3.5 First Article Inspection (AS9102)

First Article Inspection (FAI) validatesis thatnot 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 capablea offluke, producingthe anext 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 thatto meetsthe allspecific engineeringdrawing revision and designthe requirements.Purchase Order.
• Rule:

  TheIf FAIRthe (FirstRevision Articlelevel Inspectionon Report) Structure

  • Form 1 (Partdoes Accountability):not Identifiesmatch the part,Revision revision, and organization. Summarizes the result (Pass/Fail).
  • Form 2 (Product Accountability): Lists all raw materials, special processes (e.g., plating, soldering), and functional tests. Requires mapping to specific Certificate of Conformance (CoC) numbers.
  • Form 3 (Characteristic Accountability): The detailed audit. Every dimension, note, and tolerancelevel on the drawing and the PO, the FAI is assignedVoid.

  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 ("Ballooning").to Theevery inspectordimension, recordsgeometric 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 resultvariable againstdata the(e.g., "3.05 mm"), not just "OK" or "Pass."
     • requiredException: rangeOnly use "Pass" for everyattribute singledata characteristic.(e.g., "Color is Black").

     Trigger Events for FAI

  APro-Tip: newIf 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 (or Delta FAI)

  FAI is requirednot when:a one-time event; it is a state of compliance. That state can be broken.

  Re-Validation Triggers:

  • IFNew partEngineering introduction.
  • Design changeChange (Revision change) -> THEN Delta FAI (Verify only the changed features).
  • IFChange inProduction manufacturinglapses for >2 Years (24 Months) -> THEN Full FAI (The process memory has degraded).
  • IF Manufacturing source, process, inspectionor method,location changes (e.g., CNC Machine A -> CNC Machine B) -> THEN Delta FAI.
  • IF Natural disaster or location.major tooling repair -> THEN Delta FAI.
  • Lapse in production for two years.

Final Checklist

FAIControl ComponentPoint	Critical Requirement	PurposeNon-Negotiable Rule
FormData 1Integrity	PartForm Number3 &must Revisionshow actual values.	IdentificationNo "Pass/Fail" for dimensions.
Form 2Traceability	MaterialForm Certs2 &must Processeslink to specific Lot/Batch numbers.	TraceabilityGeneric ofMaterial InputsCerts = Reject.
Form 3Completeness	Ballooned100% Drawingof Databallooned items measured.	VerificationMissing ofdata Dimensionspoint = Incomplete FAI.
Delta FAIValidation	Re-verifyVerified changedby featuresQuality Engineer (not the operator).	Change"Self-signed" ManagementFAIs are invalid.
NC Handling	Any Failed characteristic on Form 3.	Stop. Do not ship. Fix process -> New FAI.