First Article Inspection Forms & FAI Reports

Easily identify non-conformances and prevent costly production delays with a powerful inspection app for automated FAI reports


What is a First Article Inspection?

First Article Inspection (FAI) is the process of verifying the design requirements of a product from the first production run. First article inspections can reduce costly production delays by ensuring the manufacturing process produces output that meets design requirements. An FAI is required by the 9102 standard developed by the International Aerospace Quality Group (IAQG) and published through the Society of Automotive Engineers (SAE).

What is a 9102 FAI?

A 9102 FAI is the first article inspection that adheres to the AS9102B or the Aerospace First Article Inspection Requirement. SAE offers a practical guide that sets the baseline requirements for performing and documenting FAI. Essentially, a 9102 FAI focuses on providing objective evidence the manufacturer’s processes can produce compliant products and that they have also incorporated statutory and regulatory requirements.

What is a Delta FAI?

A delta FAI, also referred to as a partial FAI, is one of the two most common types of first article inspections—the other one is called a full FAI, or a complete re-accomplishment of the first article inspection. Usually, a partial FAI is conducted only under certain circumstances such as changes in the design of a product, where the delta FAI report shows the difference between the original first article inspection report (FAIR) and the revised drawing.

First Article Inspection Frequency

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.

First Article Inspection Process

First article inspections provide assurance of product conformance at the start of series production and after design changes. Generally, 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 a full re-accomplishment of the first article inspection. In the 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 product’s make and packaging to provide objective evidence.

What is an FAI Report?

An FAI report, or FAIR, is a document completed by quality inspectors which usually includes part number accountability, product accountability, and characteristic accountability. Generally, electronic signatures are acceptable in an FAI, as long as their usage and control are clearly defined in the organization’s quality management system (QMS).

Jona Tarlengco
Article by

Jona Tarlengco

SafetyCulture Content Specialist
Jona Tarlengco is a content writer and researcher for SafetyCulture since 2018. She usually writes about safety and quality topics, contributing to the creation of well-researched articles. Her years of experience in one of the world’s leading business news organisations helps enrich the quality of the information in her work.

Explore more templates

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!
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.
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!
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 SafetyCulture digital inspection app, quality inspectors can improve manufacturing processes and ensure products are of high quality.