What is a First Article Inspection?

A First Article Inspection (FAI) is the process of verifying the design requirements of a product from the
first production run. Quality inspectors perform FAIs when there is a 2-year lapse in production or when
there are significant changes in the product, including design, manufacturing source/process, location of
manufacture, tooling/materials, or computer-generated program that can affect its fit, form, or
function.

Quality inspectors should document part number accountability, product accountability, and
characteristic accountability in the FAI report. Streamlined first article inspections can reduce costly
production delays by ensuring the manufacturing process produces output that meets design
requirements.

How to Perform a First Article Inspection

First article inspections provide assurance of product conformance at the start of series production and
after design changes. Here are the steps taken by quality inspectors when performing first article
inspections:

1. Prepare the engineering design and specification requirements

Quality managers should regularly coordinate with design engineers and fabrication managers to
ascertain that the as-built technical drawings (electrical, mechanical, pneumatic and process schemes)
are followed. Before the first article inspection, prepare the instruments calibration certificates and
refer to the equipment and materials data sheets to deliver high-quality machines with performance
that clients can trust.

2. Determine the part or assembly to inspect

The “first article” to be inspected is neither the prototype model nor the first product from a production
run. Quality inspectors should randomly select a representative item from the first production run and
document part number accountability which includes the part number, part name, and manufacturing
process reference.

3. Conduct raw materials, special processes, and functional testing

Quality inspectors measure and verify design characteristics through product-specific tests with required
design tooling. For product accountability, each material and process used to manufacture the product
is listed and certificates of conformance for special processes are added. Functional test procedures
should also be cited with corresponding acceptance reports as supporting documents.

4. Evaluate characteristics accountability and compatibility

Inspection results can ascertain the necessity of a delta FAI or re-accomplishment of the first article
inspection. In case of non-conforming characteristics, design revisions should be implemented. Quality
inspectors should review the manufacturing process and non-conformance documentation to improve
the performance of a delta FAI.

5. Report the first article inspection with proper documentation

Upon the completion of the first article inspection, quality inspectors validate the FAI report with their
signatures, indicating that all characteristics are accounted for; meet drawing requirements; or are
properly documented for disposition. FAI reports should include photos of the products make and
packaging to provide objective evidence.