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Guide

What does a first article inspection (FAI) report include?

What's inside an FAI, why it matters, and when you need one.

The short answer

A first article inspection (FAI) report documents that the first production part matches every requirement on the drawing. It includes a ballooned drawing, a measured result for every dimension and note, material and process certifications, and a sign-off. Many FAIs follow the AS9102 format. You need one for new part numbers, revisions, and process changes.

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What's in a typical FAI

  • Ballooned drawing: every characteristic numbered
  • Part accountability: part number, revision, serial or lot
  • Material and special-process certs (heat treat, plating, passivation)
  • Characteristic results: nominal, tolerance, actual measurement, pass/fail
  • Inspection methods and equipment used (CMM, optical, gauges)
  • Approval signatures

When you need an FAI

For a new part number, a drawing revision, a change in process, material source, or location, or after a long production gap.

FAI vs. PPAP

FAI proves the first part is right. PPAP (Production Part Approval Process) is a larger package that proves the process will keep producing it right, with capability studies, process flow, and control plans.

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