Key takeaways
- A first article is not a sample. It is the first part made with the production process, tooling and material.
- Every characteristic on the ballooned drawing needs a result, not just the dimensions that look difficult.
- The report should include material certificates, finish evidence and any functional test.
- Approval should be a written decision with a revision, not an email that says the sample looks fine.
What a first article is
A first article inspection is a full measurement and verification of the first part produced with the production process, tooling, material and operators. It is not a prototype made on a different machine or a sample pulled from a trial run with temporary tooling.
The purpose is to prove that the drawing, the process and the inspection method agree before the supplier runs the volume. A good FAI catches a bad tool, a wrong material, a missing operation or a drawing ambiguity while the fix is still cheap.
What the report contains
The exact forms vary by industry, but the evidence should cover the same ground: the drawing revision, the part identity, the material, the process, the measurements, the functional tests and the approval.
| Section | What to include | Why |
|---|---|---|
| Part identity | Part number, name, drawing revision, serial or lot | Traceability |
| Drawing | Ballooned drawing with every characteristic numbered | Complete coverage |
| Material | Certificate, grade, heat or lot, condition | Material conformity |
| Process | Route, machine, tool, operator, date | Process conformity |
| Measurements | Nominal, tolerance, actual, instrument | Dimensional evidence |
| Functional | Load, continuity, pressure, torque or other test | Fit for use |
| Finish | Plating or coating type, thickness, adhesion | Surface conformity |
| Non-conformance | Any deviation, concession or rework | Transparency |
| Approval | Reviewer, date, decision, revision | Controlled release |
Ballooning the drawing
Ballooning means numbering every characteristic on the drawing and carrying that number into the report. It stops the supplier from measuring only the dimensions that are easy to reach. It also makes the review faster because a missing number is visible.
A characteristic is not only a linear dimension. It includes a diameter, an angle, a radius, a thread, a surface finish, a geometrical control, a note and a material callout. If the drawing says the part must be free of burrs, that is a characteristic with a method and a result.
The report should follow the drawing, not the measurement plan
If the inspector starts with the instruments that are available, some characteristics will be skipped. Start with the ballooned drawing and find a method for every callout.
Production process, not a lab sample
The first article must come from the production tool and the production route. If the supplier uses a temporary tool, a different machine or a manual operation for the sample, the report does not prove the production process.
For a stamped part, the sample should come from the production die. For a moulded part, it should come from the production tool with the production gate and cooling. For a machined part, it should come from the production program and fixture. If the sample is made differently, say so and treat it as a prototype approval, not a production FAI.
Measurement and instruments
Every result needs a method. A caliper is fine for a general dimension and wrong for a tight bore or a flatness call. The report should name the instrument and, where relevant, the calibration status. For a CMM result, include the program and the datum alignment.
Gauge R&R matters when the tolerance is tight relative to the process. If the measurement system uses a large part of the tolerance, the pass or fail decision is weak. For critical features, use a method with a known uncertainty and a fixture that repeats.
| Characteristic | Typical method | Watch |
|---|---|---|
| Length or diameter | Caliper, micrometer, CMM | Temperature and operator technique |
| Hole position | CMM or functional gauge | Datum selection |
| Flatness | Surface plate and indicator, CMM | Part support |
| Thread | Thread gauge | Go and no-go |
| Plating thickness | XRF or coulometric | Measurement spot |
| Load | Spring tester or tensile machine | Fixture and rate |
The review and approval
The review should be a documented decision. Check that every balloon has a result, the material certificate matches the drawing, the finish is correct and the functional test passes. If a characteristic is out of tolerance, the supplier should raise a non-conformance before the report is sent, not hide it in a note.
Approve the report against a specific drawing revision and a specific process route. If the supplier changes the tool, the material source or the process after approval, the FAI should be repeated or a delta FAI should be completed.
- Every balloon has a result and a method.
- Material certificate matches the grade and condition.
- Finish evidence is included.
- Functional test is recorded.
- Non-conformances are visible.
- Approval names the revision and the date.
- Change control is agreed.
FAI and PPAP
A first article inspection is one part of a production part approval process. PPAP adds the process flow, the control plan, the measurement system analysis, the capability study and the sample parts. For an automotive programme, the PPAP pack is the release document. For a simpler industrial part, the FAI may be the main evidence.
Do not assume that a signed FAI is a full PPAP. If the programme needs PPAP, ask for the full element list and the submission level. If it needs only an FAI, agree the report format and the characteristics before the first part is made.
Frequently asked questions
What is the difference between FAI and PPAP?
FAI verifies the first production part against the drawing. PPAP is a broader production approval that includes the FAI plus process flow, control plan, MSA, capability and other elements. PPAP is common in automotive; FAI is used across many industries.
How many parts are inspected in an FAI?
A standard FAI inspects one part from the production process, but the sample plan can require more for multiple cavities, multiple tools or a family of parts. The important point is that the part comes from the production process, not a prototype route.
What should an FAI report include?
Part identity, drawing revision, ballooned drawing, material certificate, process route, every measured characteristic with nominal, tolerance, actual and instrument, functional tests, finish evidence, non-conformances and a signed approval.
Can I accept a first article with a deviation?
Only with a documented concession and a clear decision on whether the part is fit for use. A deviation on a critical characteristic should go through engineering, not a verbal approval. Record the deviation and the accepted quantity.
Sources and further reading
- AS9102, Aerospace First Article Inspection Requirement
- AIAG PPAP, Production Part Approval Process
- ISO 2768-1:1989, General tolerances
- Qumek FAI report builder and inspection practice
Qumek Quality Desk
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The quality team responsible for first article inspection, PPAP packs, supplier audits and the records shipped with production parts.
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