What is First Article Inspection (FAI)?

First Article Inspection (FAI) is a quality control process used in manufacturing to ensure that a product meets the required specifications before full-scale production begins. It involves inspecting and verifying the first item produced from a new or modified manufacturing process against design requirements, including dimensions, materials, and functionality.

The FAI process helps identify any discrepancies or defects early on, reducing the risk of producing large quantities of non-compliant products. This inspection is critical for ensuring consistency and reliability in industries like aerospace, automotive, and electronics.

The Purpose of First Article Inspection

At its core, the purpose of First Article Inspection is to verify that the manufacturing process can produce parts that meet the required specifications and tolerances before full-scale production begins. It acts as a validation tool, confirming that all engineering drawing and design requirements have been properly interpreted and implemented. FAI requires stringent checks to prevent costly rework, delays, and material waste by detecting issues early in the production run.

By executing a First Article Inspection, manufacturers gain an opportunity to detect discrepancies between design requirements and the actual production processes. This inspection confirms whether the manufacturing process is capable of producing a component that matches the design, ensuring the highest quality standards are upheld throughout the production cycle.

When is First Article Inspection Conducted?

FAI is typically conducted under these circumstances:

• A new part is being manufactured for the first time.
• Modifications in the product design could affect the part’s form, fit, or function.
• A new supplier is introduced, requiring validation of component standards.
• Manufacturing is transferred to a new facility or production line.
• Production of a component resumes after an extended pause, necessitating a review of processes and equipment to ensure they meet the required standards.

This approach helps maintain consistent quality and ensures that changes in production do not compromise product integrity.

How Does the First Article Inspection Process Work?

The First Article Inspection process is comprehensive and involves a series of detailed steps to validate the manufacturing process and product quality. Each of these steps must be performed methodically to ensure accurate results.

1. Production of the First Article

The first step involves producing a single component, the first article, according to the customer’s purchase order and design requirements. This part is created under the same conditions as a full production run, using the same equipment, raw materials, and production processes.

2. Inspection of the First Article

Once the first article is produced, it is subjected to an extensive inspection process. This involves both dimensional measurements and functional testing to ensure that the part conforms to all relevant engineering drawings. Every feature, dimension, and tolerance specified in the drawing is carefully measured and recorded. 

3. Documentation of Results

During the FAI process, detailed documentation is generated, including Form 1 Part Number Accountability and material certificates. The most critical document produced during this process is the First Article Inspection Report (FAIR). The FAIR serves as a record that shows whether or not the part meets the required design requirements. It typically includes:

• Part identification: The part number, description, and revision level.
• Drawing and specification review: Verification that the current engineering drawing matches the part being inspected.
• Dimensional results: Measurements of all key features, dimensions, and tolerances.
• Material certifications: Proof that the raw materials used match the specifications.
• Functional test results: Records of any functional testing conducted to validate performance.
• Sign-off and approval: Signatures from both the manufacturer and the customer approving the FAI report.

4. Approval of the First Article

Once the FAI report is complete, it is submitted to the customer for review. The customer will evaluate the FAI results to determine whether the part meets their design requirements. If the part is approved, the supplier can proceed with full-scale production. If discrepancies are found, the supplier may need to adjust the production processes and perform first article inspection again until the part meets the customer’s requirements.

The Benefits of First Article Inspection

Conducting First Article Inspection provides significant benefits for both manufacturers and customers, ensuring that quality control is maintained throughout the manufacturing process. Some of the key benefits include:

1. Early Detection of Problems

By catching design and production issues during the initial stages, manufacturers can make adjustments before mass production begins. This minimizes the risk of costly rework or scrap and ensures that the final product meets the desired design requirements.

2. Increased Confidence in Production Processes

Once a part passes FAI, both the manufacturer and the customer can have confidence that the production processes are capable of producing parts that meet all requirements. This reduces the need for constant oversight and inspections during full-scale production.

3. Improved Supplier Relationships

For customers, FAI provides assurance that a supplier can consistently produce parts to specification. This helps to build trust and long-term relationships with reliable suppliers, ensuring smoother production workflows and less downtime due to quality issues.

4. Compliance with Industry Standards

Many industries, such as aerospace, automotive, and medical device manufacturing, require FAI to ensure compliance with industry standards like AS9102 or ISO 9001. Conducting a thorough FAI ensures that manufacturers meet these regulatory requirements and maintain their quality management system certifications.

Conclusion

First Article Inspection (FAI) is an indispensable process in modern manufacturing, playing a critical role in ensuring product quality and the reliability of complex components. By validating that production processes can meet design requirements, FAI helps manufacturers avoid costly errors, improve quality control, and build stronger relationships with customers. Through its thorough inspection, documentation, and validation steps, FAI safeguards the integrity of the manufacturing process and ensures that every production run meets the highest standards.

Contact us today to learn more about how our Inspection services can ensure the quality and reliability of your products.