First Article Inspection (FAI)

First Article Inspection (FAI) is a formal, documented process used to verify that a new or significantly changed manufacturing process can consistently produce a part or assembly that meets all specified design, drawing, and specification requirements. It is typically performed on the first production run (or an early representative piece) and results in an inspection record that links measured characteristics to the design authority.

Key elements of First Article Inspection

In regulated and aerospace-oriented manufacturing, FAI commonly includes:

• A defined inspection part (the “first article”) produced using standard production tools, methods, materials, and operators.
• Complete verification of all design requirements on drawings, models, and specifications, often using ballooned characteristics.
• Recorded inspection results for each characteristic, including dimensions, notes, material or process requirements, and special characteristics.
• Traceability to manufacturing processes, work instructions, tooling, gages, and material lots used.
• Approval and retention of an FAI report as part of the quality record set.

FAI may be required for:

• New part introduction or first production use of a part number.
• Significant design changes that affect fit, form, function, or safety.
• Major changes to manufacturing processes, locations, tooling, equipment, or suppliers.
• Reinstating production after a prolonged lapse, depending on customer or internal criteria.

FAI vs routine inspection

FAI is broader than routine or in-process inspection. It verifies the complete set of design requirements and associated manufacturing process capability at a defined point in time, rather than sampling a subset of characteristics on an ongoing basis. Routine inspection focuses on ongoing product acceptance; FAI focuses on initial and change validation of the process and its documentation.

FAI in aerospace and regulated industries

In aerospace, FAI is commonly aligned with the AS9102 standard, which defines a structured methodology and forms for conducting and documenting First Article Inspections. Many OEMs and primes require FAI from their suppliers, and digital FAI workflows are often integrated with MES, PLM, or quality systems to maintain traceability, revision control, and audit readiness.

In other regulated and high-reliability sectors, similar practices exist under different standards or internal procedures, but the core purpose remains: to show that the manufacturing process, as implemented, can produce conforming parts and that this is documented in a way that can be reviewed and audited.

Operational use

Operationally, FAI shows up as:

• A required step in new product introduction workflows or engineering change processes.
• A gate in supplier approval or production release, often linked to purchase order and work order milestones.
• A set of digital or paper forms containing characteristic listings, measured values, and pass/fail status.
• A controlled quality record maintained for traceability, customer review, and audits.

Common confusion

• FAI vs Production Part Approval Process (PPAP): PPAP is a broader automotive-focused approval framework that can include dimensional results similar to FAI, along with additional documentation such as process flow diagrams, control plans, and capability studies. FAI is more narrowly focused on verifying conformance of the part and associated process at first production or after change.
• FAI vs first piece inspection: First piece inspection often refers to a shop-floor practice where the first part of a shift or setup is checked for conformance. FAI is a more formal, fully documented process typically tied to new parts, major changes, or customer/standard requirements.