First Article Inspection Requirements

Understanding First Article Inspection: The Foundation of Manufacturing Quality

In the competitive landscape of modern manufacturing, ensuring that production parts meet exact specifications from the very first piece is not merely a best practice—it is an absolute necessity. First Article Inspection (FAI) serves as the critical quality gateway between design intent and manufacturing reality, providing documented evidence that a production process can consistently deliver parts that conform to engineering requirements.

For manufacturers across Atlantic Canada, from precision machine shops in Nova Scotia to aerospace suppliers throughout the Maritime provinces, understanding and implementing robust FAI protocols is essential for maintaining competitiveness in both domestic and international markets. This comprehensive guide examines the requirements, processes, and best practices for conducting effective first article inspections that satisfy customer requirements and industry standards.

What Constitutes a First Article Inspection?

A First Article Inspection is a comprehensive, documented verification process that demonstrates a manufacturer's capability to produce parts that meet all design specifications, quality requirements, and engineering tolerances. Unlike routine in-process inspections, an FAI involves complete verification of every characteristic specified on the engineering drawing, including dimensions, material properties, surface finishes, and special process requirements.

Key Components of FAI Documentation

The FAI package typically comprises three essential forms, particularly when following the AS9102 standard widely adopted in aerospace and defence manufacturing:

• Form 1 – Part Number Accountability: Documents the part identification, design requirements, and approval signatures from responsible parties

• Form 2 – Product Accountability: Records material certifications, special process approvals, and functional testing results

• Form 3 – Characteristic Accountability: Contains the actual measurement data for each characteristic, comparing recorded values against specified tolerances

Beyond these standard forms, a complete FAI submission often includes supporting documentation such as material test reports, certificates of conformance for special processes, coordinate measuring machine (CMM) reports, and traceability records linking raw materials to finished parts.

When First Article Inspection Is Required

FAI requirements are triggered by several manufacturing scenarios that represent potential risk points for quality deviation:

• Initial production of a new part number or design

• Engineering changes affecting form, fit, or function

• Changes to manufacturing processes, tooling, or equipment

• Relocation of manufacturing operations to a new facility

• Lapse in production exceeding two years (or customer-specified duration)

• Change in material source or specification

• Correction of a nonconformance affecting production methods

Industry Standards and Regulatory Requirements

The requirements governing first article inspections vary significantly depending on the industry sector, customer specifications, and applicable regulatory frameworks. Understanding these requirements is crucial for manufacturers serving diverse markets from their facilities in Nova Scotia and throughout the Maritime region.

AS9102 – Aerospace First Article Inspection Requirement

The AS9102 standard, currently in Revision C, represents the most rigorous and widely adopted FAI specification in the aerospace industry. Developed by the International Aerospace Quality Group (IAQG), this standard establishes uniform requirements that apply throughout the global aerospace supply chain.

Key requirements of AS9102C include:

• Complete dimensional verification of all design characteristics

• Documentation of material and special process certifications

• Verification of manufacturing planning documents

• Traceability from raw material through finished part

• Approval signatures from designated quality representatives

• Retention of records for minimum periods specified by customer or regulation

For Canadian aerospace manufacturers, compliance with AS9102 is typically mandatory when supplying to prime contractors and original equipment manufacturers (OEMs) operating under AS9100 quality management systems.

PPAP – Production Part Approval Process

In automotive and related industries, the Production Part Approval Process (PPAP) serves a similar function to aerospace FAI requirements. Developed by the Automotive Industry Action Group (AIAG), PPAP documentation requirements are categorised into five submission levels, with Level 3 being the default requirement for most production parts.

PPAP submissions may include up to 18 distinct elements, including design records, process flow diagrams, control plans, measurement system analysis studies, and dimensional results. The specific elements required depend on the submission level specified by the customer and the nature of the part being supplied.

Defence and Military Specifications

Manufacturers supplying to the Department of National Defence or supporting contracts under the Canadian Controlled Goods Program may encounter additional FAI requirements beyond commercial standards. These may include requirements for qualified products lists, first article testing at government facilities, and enhanced documentation for items classified as critical safety items.

Planning and Executing an Effective First Article Inspection

Successful FAI completion requires careful planning that begins well before the first production part is manufactured. A systematic approach minimises delays, reduces costs associated with nonconforming parts, and ensures that all required documentation is available when needed.

Pre-Production Planning

The FAI planning process should commence during the contract review stage, when engineering drawings and specifications are first received. Key planning activities include:

• Characteristic identification: Systematically review all engineering documents to identify every characteristic requiring verification, including dimensions, tolerances, material requirements, and special processes

• Measurement capability assessment: Evaluate available inspection equipment against required tolerances, following the general guideline that measurement uncertainty should not exceed 10% of the tolerance band

• Special process planning: Identify processes requiring external certification (heat treatment, plating, non-destructive testing) and verify that suppliers hold appropriate approvals

• Balloon drawing preparation: Create numbered reference drawings that link each characteristic to its corresponding entry in the FAI documentation

Sample Selection and Inspection Execution

The number of parts required for first article inspection depends on customer requirements and the nature of the production process. While some specifications require inspection of a single representative part, others may mandate inspection of multiple samples to demonstrate process capability.

When inspecting multi-cavity tooling or multiple-spindle machining operations, each cavity or spindle typically requires separate FAI documentation to verify that all production positions produce conforming parts. For a four-cavity injection mould, this means completing FAI for parts from each cavity, with clear identification linking each part to its production position.

