FIRST ARTICLE INSPECTION

Guide for successful completion
of First Article Inspection
Reports

Company Confidential
Rev. Jan 2012 1

Introduction
• This presentation is intended as supplemental
information in support of the 9102 Standard for
Aerospace First Article Inspection requirements.

• This material should be used in conjunction with the
standard. The requirements cited in the standard
always take precedent.

2

Requirements
 First Article Inspection Reports are to be recorded in
English or in a language specified by the customer.

 AS/EN/SJAC9102 Revision A - Aerospace First Article
Inspection Requirement

 8.2.4.2 First Article Inspection: The organization’s
system shall provide a process for the inspection,
verification, and documentation of a representative
item from the first production run of a new part, or
following any subsequent change that invalidates the
previous first article inspection result.

 NOTE: USE (AS) (EN) (SJAC) 9102 with this
tutorial for requirements

3

Requirements
 Additional Customer requirements if applicable

 AS/EN/SJAC9102 Rev A forms are to be completed in
accordance with the Appendix A guide of the standard

 Note: If alternate forms are used, they must contain
all “Required” and “Conditionally Required”
information and have the same field reference
numbers as AS/EN/SJAC9102 Rev A

4

Definition

FIRST ARTICLE INSPECTION (FAI):

A complete, independent, and documented physical and
functional inspection process to verify that prescribed
production methods have produced an acceptable item
as specified by engineering drawings, planning,
purchase order, engineering specifications, and/or
other applicable design documents.

Ref 9102 Rev A

5

Purpose
Provides objective evidence:

that all engineering, design and specification
requirements, including process and manufacturing
validation, are correctly
 understood
 accounted for
 verified
 and recorded.

of a consistent documentation requirement for
aerospace components.

6

Evaluation Activities
• The organization should conduct the following
activities in support of FAI;
– Review documentation for the manufacturing
process (e.g., routing sheets,
manufacturing/quality plans, manufacturing work
instructions, etc.) to make sure all operations are
complete as planned.
– Review referenced exhibits supporting the FAI
(e.g., inspection data, test data, Acceptance Test
Procedures, etc.) for completeness.
– Review nonconformance documentation (if any),
for completeness.
– Review material certifications for compliance, as
applicable.

Evaluation Activities
– Verify that approved Special Process sources are
used (as applicable), and that the manufacturing
planning/routing document calls out the correct
specification.
– Verify that Key Characteristic requirements have
been met, as applicable Verify part specific gages
and/or tooling are qualified and traceable, as
applicable.
– Verify that every design characteristic requirement
is accounted for, uniquely identified and has
inspection results traceable to each unique
identifier.
– Note the company FAI procedure should address all
evaluation activities

When should FAI be performed?
 Full FAI
 New part introduction
 New supplier or new location of manufacture
 Lapse in production for more than 2 years
 When required by the customer

 Partial (Delta) FAI
 Design change
 A change in the method of manufacture (e.g.
Tooling, Processes, Machine, Location, Numerical
Control Program, Sequence of Manufacture).

9

What does it apply to?
 All product defined by engineering drawings or model
based definitions. Delete-issued by the Customer

 Assemblies- for those characteristics specified on the
assembly level drawing only

 All levels of detail parts within assembly
 including castings and forgings

 Modified Standard, Electronic or COTS Items as “make
from” with unique engineer modifications on drawing
Only the modifications

10

What does it not apply to?
Standard Parts

Electronic Components

Commercial Off The Shelf (COTS) Items

No FAI required

11

What is included?
 Verification of all design characteristics

 Material and Special Process Certifications

 Manufacturing Process Verification

 Nonconformance resolution

12

Forms
The Following Forms comprise a First Article Inspection
Report (FAIR) full instructions in 9102 appendix A

AS9102 A Form 1: Part Number Accountability shall be used
to identify the part that is being first article inspected (FAI
part) and associated sub-assemblies or detail parts.

AS9102 A Form 2: Product Accountability – Raw Material,
Specifications and Special Process(s), Functional Testing shall
be used if any material, special processes or functional testing
are defined as a design requirement.

