FAI Planning

FAI planning is the structured preparation of parts, processes, data, and documentation required to execute a First Article Inspection (FAI) and demonstrate that a manufacturing process can consistently produce parts that meet design requirements. The term is most commonly used in aerospace and other regulated industries that follow AS9102 or similar first article inspection practices.

What FAI planning includes

In industrial and aerospace manufacturing, FAI planning typically includes:

• Scope definition: Identifying which parts, assemblies, revisions, and process changes require an FAI or partial FAI.
• Requirements gathering: Collecting drawings, models, specifications, notes, and customer-specific FAI requirements.
• Ballooning and characteristic planning: Assigning unique identifiers to drawing characteristics and defining which features will be inspected, how, and with what measurement methods.
• Process and routing review: Mapping the manufacturing and special process steps that must be in place and stable before the FAI run (including suppliers and outside processing).
• Inspection plan preparation: Defining inspection sequences, sampling (if applicable), gages and equipment, and recording formats or digital forms.
• Documentation and forms setup: Preparing AS9102 or equivalent forms, data fields, and digital workflows needed to capture results and objective evidence.
• Material and configuration planning: Ensuring correct materials, part numbers, revisions, and configuration baselines are available for the FAI lot.
• Supplier coordination: Communicating FAI expectations, data requirements, and due dates to suppliers when they perform FAI on purchased or outsourced items.

Operational meaning in manufacturing systems

From an operations and systems perspective, FAI planning shows up as:

• Configuration of work orders or lots designated as FAI in MES or ERP systems.
• Linking the FAI to specific engineering revisions, CAD models, and specifications.
• Creation of digital inspection plans and ballooned drawings within FAI or quality software.
• Defining data capture requirements, attachments, and approvals needed for FAI completion and review.
• Scheduling and capacity planning to ensure time is reserved for FAI build, inspection, and potential re-runs.

Common confusion

• FAI vs. FAI planning: FAI is the actual first article inspection activity and its documented results. FAI planning refers to all the preparatory work that enables that inspection to be run correctly and documented in a compliant way.
• FAI planning vs. general inspection planning: General inspection planning covers ongoing production inspection. FAI planning is focused on the initial validation at first production, major changes, or other defined trigger events.

Relation to AS9102 and regulated environments

In aerospace, FAI planning is commonly aligned with AS9102 guidance. It supports the creation of complete and traceable FAI packages, including characteristic accountability, material and process verification, and first article reports. In regulated or highly engineered environments outside aerospace, the same planning concepts are often applied using customer- or sector-specific FAI templates and requirements.