3.5 First Article Inspection (AS9102)

First Article Inspection (FAI) is not merely a "golden sample" check; it is a forensic validation of the manufacturing process. We do not just measure the part; we audit the process that created it. If the first unit off the line is a fluke, the next thousand will be scrap. AS9102 is the aerospace standard we adopt because it leaves no room for ambiguity.

The Three-Form Architecture

The FAI package (FAIR) is split into three specific logic gates. Do not combine them.

Form 1: Part Number Accountability (The Identity)

• Connects the physical part to the specific drawing revision and the Purchase Order.
• Rule: If the Revision level on Form 1 does not match the Revision level on the drawing and the PO, the FAI is Void.

Form 2: Product Accountability (The Inputs)

• Validates that the "DNA" of the product is correct.
• Scope: Raw materials (Resin, Steel), Special Processes (Anodizing, Heat Treat, Soldering), and Functional Tests.
• Logic: IF the Plating CoC is missing -> THEN Form 2 fails -> THEN The part is scrap, regardless of dimensions.

Form 3: Characteristic Accountability (The Geometry)

• The granular audit. Every feature on the drawing must be "Ballooned" (numbered) and measured.
• Rule: Global notes (e.g., "Break all sharp edges") are characteristics. They must be ballooned and verified, not ignored.

The "Ballooning" Protocol

You cannot inspect what you have not indexed.

1. Tagging: Assign a unique number to every dimension, geometric tolerance, and text note on the engineering drawing.
2. Mapping: Create a corresponding row in Form 3 for each number.
3. Measuring: Record the actual variable data (e.g., "3.05 mm"), not just "OK" or "Pass."
   • Exception: Only use "Pass" for attribute data (e.g., "Color is Black").

Pro-Tip: If a dimension is "4x M3 Holes," that is one balloon but four measurements. Record the Range (Min/Max) or list all four values. Do not measure one and assume the other three are magic.

Trigger Logic: When to Repeat FAI (Delta FAI)

FAI is not a one-time event; it is a state of compliance. That state can be broken.

Re-Validation Triggers:

• IF Engineering Change (Revision change) -> THEN Delta FAI (Verify only the changed features).
• IF Production lapses for >2 Years (24 Months) -> THEN Full FAI (The process memory has degraded).
• IF Manufacturing source, process, or location changes (e.g., CNC Machine A -> CNC Machine B) -> THEN Delta FAI.
• IF Natural disaster or major tooling repair -> THEN Delta FAI.

Final Checklist