First article inspection: how to check a new part before the batch
A first article inspection (FAI) verifies that the first part made by a new process, supplier or revision meets every requirement on the drawing before the batch runs. The report includes a ballooned drawing with every characteristic numbered, the measured value and result for each, material and special process certificates, and a sign-off that releases production.
Guilherme Rodrigues ItinoseUpdated 2 min read
Key takeaways
- FAI happens on the first part of a new part, supplier, process or revision.
- Balloon every dimension, note and spec on the drawing and measure all of them.
- Record measured values, not just pass/fail.
- Attach material certificates and special process records.
- A partial FAI is enough when only some features changed.
The cheapest moment to find a problem is the first part. A first article inspection (FAI) makes sure the process, not just one lucky part, meets the drawing before hundreds of pieces are made.
When to do an FAI
- First production of a new part.
- New supplier or new machine, fixture or program.
- New drawing revision (full or partial FAI depending on what changed).
- Process stopped for a long period.
What goes in the report
| Section | Content |
|---|---|
| Ballooned drawing | Every dimension, note and specification numbered |
| Characteristic accountability | Requirement, measured value, method, result |
| Materials | Material certificate traceable to the part |
| Special processes | Heat treatment, plating, painting records |
| Approval | Who reviewed, date, decision |
Practical tips
- Balloon the drawing before machining starts, so the shop knows what will be checked.
- Record real values. “OK” hides how close a feature was to the limit.
- Use the right instrument for each tolerance and note it in the report.
- Keep the FAI tied to the drawing revision; a new revision triggers a review.
Clear, complete drawings make FAI faster. Our manufacturing documentation service prepares ballooned drawings and inspection-ready drawing sets.
When to outsource this
- You are qualifying a new machining or fabrication supplier
- Your customer requires FAI reports, for example in aerospace or automotive
When not to
- Simple purchased catalog parts with supplier certificates
FAQ
Is there a standard for FAI?
Aerospace uses AS9102. Automotive uses the PPAP process. Many other industries use a simplified version of the same idea.
Do I need a CMM for FAI?
Not always. Use the measuring method the tolerance requires: calipers and gauges for general tolerances, CMM for complex geometry and tight GD&T.
What if one characteristic fails?
Record it, decide disposition with engineering, correct the process and re-inspect the affected characteristics before releasing the batch.
How long should I keep FAI records?
Keep them as long as the part is supplied and as required by your quality system or customer contract.
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