The document provides an overview of AS9102 first article inspection requirements for the aerospace industry. It explains that a first article inspection verifies that the production process and documentation can produce parts that meet all requirements. The first article involves inspecting a representative part from the first production run and documenting the results. It must be repeated when changes are made that invalidate previous first article results. Forms 1-3 are used to document first article inspections and provide accountability for all part numbers, specifications, characteristics, and inspection results.

1. AS9102 A
Aerospace First Article Inspection Requirement
Alan W. Spreadbury
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2. Why do First Articles and why do
an “Aerospace” first article?
 AS9100 rev B paragraph 8.2.4.2 First Article Inspection:
– “The organization’s system shall provide for a process for the
inspection, verification, and documentation of a representative item from the
first production run of a new part, or following a subsequent change that
invalidates the previous first article inspection result.”
 AS9100 rev C paragraph 7.5.1.1 Production Process Verification
– “The organization shall use a representative item from the first production run
of a new part or assembly to verify that the production processes, production
documentation and tooling are capable of producing parts and assemblies that
meet requirements. This process shall be repeated when changes occur that
invalidate the original results (e.g. engineering changes, manufacturing
process changes, tooling changes).
 AS9102 is widely accepted throughout the industry as the accepted first
article guideline document/process.
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3. What a First Article is and what a
First Article isn‟t.
 A First Article is NOT just an inspection of a part to make sure that it
meets the print.
– In fact, in some circumstances, a part that does not meet the print
(nonconforming) could be acceptable as a first article (we’ll cover that later).
– You can’t complete a First Article if all you have is the part and the drawing.
 A First Article is as much about the plan and the process used to
produce the part as it is about the actual part itself (output of the
process).
– Its all about making sure the plan works and that the output of the plan (part)
has all of the requirements completed, accounted for, and acceptable.
 Make sure that the part is correct and complete using the plan, tools, etc that we intend to use to
make all of the future parts.
– Parts made in the prototype shop are not, typically, representative of the plan
(unless that is where they intend to make them all).
– During the development stage of a process a lot of things are going on that
can invalidate the first article (fixtures changing, software changing, schedule
demands, etc.). Its important to be cognizant of these changes and be
assured that the changes are accounted for. Property of AS9100 Solutions
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4. Delta First Articles
 Once invoked, the First Article requirement continues to apply even after
initial compliance.
 The whole idea is to make sure the plan works and produces complete
and acceptable product, therefore it is implicit that any changes to the
plan will require a new, or partial, first article.
 First Article requirements may be satisfied by a partial First Article that
addresses the differences between the current configuration and the
approved configuration.
 Only the affected portions of the documentation need to be completed for
a partial First Article.
 First Article requirements may also be satisfied by a previously approved
First Article performed on identical characteristics of similar parts
produced by similar means.
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5. Documentation (Forms 1, 2, & 3)
 AS9102 defines 3 separate forms to document the First Article
– Other forms are permitted, but they must include the same required information and have the same
reference numbers
 Form 1: Part Number Accountability
– Used to identify the part that is being First Article inspected and all associated subassemblies or detail
part numbers.
– Form 1 is like the Bill of Material and lists all of the details and their respective First Article status.
 Form 2: Product Accountability-Raw Material, Specifications and Special
Process(s), Functional Testing
– Used if any material, special processes or functional testing are defined as a design requirement.
– Form 2 is where we document: all special processes with specifications, sources, and certifications, all
raw material that is listed by specification only (i.e. not a part number or standard catalog item), and any
required functional testing.
 Form 3: Characteristic Accountability, Verification and Compatibility Evaluation
– Used to document every measurable design characteristic with a unique identifier, characteristic detail
information, and measurement results.
– Form 3 does a lot of the heavy lifting and is where all of the inspection results are documented.
 Besides these forms, a complete First Article also needs all of the supporting and
documentation evidence to support the manufacturing plan.
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6. Form 1 Example
1. Part Number 2. Part Name 3. Serial Number 4. FAI Report Number
Your Part Number Your Part name Required if Serialized Optional
5. Part Revision Level 6. Drawing Number 7. Drawing revision level 8. Additional Changes
Revision if applicable Drawing number if Drawing rev if applicable ECO‟s, ECN‟ or number for any
different than part other change docs
number
9. Manufacturing Process Reference 10. 11. Supplier Code 12. P.O. Number
Organization
Name
Number, rev, or identifier of the current process Source name, Source code number Purchase order number
address, etc.
13. Detail FAI 14. Full FAI
Partial Baseline Part Number including revision level
FAI
Assembly FAI Reason for Partial FAI:
a) if above part number is a detail part only, go to Field 19
b) if above part number is an assembly, go to the “INDEX” section below.
INDEX of part numbers or sub-assembly numbers required to make the assembly noted above.
15. Part Number 16. Part Name 17. Part Serial Number 18. FAI Report Number
Item 1 Part Number Item 1 Part Name Item 1 Serial Number Item 1 First Article report Number
Item 2 Part Number Item 2 Part Name Item 2 Serial Number Item 2 First Article report Number
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7. Form 2 Example
1. Part Number 2 Part Name 3. Serial Number 4. FAI Report Number
Your Part Number Your Part Name Required if Serialized Optional
5. Material or Process Name 6. Specification 7. Code 8. Special Process Supplier 9. Customer 10. Certificate of
Number Code Approval Conformance
Verification number
(Yes/No/NA)
Aluminum 6061-T6 Optional Northeast Aluminum N/A 121267
Hartford, CT
112113
Chem Film MIL-C-5541 Optional Southwest Coaters Yes 115116
Globe, AZ
131765
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8. How can anyone possibly make sense of this!!!

