AS9102 first article inspection basics
A First Article Inspection (FAI) proves that your production process can make a part that meets every requirement on the drawing and purchase order. In aerospace it is documented using the AS9102 format: three forms covering part accountability, product accountability (materials, special processes, functional tests) and characteristic accountability (every design characteristic, verified).
When you need one
On the first production run of a new part, and again (full or partial) after a change that affects form, fit or function: design change, new manufacturing location, new process or machine, tooling change, or a production lapse (commonly two years). Your customer's requirements may add more.
How to do it without getting rejected
- Balloon everything. Every dimension, note, tolerance and flag note gets a unique number, including notes like "break all sharp edges".
- Use production methods. The FAI part must be made with the real process, tooling and program, not a special one-off.
- Measure every characteristic and record actual values, not just "OK", unless it's truly an attribute.
- Trace materials and special processes to certs and approved sources.
- Address every nonconformance before you submit, or document it with the customer's agreement.
The most common rejections: missed notes, wrong drawing revision, missing special-process certs, and "OK" where a value was needed.
Want the templates for this? The AS9102 FAI Kit has them ready to fill in.
General guidance, not legal advice. Standards are referenced by name only. Written by Matt Norman, Norman Quality Tools (Veteran-Owned & Operated).