The document provides information on the requirements for First Article Inspection (FAI) according to AS9102 Rev B, including: - The purpose of FAI is to provide documented evidence that all design, engineering, and specification requirements are known and verified. - FAI is required when there are changes to the design, manufacturing process, or a lapse in production. It may be a full or partial FAI depending on the type of change. - Form 1 is used to document FAI and includes fields for part number, drawing details, manufacturing information, inspection results signature blocks and more. It defines which fields are mandatory or conditional.

1. First Article Inspection Standard
& their requirements
Ref: AS9102 REV B

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The purpose of the First Article Inspection is to provide documented evidence that all
design, engineering, and specification requirements are known and verified.

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WHEN FAI REQUIRED
The organization shall perform a full FAI or a partial FAI for affected characteristics, when any of
the following occurs:
1. A change in the design characteristics affecting fit, form, or function of the part.
2. A change in manufacturing source(s), process(es), inspection method(s), location of manufacture,
tooling, or materials that can potentially affect fit, form, or function.
3. A change in numerical control program or translation to another media that can potentially affect
fit, form, or function.
4. A natural or man-made event, which may adversely affect the manufacturing process.
5. An implementation of corrective action required to complete a previous FAI, as described in 4.4.
6. A lapse in production for two years shall require an update for any characteristics that may be
impacted by the
inactivity. This lapse is from the completion of last production operation to the actual restart of
production.
Ref: AS9102B 4.6 f

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WHEN DELTA FAI REQUIRED
Partial or Re-accomplishment of First Article Inspection
a. The FAI requirement, once invoked, shall continue to apply even after initial compliance.
b. The FAI requirements may be satisfied by a partial FAI that addresses only the changes from a
baseline part number provided all other characteristics were conforming on the previous FAI and are
produced by the original production processes.
c. When a partial FAI is performed, the organization shall, as a minimum, complete the affected fields
in the FAI forms.
d. When the organization performs a partial FAI, the organization shall record the “Baseline Part
Number”, including the revision level and reason for the partial FAI on Form 1 (see field 14).
e. FAI requirements may be satisfied by a previously approved FAI performed on identical
characteristics of similar parts produced by identical means. When FAI requirements (partial or full)
are satisfied in this manner, identify the “Baseline Part Number” on Form 1 (see field 14).
Ref: AS9102B 4.6

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FORM-1
1. Part Number 2. Part Name 3. Serial Number 4. FAI Report Number
5. Part Revision Level 6. Drawing Number 7. Drawing revision level 8. Additional Changes
9. Manufacturing Process
Reference
10. Organization Name 11. Supplier Code 12. P.O. Number
14. Full FAI Baseline Part Number including revision level
13. Detail FAI
Partial FAI
Assembly FAI Reason for Partial FAI:
a) if above part number is a detail part only, go to Field 18
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
1) Signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for
disposition.
2) Also indicate if the FAI is complete per Section 5.4: FAI complete FAI not Complete
19. Signature By 20. Date
21. Reviewed By 22. Date
23. Customer Approval 24. Date
WHITE fields – OPTIONAL information- not required.
BLUE or DARK GREY fields – CONDITIONALLY REQUIRED.
These fields shall be completed when applicable/
required.
YELLOW or LIGHT GREY fields – MANDATORY
information required.

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FORM-1 Contd.
1. Part Number 2. Part Name 3. Serial Number 4. FAI Report Number
5. Part Revision Level 6. Drawing Number 7. Drawing revision level 8. Additional Changes
9. Manufacturing Process
Reference
10. Organization Name 11. Supplier Code 12. P.O. Number
14. Full FAI Baseline Part Number including revision level
13. Detail FAI
Partial FAI
Assembly FAI Reason for Partial FAI:
a) if above part number is a detail part only, go to Field 18
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
Box 1. Part Number of the FAI part.
Box 2. Name of the part as shown on the
drawing.
Box 3. Serial number of the FAI part.
Box 4. The Report No. identifies the FAI. This
may be an internal report number.
Box 6. The drawing number associated with the First Article Inspection
part. (Just the drawing number- do not include dash numbers that are not
in the title block of the drawing.)
Box 7. Reference the revision status of the engineering
drawing. (Incldued PSDLs, PLs, and all applicable sheets
of the drawing.)
Box 5. The latest part revision that affects the part being first article inspected.
This is the same revision as the drawing revision level UNLESS otherwise called
out on the drawing or purchase order. Indicate if there is no revision.
Box 8. Reference Design, Engineering or Manufacturing changes
affecting the FAI part, NOT REFLECTED BY/ NOT INCORPORATED IN the
current drawing/ part revision level.

