. Under this usage, every design characteristic must be accounted for, typically using ballooned drawings and characteristic numbering, with results recorded on standardized AS9102 forms. Many organizations use digital tools and portals (such as Net-Inspect) to manage AS9102 FAIs, share data with customers, and maintain traceable records.