First Article Inspection Training

AS9102, rev B
 AS9102, Rev B - Aerospace First Article Inspection
Requirement

Invoked by AS9100C: (Quality Management Systems – Requirements for

Aviation, Space, and Defense organizations)

• 7.5.1.1 Production Process Verification

The organization shall use a representative item from the first
production run of a new part or assembly to verify that the production
processes, production documentation and tooling are capable of
producing parts and assemblies that meet requirements. This process
shall be repeated when changes occur that invalidate the original
results (e.g., engineering changes, manufacturing process changes,
tooling changes).

NOTE: This activity is often referred to as a First Article Inspection.

 FIRST ARTICLE INSPECTION (FAI)
(Also referred to as Production Process Verification)

• A planned, complete, independent, and documented inspection and

verification process to ensure that prescribed production methods have
produced an item conforming to engineering drawings, Digital Product
Definition (DPD), planning, purchase order, engineering specifications,
and/or other applicable design documents.

• It applies to organizations that are responsible for producing the design

characteristics of a product. They shall flow down the requirements to
suppliers or processors who produce design characteristics.
 Why is an FAI required?

To validate that product realization processes are capable of producing parts

and assemblies that meet engineering and design requirements. A well
planned FAI will:

• Shows manufacturing processes are capable of producing conforming product

and manufacturing process capability.

• Shows suppliers and manufacturers understand the process requirements.

• Provides assurance and reduces risk that product conforms to requirements at

the start of production and provides a vehicle for continued assurance as process
or requirements change.
 What is an FAI intended to do?

• Help ensure safety of flight.

• Improve quality, delivery, and customer satisfaction.

• Reduce costs and production delays associated with product non-

conformance.

• Identify production processes that are not capable.

• Used to initiate and/or validate corrective actions.

 Some “rules” for use
Applies to:

• Assemblies, sub assemblies, and detail parts including castings and forgings,
and modifications to commercial off the shelf items (COTS).

Unless contractually required this does not apply to:

• Development or prototype parts that are not considered part of the first
production run.

• Unique or single part run production orders not intended for ongoing
production (i.e., out of production spares)

• Standard catalogue items, COTS, or deliverable software (see definitions).

• Standards (nuts, bolts, screws, washers...............).
• Common electrical or electronic parts.
 What is included on a First Article Inspection Report
(FAIR)

• Verification of all design characteristics

• Material and Special Process Certifications

• Manufacturing Process Verification

• Non-conformance resolution

• FAIRs for major subassemblies

 Some key definitions
Attribute data:
Only an appraised vs a measured characteristic to determine whether or not it
conforms (go/no-go, accept/reject, pass/fail, etc).

Commercial Off the Shelf (COTS) items:

Items intended by design to be purchased and used as is without
modification.

Design Characteristics:
Dimensional, visual, functional, mechanical, and material features or properties that
describe or constitute the design of an article as specified by drawing or DPD
requirements.

Designed Tooling:
Product specific tooling specifically made to validate characteristics of a specific
item or family of parts (i.e., a check fixture).
Digital Product Definition (DPD):
Requirements of digital data files that disclose, either directly or by reference, the
physical or functional requirements, including data files that disclose the design or
acceptance criteria of a product.

First Article Inspection Report (FAIR):

The forms and package of documentation for a part number, subassembly, or
assembly that record FAI results.

First Production Run:

The initial group of one or more parts that are the result of a planned process
designed to be used for future production of the same parts.

Partial (Delta) FAI:

Addresses differences between current configuration and prior approved
configuration. Typically applies when only a few characteristics change. When
used list previous part number, revision level, and reason for the partial in Form 1,
Block 14.
Qualified tooling:
Universal calibrated monitoring and measuring equipment used to
validate product characteristics. Identified and traceable to calibration
records. Not part or item specific (caliper, thread gages, scales, etc).

Special Processes:
Any process or provision where the resulting output CANNOT be verified
by subsequent monitoring or measuring. Deficiencies are only apparent
after the product is in use or the service has been delivered.

Variable Data:
Quantitative measurements. Expresses as a measurement with
tolerances. Can be verified using qualified tooling and expressed as a
number.
 FAI Requirements

Part Requirements
• Perform FAI on new product representative from the first production run. First
production delivery parts require an FAI.
• For assemblies, the assembly level FAI is performed on those characteristics
specified on the assembly level drawing or DPD.
• When changes occur that invalidate the original results, a new FAI (or partial
FAI must be performed).

Planning Requirements
• Unless otherwise specified, FAI requirements are to be in accordance with
AS9102.
• Considerations for planning FAI with customers
 Digital Product Definition
(This is new to AS9102, rev B)

Requirements
When requirements are in a DPD format and traditional 2D drawing information
is not available for all applicable design requirements, DPD design characteristics
required for product verification shall be extracted, verified, and included in the
FAIR.

Organization shall
• Have a process to extract DPD information applicable to DPD design
characteristics.

• Extract the DPD information required for product realization.

• Ensure all production, inspection, and operations requiring verification have

been completed as planned and meet the DPD design characteristics.
 FAI Non-Conformance Handling

You can create or receive an FAI with a non-conformance!

