1. First Article Inspection
AS 9102
First Article Inspection

2. What is a First Article Inspection Requirement?
AS9100, para
“ …The organisation’s system shall provide a process for inspection, verification and documentation of a representative item from the first production run of a new part, or following any subsequent change that invalidates the previous first article inspection record.”
Not Optional – FAI is mandatory
AS9102 is one approach to FAI and provides consistency.
Organisations can use their own approach if customers approve.
FAI to be done of first production piece, not prototypes.

3. Some definitions (AS9102 A)
First Article Inspection
A complete, independent and documented physical and functional inspection process to verify that prescribed production methods have produced an acceptable item as specified by engineering drawings, planning, purchase order, engineering specifications, and/or other applicable design documents.
First Article Inspection Record
The forms and package of documentation for a part number or assembly, including FAI results, as per this standard. (AS9102)

4. Some definitions (AS9102 A)
Design Characteristics
Those dimensional, visual, functional, mechanical and material features or properties, which describe and constitute the design of the article as specified by drawing requirements.
There characteristics can be measured, inspected, tested or verified to determine conformance to the design requirements.
Dimensional features include in-process locating features such as target-machined (or forged/cast) dimensions on forgings and castings, and, weld/braze joint preparation necessary for acceptance of joint finish.
Material features or properties may include processing variables and sequences which are specified in by drawing. (UT, HT etc..)
These provide assurance of intended characteristics that could not be otherwise defined.

5. FAI Applicability
Applies to assemblies, sub-assemblies and detail parts including castings and forgings.
Applies to organisations responsible for producing product design characteristics.
Organisations much flow down FAI requirements to suppliers that produce design characteristics.
Not applicable to standard catalogue hardware or to deliverable software.

6. When is a FAI required?
On a new product representative of the first production run.
A change in design affecting fit, form and function of the part
A change in manufacturing source, process, inspection method, manufacturing location, tooling or material that could affect fit, form and function.
A change in NC program or translation to another media that can affect fit, form and function.
A natural or man-made event that could adversely affect the manufacturing process.
A lapse in production for 2 years or as specified by the customer.

7. FAI Evaluation Activities
Review documentation for manufacturing processes to make sure all operations are completed as planned.
Review referenced exhibits supporting the FAI for completeness.
Review non-conformance documentation for completeness.
Review material certifications for compliance.
Verify special process sources are used and that documents call up correct specification.
Verify key characteristics requirements have been met.
Verify specific gages and/or tooling are qualified and traceable.
Verify design characteristic requirements are accounted for, uniquely identified and has inspection results traceable to each unique identifier.

8. Records to be Reviewed
Routing Sheets / Manufacturing procedure conformance.
Test and Inspection Records.
Any non-conformance reports (completed)
Raw material certificates.
Special process test certificates.
Process Capability Reports.
Identification of test equipment, fixtures, NC programmes.
Inspection Reports, Test Certificates, Verification of Special Process Approvals, Qualification Identifiers.

9. Partial FAI – What is it? Partial / Delta First Article Inspection:
A partial FAI addresses the differences between the current configuration and the prior approved configurations.
When a partial FAI is performed, the Organisation shall complete only the affected fields in the FAI forms.
FAI requirements may also be satisfied by previously approved FAI performed on identical characteristics of similar parts produced by identical means.

10. Partial FAI – When?
A change in design affecting fit, form and function of the part
A change in manufacturing source, process, inspection method, manufacturing location, tooling or material that could affect fit, form and function.
A change in NC program or translation to another media that can affect fit, form and function.
A natural or man-made event that could adversely affect the manufacturing process.
A lapse in production for 2 years or as specified by the customer.

11. Summary FAI
FAI is the process whereby you can prove that your production process manufactures aircraft components to the design specification.
Is an audit of the full production process.
Should be undertaken by inspectors / auditors.
Initial FAI provides the baseline configuration for both product and manufacturing specifications.
Don’t confuse FAI with ‘first off inspection’.