AS9102 A Form 3: Characteristic Accountability, Verification
and Compatibility Evaluation shall be used to record an actual
measurement or inspection/verification of the FAI part for
every design characteristic on the drawing, including notes.
13

AS9102 A Form 1 – Part Number Accountability
1. Part Number 2. Part Name 3. Serial Number 4. FAI Report Number

5. Part Revision Level 6. Drawing Number 7. Drawing revision level 8. Additional Changes

9. Manufacturing Process 10. Organization Name 11. Supplier Code 12. P.O. Number
Reference

13. Detail FAI 14. Full FAI Baseline Part Number including revision level
Partial FAI
Assembly FAI Reason for Partial FAI:

a) if above part number is a detail part only, go to Field 19
b) if above part number is an assembly, go to the “INDEX” section below.
INDEX of part numbers or sub-assembly numbers required to make the assembly noted above.
15. Part Number 16. Part Name 17. Part Serial Number 18. FAI Report Number

YELLOW or LIGHT GREY fields – MANDATORY
information required.
BLUE or DARK GREY fields – CONDITIONALLY
REQUIRED. These fields must be completed
when information is available.
WHITE fields – OPTIONAL information required
when available.
1) Signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for
disposition.

2) Also indicate if the FAI is complete per Section 5.4: FAI complete FAI not Complete
19. Signature By 20. Date

21. Reviewed By 22. Date

23. Customer Approval 24. Date

Form 1, 9102 Rev A, Date: Oct 24, 2003

14

AS/EN/SJAC9102 Rev A First Article Inspection
Sheet 1 of _
Form 1: Part Number Accountability


Box 1. Part Number of the FAI part.
Box 2. Name of the part as shown on the drawing.
Reference Box 3. Serial number of the FAI part.
Box 4. The Report No.
Box 5. The revision of the part
Partial FAI being first article inspected. Indicate if
Assembly FAI therePartial FAI: revision.
Reason for is no
Note: The latest revision (Box 7) does not always affect all parts contained on a drawing.
Box 6. ifThe drawing numbersection below.
b) above part number is an assembly, go to the “INDEX” associated with the FAI part.
(if different from numbers or sub-assembly numbers required to make the assembly noted above.
INDEX of part part number)
Box 7. Reference the revision engineering drawing.
(if drawing number is different from part number)
Box 8. Reference Design, Engineering or Manufacturing changes
affecting the FAI part, not reflected by the current part/drawing15
revision level. 15




Reference

Box 9. Reference the internal works order.
Box 10. Name of the organization performing the FAI .
Partial FAI
Assembly FAI 11. Reference the supplier vendor code.
Box Reason for Partial FAI:
Box if12.part number is a detail part only, go to Field 19
a) above Reference the customer Purchase Order number.
Box 13. Check as appropriate.
BoxPart Number
15. 14. Check asPart Name 16. appropriate. Part Serial Partial FAI Report Number
17. For Number 18. FAI provide the
baseline drawing number, including issue status and the
reason. i.e Change of manufacturing location,
Non-Conformance, Process change, Design change etc.
16



Boxes 15, 16, 17 and 18 – this section is only
required if the Part Number in Box 1. is an
Assembly with lower level parts.P.O. Number
9. Manufacturing Process 10. Organization Name 11. Supplier Code 12.
Reference
Box 15. Reference all lower level parts or
next level sub-assembly Part Number.
Box 16. Part namePartial FAI
as shown on the drawing/ parts list.
Assembly FAI Reason for Partial FAI:


Box 17. Reference the serial number of the part.
Box 18. A reference number that identifies the FAI package.
17


Box 19. The name and signature of the
person who prepared the FAI.
Box 20. Date when the FAI was prepared.

Box 21. The name of the person who
reviewed or approved the FAI package.
Box 22. Date when the FAI was reviewed.
1) Signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for
disposition.

2) Also indicate if the FAI is complete per Section 5.4: FAI complete FAI not Complete
19. Signature By 20. Date

21. Reviewed By 22. Date

23. Customer Approval 24. Date

Form 1, 9102 Rev A, Date: Oct 24, 2003

Box 23. Customer Approval.
Box 24. Date of Customer approval.

18

AS9102 A Form 2 – Product
Accountability
1. Part Number 2 Part Name 3. Serial Number 4. FAI Report
Number

5. Material or Process 6. Specification 7. Code 8. Special Process 9. Customer 10. Certificate of
Name Number Supplier Code Approval Conformance
Verification number
(Yes/No/NA)

Boxes 1 - 4 are repeated on all forms for
convenience and traceability.