Process to perform or evaluate:

• Record the non-conformance on Form 3.

• Record the document non-conformance reference number on Form 3, block 11

(DS tag or DMR number).

• Check the “FAI Not Complete” of Form 1 of the FAIR and sign the report.
• Quarantine parts (MRB).

• Corrective actions need implemented and a partial FAI performed for the affected
characteristics on the next production run after implementation of corrective
actions.
• If the partial does not clear the non-conformance then the FAI is still not complete and
the requirement for correction is still in effect.
• A full FAI may be done in lieu of a partial FAI.
• Quarantined parts may be reworked to the FAI verified corrective actions.
 Evaluation
• Review documentation for the manufacturing process.

• Make sure all supporting documentation is present and review for completeness.

• Verify raw material and special process certifications.

• Verify customer approved processes are utilized (Form 2, Block 9). Information
should match paperwork received.

• Review any non-conformance documentation.

• Verify required designed tooling is used and recorded on Form 3, Block 10).

• Verify every design characteristic requirement is accounted for, uniquely identified,

and has results traceable to each unique identifier.

• Verify design characteristics that are the output of the manufacturing process are
measured, inspected, tested, or verified to determine conformance, including DPD
characteristics.

• Verify part marking is correct, legible, and correctly located per specifications.
 When should an FAI be performed?
(Can be Full or Partial)
When any of the following occur:

• A change in design characteristics that affects form fit or function.

• A change in manufacturing sources, processes, location of manufacture,

tooling, or materials that can potentially affect form, fit, or function.

• A change in (Computer) Numerical Controlled [(C)NC] program or translation to

another media that can potentially affect form, fit, or function.

• A natural or man-made event that may adversely affect the manufacturing

process.

• Implementation of a corrective action based on a non-conformance.

• A lapse in production for two years shall be updated for any characteristic that
may be impacted by the inactivity.
 Forms

FAIR is in three parts

• FORM 1 – Part Number Accountability

• Listing of parts, components, and subassemblies used to make the item
listed in Block 1.

• Form 2 – Product Accountability

• Materials, special processes, and functional testing used to make the item
listed in Block 1.

• Form 3 – Characteristic Accountability (see next slide)

• Balloon Drawing
• Used in conjunction with Form 3 to verify every design characteristic
requirement is accounted for, uniquely identified, and has results
traceable to each unique identifier.
 Characteristic Accountability

1. Verify every unique design characteristic during the FAI and record the
associated results. Every characteristic shall have it’s own unique
characteristic number.

2. Reference characteristics may be omitted.

3. More than one line may be used for any characteristic if needed.

4. Characteristics not measurable in the final product shall be verified

during the manufacturing process as long as they are not affected by
subsequent operations or by destructive means.
a. Detail level characteristics may be referenced on the assembly
level FAIR.
 Forms rules

1. Any format form can be used, however they shall contain all “Required”
and “Conditionally Required” information and have the same field
reference numbers.

2. A previous revision AS9102 compliant form can be used provided the

most current document form instructions are used.

3. All forms shall be completed either electronically or in permanent ink.

4. All forms shall be in English.

5. Continuation sheets and adding additional rows on a Form are

acceptable.
 Forms

1. “Mandatory” – no choice.

2. “Shall” – required if information is available.

3. “May” – indicates choice.

4. For completing blocks on the FAI Forms

a. (R) – Required. Mandatory information to be on the FAIR.

b. (CR) – Conditionally Required. Shall be completed when the
information is available. Enter “N/A” if not available – do not leave
blank.
c. (O) – Optional. Provided for convenience. May be left blank.
 Recording Results

1. Record results in the same measurement units on the drawing or DPD unless otherwise
specified by the customer.

2. Use variable data when the design characteristic is expressed in numerical terms. Attribute
data may be used in lieu of variable data when:
a. No inspection technique resulting in variable data can be done.
b. Designed or qualified tooling is consistently used as a check fixture. When used,
record the range for acceptance.

3. Attribute data shall be used when design characteristic does not specify numerical limits
(i.e., drawing notes like “deburr” or part mark). Signify results as “Verified” or “Acceptable”.
 BALLOONED DRAWING

A ballooned drawing is a required element of a FAIR package to support Box 5 of

Form 3.
• Identify 100% of characteristics:
• Balloon and number all dimensions
• Balloon and number all applicable drawing note/flagnote callouts
• Material and hardness callouts, finish callouts, part mark callout, etc.
• Don’t forget any requirements identified in the drawing itself (not in
notes/flagnotes)
 Form 1 FIRST ARTICLE INSPECTION REPORT
PART 1 - PART NUMBER ACCOUNTABILITY Sheet ____ of ____

• Fields highlighted in BLUE are 1. Part Num ber 2. Part Nam e 3. Serial Num ber 4. FAIR Num ber

required fields and completing 5. Part Revision Level 6. Draw ing Num ber 7. Draw ing Revision Level 8. Additional Changes

them accurately is mandatory. 9. Mfg Process Ref (Shopdoc) 10. Organization Nam e 11. Supplier Code 12. P.O. Num ber