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FORM-1 Contd.
1. Part Number 2. Part Name 3. Serial Number 4. FAI Report Number
5. Part Revision Level 6. Drawing Number 7. Drawing revision level 8. Additional Changes
9. Manufacturing Process
Reference
10. Organization Name 11. Supplier Code 12. P.O. Number
14. Full FAI Baseline Part Number including revision level
13. Detail FAI
Partial FAI
Assembly FAI Reason for Partial FAI:
a) if above part number is a detail part only, go to Field 18
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
Box 14. Check as appropriate. For Partial FAI provide the baseline
drawing number, including revision status and the reason. i.e
Change of manufacturing location,
Non-Conformance, Process change, Design change etc.
Box 9. Reference the internal work order or router number.
Box 10. Name of the organization performing the FAI .
Box 11. Reference the supplier vendor code.
Box 12. Reference the customer Purchase Order number.
Box 13. Check as appropriate.
Detail = part that has no pieces/parts going into it.
Assembly = part that has pieces/ parts built into it-(sometimes part description
says assembly).

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FORM-1 Contd.
1. Part Number 2. Part Name 3. Serial Number 4. FAI Report Number
5. Part Revision Level 6. Drawing Number 7. Drawing revision level 8. Additional Changes
9. Manufacturing Process
Reference
10. Organization Name 11. Supplier Code 12. P.O. Number
14. Full FAI Baseline Part Number including revision level
13. Detail FAI
Partial FAI
Assembly FAI Reason for Partial FAI:
a) if above part number is a detail part only, go to Field 18
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
Boxes 15, 16, 17 and 18 – this section is only required
if the Part Number in Box 1. is an Assembly with
lower level parts.
Box 15. Reference all lower level parts or
next level sub-assembly part numbers to be included in the assembly.
Box 16. Part name as shown on the drawing/ parts
list.
Box 17. Reference the serial number of the
part, when applicable.
Box 18. A reference number that identifies the
FAI package/ report for the detail part.

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FORM-1 Contd.
a) if above part number is a detail part only, go to Field 18
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
1) Signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for
disposition.
2) Also indicate if the FAI is complete per Section 5.4: FAI complete FAI not Complete
19. Signature By 20. Date
21. Reviewed By 22. Date
23. Customer Approval 24. Date
Box 19.1 The name and signature of the person who prepared the FAI.
Box 19.2 Check if FAI is complete or not.
**NOTE= FAI IS NOT COMPLETE UNTIL THE ORGANIZATION CLOSES ALL NON-
CONFORMANCES AFFECTING THE PART AND IMPLEMENTS CORRECTIVE ACTIONS. The
organization shall re-do an FAI for those affected characteristics and shall record the
results
Box 20. Date when the FAI was prepared.
Box 21. The name of the person who reviewed
or approved the FAI package.
Box 22. Date when the FAI was reviewed.
Box 23. Customer Approval.
Box 24. Date of Customer approval.

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FORM-2
1. Part Number 2 Part Name 3. Serial Number 4. FAI Report
Number
5. Material or Process
Name
6. Specification
Number
7. Code 8. Supplier 9. Customer
Approval
Verification
(Yes/No/NA)
10. Certificate of
Conformanc
e number
11. Functional Test
Procedure Number
12. Acceptance report number, if applicable
13. Comments
14. Prepared By 15. Date
Boxes 1 - 4 are repeated on all forms for
convenience and traceability.

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FORM-2 contd
Box 5. Enter the name of the material or process i.e.
Aluminium Alloy, Cadmium Plate etc.
Box 6. Enter the material or process specification number, class
and material form i.e. S82D Bar (Include ‘make from’ materials,
weld/ braze filler materials, standard catalogue hardware etc).
Box 7. Reference any material code specified.
Box 8. SUPPLIER NAME AND COMPLETE ADDRESS
Box 9. Indicate if technical approval is required by the customer. **NOTE:
MUST HAVE ‘Yes’, ‘No’, or ‘N/A’.
‘Yes’ = Customer approval required and vendor complies.
‘No’ = Customer approval required and vendor does not comply.
‘N/A’ = Customer approval is not required.
Box 10. Reference any Certificate of Conformance number(s)
e.g. Special Process certification, Raw material & Mill certification,
Laboratory Reports etc.

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FORM-2 contd
Box 11. Reference the Functional Test procedure
as stated on the drawing.
Box 12. Reference the Functional Test report/ certification
indicating that test requirements have been met.
Box 13. Comments – As applicable.
Box 14. The name of the person who prepared this form.
Box 15. Date when this form was completed.

