FAI is the formal inspection of the first part (or batch) produced on a new setup to verify it meets drawing requirements. Automotive calls it PPAP; aerospace calls it AS9102 FAI; medical calls it IQ/OQ. The principle is the same: before production commits to 1,000 parts, prove the process produces correct parts.
A proper FAI package includes:
For aerospace parts, this is formalized into AS9102 Forms 1, 2, and 3. For automotive, the equivalent is PPAP Part Submission Warrant + supporting documentation.
| Standard | Industry | Typical use |
|---|---|---|
| AS9102 FAI | Aerospace / defense | Required by AS9100 quality system; comprehensive dimensional and process verification |
| PPAP Level 3 | Automotive | Required by IATF 16949; includes process capability studies beyond dimensional |
| Generic FAI | Commercial | Simplified dimensional report, often 1 page per drawing |
| IQ/OQ/PQ | Medical devices | Installation/Operational/Performance Qualification under ISO 13485 |
| Source inspection | Defense | Government or prime-contractor inspector witnesses first articles at supplier |
Always. First production batch should have FAI regardless of total order size. Catches drawing ambiguity, setup errors, process mistakes.
Required by the quality system. No option. Supplier maintains FAI records for audit.
Parts where failure means injury or death. Aerospace structural, medical implants, automotive safety systems. FAI is part of the risk-management process.
If each part costs $1,000+ and rework means scrap, FAI on first article is cheap insurance. Catches issues before 100 parts are made wrong.
Any drawing with 10+ GD&T callouts should have FAI. Multi-feature parts are where interpretation errors occur.
| Complexity level | FAI prep time | Typical FAI cost |
|---|---|---|
| Simple (10-15 dimensions) | 2-4 hours | $100-300 |
| Standard (20-40 dimensions with some GD&T) | 4-8 hours | $300-600 |
| Complex (50+ dimensions, extensive GD&T) | 8-16 hours | $600-1,200 |
| AS9102 aerospace full submission | 12-24 hours | $800-1,500 |
| Source-inspected (customer witness) | Similar + customer travel | $1,000+ with logistics |
On production runs, FAI cost is amortized. On a 100-unit order at $50/unit ($5,000 total), $300 FAI is 6% of order — acceptable for quality assurance. On a 10-unit order at $500/unit, $300 FAI is 6% — same proportion. On a prototype-only 2-unit order, FAI may not be economically justified.
Once an initial FAI is approved, future orders of the same part typically don't require full FAI:
For long-running production programs, FAI is a one-time cost per revision. Unless something changes, subsequent batches use standard in-process quality inspection.
Email [email protected] and specify the FAI standard required (AS9102, PPAP Level, generic dimensional). We include FAI in the quote when required, and maintain records for program duration.
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