• Fields highlighted in ORANGE are Baseline Part number (including revision level):
13. Detail FAI 14. Full FAI

• Conditionally required fields. They Assem bly FAI Partial FAI

Reason for Partial FAI:

are to be completed when the a) if above part num ber is a detail part only, skip to Field 19.

information is available. If no b) if above part num ber is an assem bly, continue to Field 15.
INDEX of part numbers or sub-assembly numbers required to make the assembly noted above.

information is available then enter

15. Part Num ber 16. Part Nam e 17. Part Serial Num ber 18. FAIR Num ber

“N/A”.
• Fields that are are optional
and can be left blank.
• Highlights:
1. Block/column 15 is where all
components used to make
the part number shown in
block 1 are to be listed.
These would be the items
typically on the Bill of 1) Signature indicates that all characteristics are accounted for, m eet draw ing requirem ents or are properly

Materials. docum ented for disposition.

2) Indicate if the FAI is com plete. FAI Com plete FAI Not Com plete

1. REMEMBER: Some of 19. Prepared By (Nam e and Signature) 20. Date 25. Entered into FAI Database

these items may also 21. Review ed by (Nam e and Signature 22. Date

require FAIR of their 23. Custom er Approval Signature 24. Date

own.
 Form 1
Instructions
 Form2 FIRST ARTICLE INSPECTION REPORT

PART 2 - PRODUCT ACCOUNTABILITY (Materials, special processes, functional testing) Sheet ____ of ____
• Fields highlighted in BLUE are required fields
and completing them accurately is 1. Part Number 2. Part Name 3. Serial Number 4. FAIR Number

mandatory.
5. Material or Process 6. Specification 7. Code 8. Supplier 9. Customer 10. Certificate of

• Fields highlighted in ORANGE are Name Number Approval

Verification
Conformance Number

• Conditionally required fields. They are to be

completed when the information is available.
If no information is available then enter
“N/A”.
• Fields that are are optional and can be
left blank.
• Highlights:
• If there is a material of process listed in
Block/column 6 then all block entries
across that line entry need to be
completed.
• If there is a material listed make sure
the Certificate of Conformance number
is listed.
11. Functional Test Procedure Number 12. Acceptance report number, if applicable

• Include the name and address of any

vendor supplying material or
performing any process for you is
shown in Block/column 8 in
Block/column 9. 13. Comments
14. Prepared By (Name and Signature) 15. Date
 Form 2
Instructions
 Form 3 FIRST ARTICLE INSPECTION REPORT

PART 3 - CHARACTERISTIC ACCOUNTABILITY Sheet ____ of ____

• Fields highlighted in 1. Part Number 2. Part Name 3. Serial Number 4. FAIR Number
Characteristic Accountability Inspection / Test Results
BLUE are required fields 5. 6. Reference 7. Characteristic 8. Requirement 9. Results 10. Designed Tooling 11. Non- 14. Additional Data/Comments
Char Location Designator Conformance
and completing them No. Number

accurately is
mandatory.
• Fields highlighted in
ORANGE are
• Conditionally required
fields. They are to be
completed when the
information is available.
If no information is
available then enter
“N/A”.
• Fields that are
are optional and can be
left blank.
Signature below indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition.

12. Prepared By (Name and Signature) 13. Date

• Highlights
• Block/column 6 can be a drawing reference location, such as “ Sheet 3, Zone A-6”.
• Block/column 7 identifies items like key characteristics.
• Block/column 10 is used to record what was used to make the measurement (caliper, CMM, fixture, etc.)
• If the characteristic measured was out of tolerance and the item has to be tagged as discrepant that
tag number goes in Block/column 11. Block/column 14 can be used to describe the discrepant condition.
 Form 3
Instructions
 BALLOONED DRAWING
Note 2

1
11 1

8
10
2

2
7 6
3

8 9
4 4

3
7 5

5
6
 Some Final FAI Comments

• The block at the top of each Form that says “Sheet ___ of ___” is for that Form
only.
– Example: If each Form is only one page then all three Forms will say “Sheet 1 of 1”.
• As you can add pages to each Form as needed to include all needed information
then Forms would be numbered accordingly.
– Example: If Form 2 needed two pages Form 2 would be numbered “Sheet 1 of 2” and “Sheet 2 of 2”.
Forms 1 and 3 would both stay “Sheet 1 of 1”.
• A complete FAI package may consist of several First Article Inspection Reports.
– If the FAIR is a top level assembly, anything listed on Form 1 that is a sub-assembly, component, or
modified commercial item should have their own FAIR attached to and as part of that top level FAIR.
• A First Article Inspection Report does not have to have all three Forms. If the FAIR
is for a process only, such as plating, and has no characteristics to capture then
Form 3 is not needed. If the FAI has no materials and special processes not already
accounted for then Form 2 is not needed.
– The same applies for Partial FAI’s. Only the Forms needed to capture the reason or characteristics
driving the Partial requirement are needed.
• An FAI can fail and have a non-conformance as indicated on Form 3 instructions. It
is still a completed FAI with a failed feature. The FAI can be corrected by rework or
on the next production run and a partial FAI done for the feature that failed that
indicates correction of the defective condition.