First Article Inspection
First Article Inspection (FAI) is a formal verification that a new production process produces parts that meet all drawing and specification requirements. You run the first piece, measure everything, and document that it conforms. It's required in aerospace (AS9102) and expected by most precision customers on new parts or after significant process changes.
When FAI is required
FAI is required when: (1) you're manufacturing a part for the first time, (2) there's been a significant change to the manufacturing process, tooling, or materials, (3) there's been a design change that affects form, fit, or function, (4) production has been interrupted for an extended period (typically 2+ years), or (5) the customer specifically requests it.
For AS9100 shops, FAI requirements are defined in AS9102. For non-aerospace shops, FAI is still good practice — it catches problems before you run 500 parts to a bad dimension.
What to document
A complete FAI includes: (1) the part drawing with every dimension identified and numbered, (2) actual measured values for each dimension, (3) pass/fail for each measurement against tolerance, (4) material certification tracing the raw material to the vendor and lot, (5) any special process certifications (heat treat, plating, NDT), and (6) the sign-off of the quality inspector.
The goal is a complete record that proves this specific part, made with this specific process, from this specific material, meets all requirements.
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