11. Functional Test 12. Acceptance report number, if applicable
Procedure Number

13. Comments

14. Prepared By 15. Date

19

Accountability

1. Part Number 2 Part Name 3. Serial Number 4. FAI Report
Number

5. Material or Process 6. Specification 7. Code 8. Special Process 9. Customer 10. Certificate of
Name Number Supplier Code Approval Conformance
Verification number
(Yes/No/NA)

Box 5. Enter the name of the material or process i.e. Aluminium
Alloy, Cadmium Plate etc.
Box 6. Enter the material or process specification number, class and
material form i.e. AMS4928 Bar (Include ‘make from’ materials, weld/
braze filler materials, standard catalogue hardware etc).
Box 7. Reference any material code specified.
Box 8. Reference Special Process Supplier Vendor code,
name & address.
Box 9. Indicate if technical approval is required by the customer.
Box 10. Reference Certificate of Conformance number(s) e.g. Special
Process, Raw material & Mill certifications, Laboratory Reports etc.
20

Accountability

11. Functional Test 12. Acceptance report number, if applicable
Procedure Number

Box 11. Reference the Functional Test procedure
as stated on the drawing.
Box 12. Reference the Functional Test report.
13. Comments


Box 13. Comments – As applicable.
Box 14. The name of the person who prepared this form.

Box 15. Date when this form was completed.

21

Ballooned Drawings
 A ballooned drawing is optional and considered an
industry best practice to support Box 5 of Form 3
 Identify 100% of characteristics
 Balloon and number all dimensions
 Balloon and number all surface finish callouts
 Including exclusion and inclusion area callouts
 Balloon and number all material and hardness
callouts
 Don’t forget the requirements identified in the title
boxes at the bottom of the drawings.

22

BALLOONED Note 2

DRAWINGS 1

2

3

8 4

7 5

6

Note: In this example not all characteristics ballooned
23

AS9102 A Form 3 – Characteristic Accountability,
Verification and Compatibility Evaluation
1. Part Number 2. Part Name 3. Serial Number 4. FAI Report

Characteristic Accountability Inspection / Test Results Optional
5. 6. 7. Characteristic 8. 9. 10. 11. 14.
Char Reference Designator Requirement Results Designed Non- [Insert columns, etc., as required by
No. Location Tooling Conformance Organization or Customer}
Number

Boxes 1 - 4 are repeated on all forms for
convenience and traceability.

The signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition.

24


Characteristic Accountability Inspection / Test Results Optio
5. 6. 7. Characteristic 8. 9. 10. 11. 14.
Char Reference Designator Requirement Results Designed Non- {Insert columns, etc. as required by Organization
No. Location Tooling Conformance or Customer}
Number

Box 5. Assign a unique number for each design
Box 6. Reference the drawing zone
Box 7. Reference any zoned characteristics i.e. Key
characteristic.
(include Sheet No. and Zone).
These are to be traceable Critical Characteristic, etc.
Characteristics, Safety to each drawing requirement.


25


Characteristic Accountability Inspection / Test Results Opt
5. 6. 7. Characteristic 8. 9. 10. 11. 14.
Char Reference Designator Requirement Results Designed Non- {Insert columns, etc. as required by Organization
No. Location Tooling Conformance or Customer}
Number

Box 9.
Indicate measurements specified for each designof specially
Box 10. Record the tool identification number characteristic.
Box 8. Indicate the obtained a media of inspection.
designed tooling used as requirement for thenumber if any
design
Box 11. Record non-conformance be features reference values.
Multiple characteristics shall document with minimum and
i.e. Dimensional listed as individual
characteristicRecord any addition information required.
Box 14.
maximum value of tolerance, foundaccountedSpecification
design characteristicmust be non-conforming.
All drawing notes is Drawing notes, for.
requirements etc.
Processes that require design verification must have statement of
compliance recorded on the form i.e. Certification of Compliance –
state ‘Accept’.
Laboratory reports or Certificate of test must show specific values for
requirements and actual results.

26


Characteristic Accountability Inspection / Test Results Optio
5. 6. 7. Characteristic 8. 9. 10. 11. 14.
Char Reference Designator Requirement Results Designed Non- [Insert columns, etc., as required by Organization
No. Location Tooling Conformance or Customer]
Number

Box 12. Name of the person who prepared this form.

Box 13. Date when this form was completed.


27

Forms Link

AS9102 A forms can be downloaded at:

www.sae.org/aaqg/publications/as9102a-faq.htm

9102 FAQ Link

www.sae.org/iaqg/publications/faq9102.htm

28

Most Common Reasons for FAI Rejection

C of Cs do not accompany the FAI Report.
Missing FAI Reports or Test Reports for sub-assemblies
and/or fabricated detail parts.
Variable data requirements from the engineering drawing
are not provided with numerical results.
Missing or wrong information provided.
Missing special processor full address on AS9102 A Form
2, box 8.
Missing tolerances on AS9102 A Form 3, box 8.
Customer flow down requirements not met.

29

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