It’s also worth bearing in mind that you may need additional first article inspections if your initial one reveals something that’s not 100-percent compliant with the drawing. In such cases, you’ll need to take corrective action, do another production run, and conduct another FAI.
When do you need a first article inspection?
There are two types of FAI: full and partial. Full FAIs are required for new parts, new suppliers or facilities, or if the part hasn’t been manufactured in at least two years. A partial first article inspection—sometimes called a delta FAI—is required if there are changes to the part’s design or production process, including new materials, tooling, machines, or anything else that would potentially affect its fit, form, or function.
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Step 2: Conduct first production run
Manufacture the part using the same materials, machines, processes, and tooling that will be used in mass production.
First published July 13, 2023, on engineering.com.
A first article inspection is not tantamount to a comprehensive evaluation of process capability; nor does it guarantee defect-free production. Assessing the overall process quality or the tool selection for each process is beyond the scope of an FAI. However, FAI can fulfill the process validation requirement for a quality management system such as ISO9001 or AS/EN9100.
First article inspections are essential for ensuring that new and revised products conform to design specifications. By catching deviations and nonconformities early, they minimize the risk of defects and safety hazards in the final product. They aren’t always easy, but the transparency and accountability they provide can be a competitive advantage, fostering better customer relationships and overall satisfaction.
The balloon drawing supports Form 3, appending a uniquely numbered balloon to each design characteristic that corresponds to the characteristics’ numbers on Form 3. These balloons or bubbles identify the characteristics that the inspector needs to check when conducting the FAI.
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It’s important to remember that the goal of FAI is only to confirm that the product meets the specified dimensions and features according to the engineering drawing. In other words, FAI may be the first step in quality control, but it’s far from the last.
It should also be noted that while FAIs can be required in any discrete manufacturing industry, they are most common in aerospace, automotive, defense, and medical manufacturing. Each of these industries also have their own unique requirements that either operate separately from FAIs or subsume them. For example, a first article inspection is part of AS9145—“Requirements for advanced product quality planning and production part approval process.”
Creating a first article inspection report
Step 7: Review and approval
Have the FAIR reviewed by the relevant stakeholders—such as those responsible for quality control—and get approval from the customer by obtaining their name and signature.
Why FAI matters
Each form includes fields (such as the part number, the date, and the signature of the person who completed the form) that are always necessary, and some that are conditionally required (such as the part serial number, the name of the raw material, or the tool identification number).
Step 6: Generate FAI report
Prepare the FAI report by filling out Forms 1, 2, and 3, as well as any accompanying balloon drawings.
In a nutshell: Whenever you’re either about to start production of a new part or you change something in the way an existing part is designed or manufactured, you ought to conduct a first article inspection. Additionally, you’ll need to conduct a (full) FAI if your customer requests one.
Step 4: Perform FAI
Inspect the sample to verify compliance with product specifications, ensuring that the characteristics fall within tolerances and that all measured results conform to customer requirements.
First article inspections are conducted by the supplier or an external inspector using metrology tools such as coordinate measuring machines (CMMs), 3D scanners, hand tools such as calipers and micrometers, and testing equipment such as scrape testers and multimeters. The inspector takes a random sample from the first production run and compares it against the customer specifications from the purchase order.
While many manufacturers still complete FAI reports on paper, there are also software tools and templates available that simplify and expedite the process. These include everything from Excel templates to CAD packages for automatically generating balloon drawings.
A complete list of always required and conditionally required fields is included below:
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