Glossary

FAI performance metrics

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

AS9102 First Article Inspection and Net-Inspect AS9102 / FAI

FAI performance metrics commonly refers to the measures used to evaluate how first article inspection activities are performing over time. In aerospace and other regulated manufacturing environments, these metrics are used to monitor whether FAI work is being completed on time, with complete documentation, with acceptable data quality, and with effective closure of issues found during review.

The term usually applies to the performance of the FAI process itself, not to the dimensional or functional results of a single part alone. It can include operational measures taken from quality systems, MES, ERP, PLM, supplier portals, or FAI software workflows. Examples include cycle time to complete an FAI package, percentage of first-pass approvals, rework or resubmission rates, missing characteristic counts, overdue open actions, and supplier on-time FAI submission rates.

What it includes

Timeliness metrics, such as elapsed time from part readiness to FAI completion
Completeness metrics, such as missing fields, missing records, or unlinked characteristics
Quality metrics, such as error rates, rejection rates, or number of corrections per package
Closure metrics, such as time to resolve findings, nonconformances, or documentation gaps
Throughput metrics, such as number of FAIs completed in a period or backlog volume

What it does not mean

FAI performance metrics does not usually mean general shop-floor KPIs such as OEE, labor efficiency, or machine uptime unless those measures are specifically tied to FAI workflow performance. It also does not mean the engineering definition of product requirements themselves. The metrics describe the execution and control of the first article process, not the design intent.

Common confusion

FAI performance metrics is often confused with product quality metrics and with broader quality management KPIs. Product quality metrics focus on the part or assembly result, such as defect counts or yield. FAI performance metrics focus on how well the first article inspection process is executed, documented, reviewed, and closed. It may also be confused with supplier scorecards, which are broader and can include delivery, responsiveness, and commercial measures beyond FAI.

Operational context

In day-to-day operations, these metrics often appear in dashboards, compliance reviews, supplier oversight, or program readiness reporting. Organizations may track them by program, part family, site, customer, or supplier to identify recurring delays, documentation gaps, or process bottlenecks in first article execution.

Relationship to FAI standards and workflows

Where FAI is managed under standards such as AS9102, performance metrics are commonly used to monitor how consistently the required inspection and documentation workflow is being carried out. The metrics are management indicators for process performance. They are not, by themselves, proof that any specific FAI package is acceptable or compliant.

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.