Top 5 First Article Inspection Forms

Easily identify non-conformances and prevent costly production delays

Powerful inspection app for automated FAI reports

A First Article Inspection (FAI) is the process of verifying the design requirements of a product from the first production run. Quality inspectors perform FAIs when there is a 2-year lapse in production or when there are significant changes in the product, including design, manufacturing source/process, location of manufacture, tooling/materials, or computer-generated program that can affect its fit, form, or function.

Quality inspectors should document part number accountability, product accountability, and characteristic accountability in the FAI report. Streamlined first article inspections can reduce costly production delays by ensuring the manufacturing process produces output that meets design requirements.

This article will briefly discuss:

  1. how to effectively perform a first article inspection;
  2. a powerful inspection app for automated FAI reports; and
  3. free first article inspection forms you can download, customize, and use.

Click here to download Top 5 First Article Inspection Forms

First article inspections provide assurance of product conformance at the start of series production and after design changes. Here are the steps taken by quality inspectors when performing first article inspections:

1. Prepare the engineering design and specification requirements

Quality managers should regularly coordinate with design engineers and fabrication managers to ascertain that the as-built technical drawings (electrical, mechanical, pneumatic and process schemes) are followed. Before the first article inspection, prepare the instruments calibration certificates and refer to the equipment and materials data sheets to deliver high-quality machines with performance that clients can trust.

2. Determine the part or assembly to inspect

The “first article” to be inspected is neither the prototype model nor the first product from a production run. Quality inspectors should randomly select a representative item from the first production run and document part number accountability which includes the part number, part name, and manufacturing process reference.

3. Conduct raw materials, special processes, and functional testing

Quality inspectors measure and verify design characteristics through product-specific tests with required design tooling. For product accountability, each material and process used to manufacture the product is listed and certificates of conformance for special processes are added. Functional test procedures should also be cited with corresponding acceptance reports as supporting documents.

4. Evaluate characteristics accountability and compatibility

Inspection results can ascertain the necessity of a delta FAI or re-accomplishment of the first article inspection. In case of non-conforming characteristics, design revisions should be implemented. Quality inspectors should review the manufacturing process and non-conformance documentation to improve the performance of a delta FAI.

5. Report the first article inspection with proper documentation

Upon the completion of the first article inspection, quality inspectors validate the FAI report with their signatures, indicating that all characteristics are accounted for; meet drawing requirements; or are properly documented for disposition. FAI reports should include photos of the products make and packaging to provide objective evidence.

iAuditor First Article Inspection App

Quality inspectors can use iAuditor, the world’s most powerful inspection app, to streamline FAI documentation and reporting, standardize product quality, and prevent costly production delays. With iAuditor, you can:

  • Perform inspections offline or online
  • Capture photo evidence
  • Assign actions for non-conformance
  • Gather digital signatures
  • Automatically generate FAI reports
  • Get unlimited online data storage
iAuditor Digital Checklist App

To help you get started, here are 5 of the best first article inspection forms you can download and customize for free.

Top 5 First Article Inspection Forms

1. First Article Inspection (FAI) Report Form

A First Article Inspection (FAI) Report form is used by quality inspectors to properly document manufacturing process verification and prevent costly production delays. This FAI Report form has been converted into an iAuditor mobile app to automatically generate a shareable report from the moment you complete a first article inspection. Quality inspectors can take advantage of iAuditor to efficiently perform the following:

  1. Document engineering design requirements
  2. Capture photo evidence of products make and packaging
  3. Specify the materials/processes, special processes, and functional tests
  4. Assign corrective actions for non-conforming characteristics
  5. Complete the first article inspection with digital signatures

2. First Article Inspection AS9102 Form 1

The First Article Inspection AS9102 Form 1 details the part number accountability of an FAI performed on aerospace components or assemblies. AS9102 is a part of the international standard for aerospace quality management systems. Easily add engineering or manufacturing changes with the use of this digital FAI AS9102 form 1. Access FAIs anytime, anywhere and on any iOS, Android, or Windows mobile device!

3. First Article Inspection AS9102 Form 2

The First Article Inspection AS9102 Form 2 describes product accountability, including materials/processes, special processes, and functional tests of aerospace components or assemblies. AS9102, Aerospace First Article Inspection Requirement, is an international standard integrated with the ISO 9001 quality management system requirements. This digital FAI AS9102 form 2 has been designed to make it easier for quality inspectors to record the materials and processes used to manufacture the product.

4. First Article Inspection AS9102 Form 3

The First Article Inspection AS9102 Form 3 documents the characteristics accountability, verification, and compatibility evaluation of an FAI in the aerospace industry. The AS9102 standard outlines the best practices in performing first article inspections for an aerospace detail part or assembly. Use this digital FAI AS9102 form 3 to automatically save and store inspection results in the cloud. No need to worry about lost paperwork!

5. First Article Inspection Checklist

A First Article Inspection Checklist is used by quality inspectors to ensure that an FAI has proper documentation. Complete engineering design and specification requirements, manufacturing process verification, and documentation with referenced exhibits using this FAI checklist. With the iAuditor digital inspection app, quality inspectors can improve manufacturing processes and ensure products are of high quality.