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FORM-3
1. Part Number 2. Part Name 3.
Serial
Number
4.
FAIR
Number
Characteristic Accountability Inspection / Test Results
5.
Char
No.
6.
Reference
Location
7.
Characteristic
Designator
8.
Requirement
9.
Results
10. Designed /Qualified Tooling 11. Non-Conformance
Number
14.Additional
Data/ Comments
The signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition.
12. Prepared By 13. Date
Boxes 1 - 4 are repeated on all forms for
convenience and traceability.

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FORM-3 contd
1. Part Number 2. Part Name 3.
Serial
Number
4.
FAIR
Number
Characteristic Accountability Inspection / Test Results
5.
Char
No.
6.
Reference
Location
7.
Characteristic
Designator
8.
Requirement
9.
Results
10. Designed /Qualified Tooling 11. Non-Conformance
Number
14.Additional
Data/ Comments
The signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition.
12. Prepared By 13. Date
Box 5. Assign a unique number for each design characteristic. (CMM
report can be used as long as each characteristic is identified and has
the required and conditionally required fields.)
Box 6. Reference the drawing zone (include Sheet
No. and Section).
Box 7. If applicable, record characteristic type (e.g. key, flight
safety, critical, major, etc.)

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FORM-3 contd
1. Part Number 2. Part Name 3.
Serial
Number
4.
FAIR
Number
Characteristic Accountability Inspection / Test Results
5.
Char
No.
6.
Reference
Location
7.
Characteristic
Designator
8.
Requirement
9.
Results
10. Designed /Qualified Tooling 11. Non-Conformance
Number
14.Additional
Data/ Comments
The signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition.
12. Prepared By 13. Date
Box 9.
Indicate measurements obtained for each design characteristic.
Multiple characteristics shall be listed as individual values or list range once with
the min. and max. of measured value attained. Also number of measurements
taken (ie. 4X, 36x, etc.) for range attained shall match drawing requirement.
ALL DRAWING NOTES MUST BE VERIFIED.
-Variable data- shall be verified as a true measurement.
-Attribute data- shall be verified as “accept”, “complies”, etc.
Laboratory Reports or Certificate of Test must show specific values for the
requirements and actual results.
Box 10. Record the tool identification number of specially
designed tooling used as a media of inspection.
.
Box 8. Specified requirements for the design characteristic (i.e. drawing
dimensional characteristics with nominal and TOLERANCES included, drawing
notes, specification requirements, etc.)
NOTE: State what is on drawing.
NOTE: If drawing defines multiple measurements required
(i.e 4x or 36x), include requirement in Box 8.
Box 11. Record non-conformance document reference number if any design
characteristic is found non-conforming.
Box 14. Any additional data like CMM Report or DPD as applicable

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FORM-3 contd
1. Part Number 2. Part Name 3.
Serial
Number
4.
FAIR
Number
Characteristic Accountability Inspection / Test Results
5.
Char
No.
6.
Reference
Location
7.
Characteristic
Designator
8.
Requirement
9.
Results
10. Designed /Qualified Tooling 11. Non-Conformance
Number
14.Additional
Data/ Comments
The signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition.
12. Prepared By 13. Date
Box 12. Name of the person who prepared this form.
Box 13. Date when this form was completed.

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REJECTION OF FAIRS
Most Common Reasons
First Article Inspection Reports are Rejected:
o C of Cs do not accompany FAI Report.
o Missing for FAIRs, C of Cs, or Test Reports for subassemblies and/or
fabricated/detail parts.
o Numerical requirements in drawing notes are not provided with a results
measurement.
o Missing/wrong information in required and conditionally required boxes.

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Causing Grief
Form 3 boxes- 32.2% Form 2 boxes- 18.7%
C of C Errors- 22.6% Other Certs Missing- 17.4%
Form 1 boxes- 22.6% Cert Errors- 8.3%
FAI Missing- 19.1% C of C Missing- 7.4%
59.9% of
Grief's are for
incorrectly
completed
FAIR’s.
0%
5%
10%
15%
20%
25%
30%
35%
Form 3 boxes
C of C Error
Form 1 boxes
FAI missing
Form 2 boxes
Certs Missing
Cert Error
C of C Missing
Heat Treat Cert Error
Delta FAI required
FAI Error
ITF Error
Spec missing
Spec Error
Problem
Most Common Causes for Griefs

19. Thank you