First article inspection
Planning and documenting production-representative verification, characteristic accountability, change assessment and customer-specific release requirements.
Tags: inspection, quality-documentation, production
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Purpose and applicability
A first article inspection report (FAIR) ties design characteristics and results to a production-representative item. Northrop Grumman Defense Systems distinguishes these items from prototypes made by a different process. Northrop Grumman Q1-4-24-DSF, June 3, 2024, pp. 4–5
Original planning example: a bracket's hole changes from 6.00 ±0.05 mm to 6.20 ±0.05 mm, and the drilling fixture is replaced. Identify the revised hole requirement, but also assess fixture-controlled location, datum relationships and interacting operations. A new reading of 6.19 mm is within the stated size limits, 6.15–6.25 mm. It says nothing by itself about hole position, material condition or unaffected characteristics. The actual change assessment and customer requirements determine the partial-FAI scope; this example does not prescribe that scope.
The aerospace 9102 framework standardizes the FAI process across aviation, space and defense supply chains. IAQG notes that it can also be used in other sectors, but its aerospace origin does not make it a universal requirement for every manufactured part. Establish applicability from the purchase order, quality agreement and governing requirements. IAQG, 9102 overview
SAE lists AS9102C, revised June 28, 2023, as establishing requirements for performing and documenting FAI. Those requirements complement customer and applicable statutory/regulatory requirements. A FAIR template by itself therefore cannot determine what a particular customer requires. SAE AS9102C scope and revision
FAI is not a product acceptance document, a distinction expressly highlighted in IAQG's revision-C changes. Treating one representative item as evidence of long-term statistical stability also exceeds what its measurements alone can establish. Ongoing production controls, product acceptance and any required capability studies remain separate activities. IAQG revision-C changes, July 11, 2023, slide 3
Plan before the item reaches final inspection
FAI planning needs manufacturing, inspection, purchasing and process knowledge. Boeing's published planning requirements call for appropriate resources, competent personnel, inspection sequencing and accounting for all design characteristics. They include implicit and explicit digital-product-definition requirements that may not appear on a 2D drawing, plus material, finish and process specifications. Boeing, FAI planning
Create a controlled requirements baseline: part number and revision, drawing/model identifiers and revisions, referenced specifications and customer requirements. Assign each characteristic a unique identifier linking its requirement to its verification record. A ballooned drawing is a navigation aid; it does not replace requirements embedded in notes, specifications or model data.
Decide when evidence must be collected. A characteristic hidden by assembly, coating or subsequent machining may need in-process verification. Identify required approved processors and material sources before ordering work, and plan the records each supplier must return. These activities are explicitly included in Boeing's planning guidance. Boeing, in-process evidence and source planning
Keep the representative item linked to its actual manufacturing route. Otherwise, a report can describe the right part number while combining evidence from different revisions, processes or specimens. Preserve the traveller/router reference, item identity and relevant material/batch links alongside the measurements.
Organize the report so requirements can be followed
The three AS9102 reporting areas provide a practical structure:
| Reporting area | Main question |
|---|---|
| Form 1: part-number accountability | Which part, configuration and assembly/detail relationships does this FAIR represent? |
| Form 2: product accountability | Which materials, processes and functional-test records support it? |
| Form 3: characteristic accountability and verification | What was required, and what evidence verifies each characteristic? |
Northrop Grumman's revision-C guidance explains these forms and their supporting records. The forms work together; a dimensional-results table alone leaves material, process and configuration accountability unresolved. Northrop Grumman, sections 4.1–4.3
Use the correct revision of the forms and instructions. IAQG makes revision-B and revision-C forms available separately and states that the forms are not all-inclusive substitutes for the associated standard. Control their revision just as carefully as the drawing baseline. IAQG forms management
Results should be directly comparable with the requirement. An attached CMM report needs traceable characteristic identifiers; unlabelled coordinate output does not explain conformance to a positional tolerance. IAQG's February 19, 2015 revision-B FAQ discusses this reporting principle. Use it as explanatory guidance, while applying current revision-C instructions for fields and required information. IAQG FAQ, pp. 3–4
Full, partial and changed production
A partial FAI is anchored to an identified baseline and the characteristics requiring renewed verification. It is not simply a shorter report chosen to save time. IAQG's revision-C summary identifies a documented change-evaluation process and a focus on characteristics invalidated or not represented by previous results. It also notes that revision C removed the unique single-run production-order exemption. Avoid importing revision-B exceptions or old field instructions into a revision-C procedure. IAQG revision-C changes, slides 3 and 8
Assess design changes, process or tooling changes, relocation and other applicable events under the selected standard and customer rules. Document the baseline, change, affected characteristics, rationale and authorization. Determine whether full re-accomplishment or partial verification is appropriate; a drawing remaining unchanged does not by itself establish that the old manufacturing evidence remains representative.
Customer requirements and release
A bounded contractual example is Boeing Q071, effective September 22, 2026. It requires FAI under AS/EN/SJAC 9102 and says subsequent contracts for the same good do not require a new FAI unless re-accomplishment/partial FAI is required or the buyer specifies otherwise. Where supplier first article oversight is required, coordination occurs before related procurement/manufacturing/processing; goods must not ship before oversight completion unless directed by the supplier-quality representative. The clause also requires FAIR delivery with the relevant shipment or as directed. These are Q071 obligations when incorporated, not universal FAI rules. Boeing Q071, one-page clause
Determine which clause version applies to the actual contract. Boeing's clause index explains that, unless the contract states otherwise, incorporated clauses generally use the version effective on the original contract date; subsequently added clauses follow the applicable contract-change date. The newest public PDF is consequently not automatic authority for every open order. Boeing quality-clause applicability
Review and useful completion criteria
Before submission, reconcile the characteristic list, results and supporting records against the baseline. Resolve missing evidence and document nonconformances through the authorized process; a FAIR signature cannot turn an out-of-tolerance result into conforming product. Revision C changed Form 1's former complete/not-complete terminology to identify whether the FAIR contains documented nonconformances. IAQG revision-C changes, slides 7 and 9
Keep technical verification, report review, customer approval where required and shipment authorization distinguishable in the record. A useful package lets a reviewer follow each requirement to its result, identify the item and production conditions represented, and understand any remaining disposition or release conditions.