Quality Assurance and Quality Control
First article inspection (FAI)
Every characteristic on the drawing verified on a part made with production tooling, processes and operators, before series production is released.
01What the service involves
First article inspection is a complete, documented verification that a part produced by the intended production process meets all design requirements. Every dimension, note, material requirement, special process and marking on the drawing is ballooned, measured or verified and recorded against its requirement.
QUALITAS TR performs or witnesses FAI at the supplier, reviews the supplier's FAI package when one is required by your standard (for example AS9102 forms in aerospace or the dimensional results within a PPAP in automotive), and confirms that the parts were made under production conditions.
02Why buyers need it
A first article proves the process, not just the part. It is the moment to find drawing misinterpretations, fixturing errors and wrong material before they are multiplied over thousands of parts.
For buyers sourcing from new suppliers, an independently verified FAI is the most reliable basis for releasing series production.
03Typical applications
- New part introduction at a new supplier
- Transfer of production to another supplier
- Engineering change affecting form, fit or function
- New tooling, moulds or dies
- Restart after a long production break
- Aerospace and defence parts requiring AS9102 FAI
04Methodology
Drawing ballooning
Every requirement numbered on the drawing, including notes, specifications and general tolerances.
Production evidence
Confirmation that the part was made with production tooling, programme, material and operators.
Measurement
All characteristics measured with suitable methods, including CMM for complex geometry.
Material and process
Material certificates, special process certificates (heat treatment, plating, welding) and functional tests verified.
FAI report
Characteristic accountability with results, deviations and an approve or reject recommendation.
05Applicable standards and references
In aerospace, FAI documentation commonly follows SAE AS9102. In automotive, the dimensional results and material records form part of the PPAP submission under the AIAG manual. Drawings may use ISO GPS (ISO 1101) or ASME Y14.5 dimensioning; the drawing standard is confirmed before measurement.
06Deliverables
- Ballooned drawing
- Characteristic accountability with measured values
- Material and special process verification
- Photographs of the first article and identification
- FAI approval recommendation or nonconformity list
07Customer benefits
- Prevents series production of a wrong part
- Objective release decision for new suppliers
- Detects drawing interpretation issues early
- Creates a reference for later inspections
- Supports PPAP and AS9102 requirements
08How QUALITAS TR supports you
Our engineers read ISO and ASME drawings fluently and know which characteristics typically fail on cast, forged, machined, sheet metal and moulded parts. Where the supplier has no suitable equipment we coordinate CMM measurement with an independent metrology provider.
Frequently asked questions
How many parts should a first article include?
Usually one part per cavity, die, or production route. Multi-cavity moulds require one part from each cavity.
Can FAI be partial?
A partial FAI, covering only affected characteristics, is common after an engineering change. A full FAI is needed for a new part or a new process.