First Article Inspections: What Engineers Need to Know
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Step 5: Record measured results Document the measurements obtained during inspection and record the values for each characteristic or design requirement.
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.
Step 3: Select a sample Although sample sizes may vary depending on product requirements and industry standards, ideally the sample should be selected randomly if possible.
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 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
Step 6: Generate FAI report Prepare the FAI report by filling out Forms 1, 2, and 3, as well as any accompanying balloon drawings.
A first article inspection report (FAIR) consists of three forms plus a balloon or bubble drawing: • Form 1—Part number accountability: Summarizes the part of the article that is being inspected (the FAI part) and its associated subassemblies or detail parts • Form 2—Product accountability: Used for all raw materials, specifications, processes, and functional tests that are part of the design requirements • Form 3—Characteristic accountability: Summarizes specific design characteristics, including dimensions, tolerances, and drawing notes, along with the actual measurement results of the FAI parts for design characteristics on the drawing
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?
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).
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.
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.
Management
First Article Inspections: What Engineers Need to Know
All the information you need to create your first FAI report
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.
Step 2: Conduct first production run Manufacture the part using the same materials, machines, processes, and tooling that will be used in mass production.
A complete list of always required and conditionally required fields is included below:
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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
Published: Monday, August 7, 2023 – 12:03
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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.
Step 1: Identify the need for FAI Determine whether you need a full or partial first article inspection, depending on whether you’re producing a new or revised part.
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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.
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.
Here’s the first article inspection process in seven steps:
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’s been a long and arduous road, but you’re almost ready for that first production run. You made it through supplier selection, your designs and production processes have been finalized, preproduction is finished, and now there’s just one more hurdle to clear: first article inspection (FAI).
