First article inspection (FAI)
First article inspection is a complete, documented verification that the first part produced by a new or changed process meets every requirement on the drawing and purchase order.
An FAI checks every characteristic on the drawing, plus material, special processes, and any functional tests, on a representative part from the first production run. The point is to prove the process, not just the part: if the first article passes with objective evidence, the shop has shown its setup, program, and inspection can produce conforming parts.
In aerospace, FAI is usually documented to AS9102. Customers in other industries may have their own FAI formats or ask for a dimensional report. FAI is typically required for a new part, and again after changes that could affect the part, such as a design revision, a new manufacturing process or location, a tooling change, or a long gap in production.
For a small shop, the pain is retyping: part data, material certs, and measurement results already exist but have to be copied into forms. Traveler's compliance suite is designed to build FAI forms from part, job, and material lot data already in the system, with characteristics imported from a ballooned print made in a dedicated ballooning tool.
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Free, no signup: AS9102 Form 3 / FAI Template →