Full FAI

Full FAI commonly refers to a complete First Article Inspection performed in accordance with AS9102 or similar aerospace and defense requirements. It involves verifying and documenting every design characteristic on the drawing or model for a part or assembly, rather than a limited subset of features.

What Full FAI includes

In regulated and aerospace manufacturing environments, a Full FAI typically includes:

• Ballooned drawings or models identifying all required characteristics (dimensions, notes, material, finishes, special processes, etc.)
• A completed first article inspection report covering every ballooned characteristic
• Objective evidence such as measurement records, certifications, and process documentation
• Traceability to the specific part, lot, configuration, and manufacturing process used to produce the first article
• Signatures or electronic approvals from responsible functions (for example, quality and engineering)

Operationally, performing a Full FAI usually occurs when a part is produced for the first time, after significant design or process changes, or when required by customer or regulatory flowdown. In digital MES or FAI tools, a Full FAI workflow will drive collection of all required data elements rather than allowing partial coverage.

What Full FAI does not include

Full FAI does not typically refer to:

• Routine in-process or final inspections performed on every batch
• Sampling inspections that only check a portion of characteristics or units
• Capability studies or process validation activities, unless specifically tied into the FAI package

Common confusion

“Full FAI” is often contrasted with:

• Partial FAI: Only characteristics affected by a specific change (for example, drawing revision, tool change, or new supplier) are re-inspected and documented.
• Delta FAI: A limited update to an existing FAI, documenting only the changes since the last approved FAI.

Unlike general incoming or in-process inspections, a Full FAI is a structured, traceable, and usually one-time or event-driven activity intended to demonstrate that the manufacturing process can produce a part that meets all specified requirements.

Tie to AS9102 context

Within AS9102 programs, a Full FAI usually means completing the entire AS9102 FAI package (all forms and associated evidence) for every applicable drawing characteristic. Digital FAI solutions, Net-Inspect workflows, or MES-integrated FAI modules often distinguish between initiating a Full FAI versus a partial or delta FAI to align with customer and regulatory expectations.