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What Is a First Article Inspection (FAI)?
A First Article Inspection (FAI) is a formal quality process used to verify that a manufactured part or product meets all design, engineering, and specification requirements before full production begins. It confirms that processes, materials, tools, and methods can consistently produce parts that match drawings and customer requirements.
Why Are First Article Inspections Important?
FAIs are important because they catch issues early, before mass production starts. By validating the first produced item, companies reduce scrap, rework, delays, and costly quality escapes—protecting both compliance and customer trust.
When Is a First Article Inspection Required?
A First Article Inspection is typically required:
- Before the first production run
- After design or drawing changes
- When switching materials, suppliers, tools, or processes
- After long production breaks
- When requested by customers or required by standards
What Does a First Article Inspection Include?
An FAI usually includes:
- Verification of dimensions and tolerances
- Material and specification checks
- Review of manufacturing processes
- Inspection of critical characteristics
- Documentation showing compliance with drawings and standards
All results are recorded to provide full traceability.
Who Is Responsible for Performing an FAI?
FAIs are commonly performed by quality engineers or inspectors, often in collaboration with manufacturing and engineering teams. In regulated industries, customers or third-party auditors may also review or approve the FAI.
What Industries Commonly Use First Article Inspections?
First Article Inspections are widely used in industries where precision and compliance are critical, including:
- Aerospace and defense
- Automotive manufacturing
- Medical devices
- Electronics and semiconductors
- Industrial manufacturing
What Standards Govern First Article Inspections?
Common standards and guidelines for FAIs include:
- AS9102 (aerospace)
- ISO 9001 quality management systems
- Customer-specific requirements
- Industry or regulatory standards depending on the product
What Is the Difference Between a PPAP and an FAI?
The main difference between PPAP (Production Part Approval Process) and FAI (First Article Inspection) is their scope and purpose.
- FAI focuses on verifying that the first produced part meets design and specification requirements.
- PPAP is a broader approval process that validates the entire production system, including processes, controls, capability studies, and documentation.
FAI is often one component of PPAP, especially in automotive and highly regulated manufacturing environments.
Is FAI a One-Time Inspection?
No. While an FAI is required for the first production run, it must be repeated whenever significant changes occur, such as design updates, tooling changes, new suppliers, or process modifications.
How Does FAI Support Quality Management Systems?
FAIs support quality management systems by providing documented evidence of compliance, ensuring process readiness, and reducing variability. They help organizations meet audit requirements and maintain consistent production quality.
How Is FAI Managed in Modern SaaS Quality Platforms?
In SaaS quality management platforms, FAI is digitized through:
- Structured inspection checklists
- Automated data capture and validation
- Version-controlled drawings and specs
- Real-time reporting and approvals
- Full audit trails for compliance
This eliminates manual paperwork and speeds up approvals.
What Are the Benefits of Digitizing First Article Inspections?
Digitizing FAI helps organizations:
- Reduce inspection errors and omissions
- Speed up approvals and production release
- Improve traceability and audit readiness
- Standardize inspections across locations
- Drive continuous quality improvement
How Does FAI Reduce Production Risk?
FAI reduces production risk by ensuring everything works as intended before scaling up. It confirms that designs are manufacturable, processes are stable, and quality expectations are clearly met—preventing costly downstream failures.
Is First Article Inspection Mandatory?
FAI is not always legally mandatory, but it is often required by customers, contracts, or industry standards. In many regulated industries, failing to perform an FAI can result in rejected parts or lost contracts.