AS9102 First Article Inspection: A Buyer's Guide
An AS9102 first article inspection is a documented check that a supplier's production process can make a part that meets every requirement on the drawing and purchase order. It is recorded on three standard forms, done in full for a new part, and repeated in full or in part when the design, process, source, or location changes, or after a long production gap.
What a first article inspection is for
A first article inspection verifies the production process, not just one good part. The supplier takes a part made with the production method, tooling, and program it plans to use, and shows objective evidence that every design characteristic, material requirement, special process, and functional test is met.
The aerospace standard for this is SAE AS9102, published under the International Aerospace Quality Group. The current revision is AS9102C, released in June 2023. It works alongside the production process verification requirements in AS9100. Many buyers invoke it in their quality clauses, sometimes with extra requirements of their own.
One point that trips people up: an FAI is not product acceptance. Passing a first article shows the process can make conforming parts. Each production lot still has to be inspected and accepted under your normal requirements.
The three AS9102 forms
An AS9102 FAI report is built on three forms. A buyer should expect to see all three, or a clear reason one is not applicable.
| Form | Name in AS9102C (as used in prime supplier training) | What it records |
|---|---|---|
| Form 1 | Part Number Accountability | The part being inspected, its revision, whether the FAI is full or partial and why, and the subassemblies, detail parts, and commercial off-the-shelf items in the build |
| Form 2 | Product Accountability: Raw Material, Specifications and Special Processes, