What does FAI establish?
First Article Inspection is a documented verification of an initial output that represents a defined manufacturing setup. The team compares applicable characteristics with the agreed technical requirements, records evidence and reviews open issues before deciding what happens next.
An FAI helps answer which drawing revision was used, whether the requested characteristics were checked, whether material and process evidence can be traced, and whether any deviation received the required disposition. A first article report does not by itself prove that every unit in a production lot conforms, and it does not replace routine production controls.
When should FAI be agreed?
A customer may ask for FAI at the start of a new part, after a drawing or process change that affects technical requirements, when production moves to a different material or site, or whenever the contract specifies a report. These are common discussion points, not universal rules for every sector.
Before production, agree on which item represents the first article, which operations must be complete on it, which characteristics require measurement or testing, and who may accept a deviation. If the purchase order cites a standard, use the revision and forms required by that contract.
What should an FAI record show?
A clear record lets a reviewer trace results to the correct part, technical revision and inspection method. Depending on the agreed scope, it may include these information groups:
| Information group | Useful details |
|---|---|
| Identification | Part number, name, purchase order, lot or serial number where applicable, inspection date and report owner. |
| Technical basis | Drawing and model identifiers and revisions, specifications, and the acceptance criteria agreed for the project. |
| Measurement results | Characteristic ID, nominal requirement and tolerance, actual value, units, method or instrument, and conclusion. |
| Material and process | Material certificate or lot reference, plus evidence for heat treatment, coating, finishing or special processes when requested. |
| Appearance and function | Evaluation criteria, observation or test result, and supporting photographs when requested. |
| Deviations and approval | Description of nonconformity, disposition, authorized approval and release status. |
When the customer asks for actual readings, a simple pass/fail entry may not provide enough information for review. A marked-up drawing can help connect each requirement to a report row, while the required report format should follow the contract and applicable quality procedure.
How to organize the inspection
- Set the inspection baseline. Collect the correct drawing revision, purchase order, material, finishing requirements, cited standards and acceptance criteria. Flag documents that still need approval.
- Map the characteristics. Separate requirements into dimensions, geometry, appearance, material, function and process evidence. Assign IDs that link the drawing to the report.
- Select suitable methods. Choose a gauge, fixture, instrument or test for each characteristic; check its range, resolution and calibration status under the applicable system.
- Inspect the representative item. Record results from the selected part. If a characteristic can only be verified during manufacture or before an assembly is closed, plan to capture evidence at that operation.
- Review and decide. Compare evidence with requirements, route deviations to the authorized disposition, close missing records and release the item only after responsible parties agree on its status.
Points to consider by process family
No single inspection list fits every product. Select characteristics based on function, drawing, material, process and customer requirements.
CNC machining
Consider datums, diameters, hole locations, threads, flatness, concentricity and specified mating surfaces. Make the setup and measurement references clear so results can be compared.
Sheet metal
Review thickness, profile, hole locations, bend angles, flatness and edge condition where specified. Agree on measurement timing if a later operation could change the geometry.
Additive, casting and moulding
Agree on build orientation or sample conditions when they affect a requirement. Measure functional areas and separately record material or mechanical tests if the contract calls for them.
Surface treatment
Specify coated areas, thickness or color where defined, roughness, appearance and verification method. Process evidence should be traceable to the relevant part lot.
If a result does not conform
Identify the characteristic and affected item, hold its status to prevent accidental release, and record the disposition under the agreed process. Do not revise a drawing limit or treat a deviation as accepted without suitable approval. After correction, decide which checks must be repeated and link the updated evidence to the new result.
Information to send with an FAI request
- The production drawing and revision; include a 3D model when needed for comparison.
- Part number, quantity, material, surface treatment and applicable standards.
- Characteristics that need actual readings, test methods and acceptance criteria.
- Required forms, traceability documents or photos, plus the delivery format and due date.
- The authorized reviewer and the route for handling a deviation.
Sharing these requirements early gives the manufacturing team time to plan the inspection method and report before producing the sample.
Discuss FAI requirements ↗References
The sources below describe requirements or guidance within their own scopes. Check which clauses the project contract invokes.