FAI First Article Inspection: Build an AS9102-Compliant Report
What is FAI?
First Article Inspection (FAI) is the complete dimensional, material and functional verification of one or more parts from the first production run, confirming that the manufacturing process consistently meets drawing and specification requirements. In aerospace, FAI is performed to AS9102, which requires a systematic inspection and report for every new part or after a process change. The completed report should be reviewed and signed by quality and engineering owners and delivered with the first production batch.
When to Use It
Use it before first mass production of a new product, and again after design or process changes, tooling or equipment replacement, or restart after an extended production stoppage. It is also required when submitting FAI reports to aerospace primes and customers, and when reviewing supplier first article reports. Key and safety characteristics can be flagged with stars so auditors prioritize them.
How to Use It (Step by Step)
Complete the three AS9102 forms: Form 1 records part accountability such as part number, revision, batch and supplier; Form 2 lists each part characteristic with drawing reference, tolerance, measured value and verdict; Form 3 records material certifications, special processes and functional test evidence. The tool guides data entry by form structure, auto-numbers by drawing number and revision, and summarizes results.
Key Formulas / Example
There is no scoring formula; the deliverable is the three-form report with measured values for every characteristic. Record actual measured values rather than pass/fail verdicts alone. Remember that drawing revisions, changes of manufacturing location, or restart after a long stoppage require a new FAI per AS9102.