GlossaryKind of term: Manufacturing termFirst article inspection
What is first article inspection?
First article inspection (FAI) is the full, documented check of a first production part against every drawing and order requirement before release.
The part must come from the actual production process, and the check covers dimensions, form, orientation, location and runout tolerances, roughness, threads, notes, material and finish, with certificates where they are required. The requirements are numbered, often on a ballooned drawing, and the report gives the measured value or the evidence for each number. Once approved, the process for that part is released. FAI is distinct from the first-off check after each batch setup, which shops also call a first-piece inspection.
What does the standard say about first article inspection?
What an FAI covers is set by the agreement with the customer. In aerospace, the AS9102 standard defines content and forms; in automotive, PPAP asks for comparable evidence within a larger package. Under such requirements a new or partial FAI is needed after a change that can invalidate the earlier evidence, such as a new revision, a different production location or a different process, or after a long break in production. The exact triggers and time limits are in the standard or the customer's requirements.
How does first article inspection work in practice?
An FAI takes inspection time, programming time for the measuring machine and time for the report, and that time grows with the number of requirements on the drawing and the report format asked for. Because it is needed once per part and revision, many cost engineers treat it as a one-off cost, separate from the time per piece; whether it is charged to the first order or spread over several is an estimating convention. The first-off check on every batch is smaller in scope: the critical dimensions are measured after setup, before the batch runs on.
What is first article inspection often confused with?
FAI is not the first-off check after setup: that approves the setup on every batch, the FAI approves the process once against every requirement. Nor is it final inspection: that checks the delivered batch, by sampling or in full. And an inspection report covering a few critical dimensions is not an FAI.
Frequently asked questions
Do I need a new FAI for every repeat order?
Usually not at the same revision, process and location. After a revision, a process change or a long production break, the customer often asks for a new or partial FAI covering what changed. The customer's requirements decide.
Does the FAI belong in the price?
Yes, when it is required. The time depends on the number of requirements, the measuring equipment and the report format. Treated as a one-off cost, it is not charged again on a repeat order at the same revision.