9. Basic dimensions are not recordable
dimensions and as such do not require
numbering
2 1
5
6
Ø 0.750 .002 thru
0.750
+ .005Ø m -A- -B- m -C-
.002
1.500
3 .002
-C- .001 1.250
-B- 0.750
.002
4
2.000
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10. Material specifications, be careful here. Stating
“conforms‟ means that someone reviewed the
certification and lab report against the material
Form 3 Example specification and confirmed ALL of the
requirements (chemical, physical, heat treat,
hardness, etc.). Assume nothing, verify everything
1. Part Number 2. Part Name 3. Serial Number 4. FAI Report
Your Part Number Your Part Name Required if Serialized Optional if used
Characteristic Accountability Inspection / Test Results Optional Fields
5. Char 6. Reference 7. Characteristic 8. Requirement 9. Results 10. Designed 11. Non- 14.[Insert columns, etc, as required by Organization or Customer]
No. Location Designator Tooling Conformance
Number Attribute results would be acceptable. It‟s not
1 Note 1 Material: Conforms feasible to measure variable data around every
Aluminum 6061- edge of every surface accurately to report variable
T6 results. But, „conforms‟ means that it was
2 Note 2 Remove all Conforms evaluated all over and not assumed.
burrs and break
all sharp edges Be sure to read the specification and determine if
.010 max any measurable characteristics need to be
3 Note 3 Finish: Chem Conforms reported. Any measurable characteristics from the
film per Mil-C specification must be numbered and accounted
5541 for.
4 Note 4 All diameters to See table
This callout is a little different. The drawing has
be true position
several holes and only this one true position
w/in .004 to
requirement to tolerance the hole locations. This
relative datums
could be handle several ways: they could all be
unless otherwise
listed here, they could be listed later on with each
specified
of the diameter callouts, or as shown here included
5 Note 5 Tolerances Conforms in an attached table. In either case a location result
apply after must be recorded for each diameter covered by
plating this note.
6 Note 6
Depending on the thickness of the plating, the mfg
plan may require some in-process dimensions to
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be modified to account for plating thickness.
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11. Form 3 Example
1. Part Number 2. Part Name 3. Serial Number 4. FAI Report
Your Part Number Your Part Name Required if Serialized Optional if used
Characteristic Accountability Inspection / Test Results Optional Fields
5. Char 6. Reference 7. Characteristic 8. Requirement 9. Results 10. Designed 11. Non- 14.[Insert columns, etc, as required by Organization or Customer]
No. Location Designator Tooling Conformance
Number
1 Note 1 Material: Conforms
What about Block 14? What is supposed to go here?
Aluminum 6061-
T6
2 Note 2 Remove all Conforms
The revision A version and break removed fields from
burrs of AS9102
all sharp edges
this area to permit some flexibility by the organization or
.010 max
customers to specify additional fields. Some additions
3 include:
Note 3 Finish: Chem Conforms
•Measurement Method (Final)
film per Mil-C
•Measurement Method (in-process)
5541
4 •Op
Note 4 No. Generated diameters to See table
All
•Op No. Inspected true position
be
•Justification for <100% inspection
w/in .004 to
relative datums
unless otherwise
specified
5 Note 5 Tolerances Conforms
apply after
plating
6 Note 6
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12. Form 3 Example (continued)
1. Part Number 2. Part Name 3. Serial Number 4. FAI Report
Your Part Number Your Part Name Required if Serialized Optional
Characteristic Accountability Inspection / Test Results Optional Fields
5. Char No. 6. Reference 7. Characteristic 8. Requirement 9. Results 10. Designed Tooling 11. Non-Conformance 14.[Insert columns, etc, as required by Organization or Customer]
Location Designator Number
6A Ø .109 ± .005 .107
7A Ø .187 ± .005 .1875
8A .125 ± .005 Deep .127
This is an example of one way to delineate
Note True Position w/in .0026 the data for each of several multiple
4(6A) .004 features (i.e. hole patterns, etc.). This
6B Ø .109 ± .005 .108 table lists variable results for each hole
7B Ø .187 ± .005 .187 for thru hole size, counterbore size,
8B .125 ± .005 Deep .128
counter bore depth and true position. As
Note True Position w/in .0022
4(6B) .004 well as true position for each end of a slot.
Not 4 True Position w/in .0015
(15A) .004
Not 4 True Position w/in .0017
(15B) .004
33A Ø .140 ± .005 .137
34A Ø .203 ± .005 .202 All variable data for all of
35A .050 ± .005 Deep .050
Not 4 True Position w/in .0033 the holes and slots. No
(33A) .004
33B Ø .140 ± .005 .136 attribute results here.
34B Ø .203 ± .005 .202
35B .050 ± .005 Deep .049
Not 4 True Position w/in .0028
(33B) .004
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13. Final Points
 Assume nothing, verify everything
 A proper AS9102 1st article requires painstaking detail.
 Sometimes you’ll almost feel embarrassed to ask for some obscure bit of
information, but don’t be.
 You are just trying to verify every design characteristic and assuring that,
at least once, everything was checked out and found acceptable.
 Be firm and insist on variable data for each item if possible.
 Take the time to carefully evaluate the whole package.
 Making sure it is right the first time is what its all about.
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14. More Information/Additional
Support
 Supply Chain Management Handbook (www.IAQG.org)
– An information tool offered by the International Aerospace Quality
Group with lots of good information
– The SCMH has valuable information concerning AS9102 first articles
along with other aerospace quality information.
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