Documentation Best Practices

The quality of FAI documentation significantly impacts the speed of customer approval and the ability to resolve questions that arise during review. Effective documentation practices include:

• Recording actual measured values rather than simply noting "pass" or "conforming"

• Clearly identifying measurement methods and equipment used for each characteristic

• Including serial numbers or unique identifiers for inspection equipment, linked to current calibration records

• Providing clear traceability between balloon numbers, characteristic entries, and supporting documentation

• Documenting any deviations or concessions approved by the customer

Common Challenges and Solutions in FAI Completion

Even experienced manufacturers encounter difficulties when completing first article inspections for complex parts or demanding customer requirements. Understanding common challenges enables proactive planning to avoid delays and additional costs.

Measuring Complex Geometries

Modern engineered components frequently incorporate complex curved surfaces, compound angles, and features that challenge traditional measurement methods. For manufacturers in Atlantic Canada, access to advanced metrology equipment may require investment in CMM capabilities or partnerships with regional inspection service providers.

Solutions for complex measurement challenges include:

• Portable CMM equipment for large structures that cannot be transported to fixed measuring machines

• Optical and laser scanning systems for complex surface profiles

• Gauge design and fabrication for repetitive production characteristics

• Coordinate with engineering to establish alternative measurement methods when design features cannot be directly measured

Managing Special Process Documentation

Parts requiring multiple special processes—such as heat treatment, chemical surface treatments, and non-destructive testing—present documentation challenges because certifications must be coordinated from multiple sources and linked to the specific FAI samples.

Effective management strategies include maintaining approved supplier lists with current process approvals, establishing clear communication protocols with process suppliers regarding documentation requirements, and implementing lot control systems that maintain traceability throughout the manufacturing sequence.

Addressing Nonconforming Characteristics

When inspection reveals characteristics outside specified tolerances, manufacturers must decide whether to pursue customer concession, implement corrective action, or scrap the FAI samples and restart production. The appropriate response depends on the magnitude of the deviation, the criticality of the affected characteristic, and customer requirements regarding concessions during first article approval.

Digital Solutions and Technology in Modern FAI

The digital transformation affecting all aspects of manufacturing has significantly impacted first article inspection processes. Modern software solutions and connected measurement systems offer opportunities for improved efficiency, accuracy, and traceability.

FAI Management Software

Dedicated FAI software applications streamline the process of creating balloon drawings, generating compliant documentation, and managing the approval workflow. These systems typically offer:

• Automatic extraction of characteristics from CAD models and PDF drawings

• Direct import of measurement data from CMMs and other digital inspection equipment

• Automatic tolerance evaluation and nonconformance flagging

• Electronic signature capture and approval routing

• Integration with enterprise quality management systems

Model-Based Definition and Digital Threads

The aerospace industry's movement toward model-based definition (MBD) is changing how FAI requirements are communicated and documented. Rather than extracting characteristics from traditional 2D drawings, inspection requirements are increasingly embedded within 3D CAD models, enabling more direct integration between design intent and inspection execution.

For manufacturers investing in digital transformation, these capabilities offer significant long-term benefits in reduced documentation effort and improved accuracy, though initial implementation requires careful planning and workforce training.

Building FAI Capabilities for Competitive Advantage

For manufacturers across Nova Scotia and the broader Atlantic Canadian region, strong first article inspection capabilities represent a genuine competitive advantage. As supply chains become increasingly global and quality requirements continue to intensify, customers seek suppliers who can demonstrate robust processes for ensuring conformance from the first production part.

Investment in FAI capabilities should be viewed not as a cost of compliance but as an investment in customer confidence, reduced production risk, and enhanced market access. Manufacturers who consistently deliver complete, accurate FAI packages on schedule differentiate themselves from competitors and position themselves for growth in demanding sectors such as aerospace, defence, and precision industrial equipment.

Continuous Improvement in FAI Processes

Leading manufacturers treat each FAI completion as an opportunity for process improvement. Post-FAI reviews should examine cycle time, documentation quality, and any issues identified during customer review. This data enables systematic improvement in FAI efficiency and effectiveness over time.

Partner with Sangster Engineering Ltd. for Your Quality Engineering Needs

Successfully navigating first article inspection requirements demands expertise in quality engineering, metrology, and documentation practices. At Sangster Engineering Ltd., our team brings decades of experience supporting manufacturers throughout Nova Scotia and Atlantic Canada in developing and implementing robust FAI processes that satisfy the most demanding customer requirements.

Whether you require assistance with FAI planning for complex aerospace components, need guidance on implementing AS9102-compliant documentation systems, or seek engineering support for measurement capability development, our Amherst-based team is ready to help. We understand the unique challenges facing Maritime manufacturers and provide practical, cost-effective solutions tailored to your specific requirements.

Contact Sangster Engineering Ltd. today to discuss how we can support your first article inspection requirements and help you build the quality capabilities that drive business growth. Our commitment to technical excellence and customer service has made us a trusted partner for manufacturers across Atlantic Canada—let us demonstrate how we can contribute to your success.

Partner with Sangster Engineering

At Sangster Engineering Ltd. in Amherst, Nova Scotia, we bring decades of engineering experience to every project. Serving clients across Atlantic Canada and beyond.

Contact us today to discuss your engineering needs.