FAI package

An FAI package is the complete set of first article inspection documentation compiled for a specific part number or assembly, typically in accordance with AS9102 in aerospace and other regulated manufacturing. It groups the required forms and objective evidence needed to demonstrate that a production process can consistently make a part that meets all approved design requirements.

What an FAI package usually includes

The exact contents can vary by customer, contract, or internal procedure, but an FAI package commonly includes:

• AS9102 Forms 1, 2, and 3 (or equivalent internal forms) covering part information, materials and special processes, and detailed characteristic results
• Ballooned or numbered drawings and models that link each design characteristic to an inspection result
• Inspection records and measurement data (e.g., CMM reports, gage readings, surface finish and hardness results)
• Certificates of conformance and material certificates (e.g., raw material, special processes, heat treatment, coatings, welding, NDT)
• Process documentation that may be required to support traceability (e.g., routers, travelers, control plans, or work instructions)
• Change-control records when applicable (e.g., engineering change notices, configuration baselines, or revision history)
• Evidence of approvals, sign-offs, and dates associated with the FAI review and completion

In digital environments, an FAI package may be stored and managed as a single record in an MES, QMS, PLM, or specialized FAI tool, with links to controlled documents and data sources.

How FAI packages are used in operations

• Qualification of production processes: The package documents that the initial or changed production configuration can meet all drawing and specification requirements.
• Customer and regulator evidence: Customers, primes, and auditors commonly review sampled FAI packages during audits or source inspections to verify process control and documentation practices.
• Baseline for future builds: The approved FAI package becomes a reference for subsequent production runs, engineering changes, and recurring FAIs.
• Traceability and genealogy: FAI packages contribute to overall part history by linking parts, lots, processes, and materials to verified design requirements.

What an FAI package is not

• It is not routine in-process inspection for every lot or shipment, although it may reuse similar inspection methods.
• It is not a full product qualification or certification in a regulatory sense; it is focused on verifying conformity to design and process capability for a defined configuration.
• It is not limited to a single form or report; the term refers to the complete, organized set of all relevant FAI documentation.

Common confusion

• FAI vs. FAI package: “FAI” often refers to the inspection activity itself, while the “FAI package” is the documented evidence set that results from that activity.
• AS9102 forms vs. package: The AS9102 forms (1, 2, 3) are part of an FAI package, but a complete package also includes supporting documents such as ballooned drawings, inspection data, and certificates.

Link to AS9102 audit context

In AS9100 or AS9102-focused audits, reviewers commonly sample FAI packages to confirm that first article inspections were performed per requirements, that all characteristics are accounted for, and that supporting evidence such as drawings, records, and certificates is complete and properly controlled.