A First Article Inspection (FAI) is a formal, documented verification that the first production unit of a new or revised part conforms fully to all design and engineering requirements.
The FAI process involves measuring or verifying every characteristic called out on the engineering drawing or model, comparing results against the specified tolerances, and recording the evidence in the three AS9102 forms.
FAI is triggered by specific events: first production of a new part, a design change, a manufacturing process change, a tooling change, or a gap in production exceeding a contractually defined period (commonly 2 years).
The deliverables of an FAI package typically include: completed AS9102 Forms 1, 2, and 3; dimensional reports (CMM or hand measurement); material certifications; process certifications (heat treatment, surface treatment, NDT); and applicable test reports.
Concrete example
After qualifying a new CNC machining center for an existing part, the supplier must perform a new FAI — even if the drawing has not changed — because the manufacturing process has changed.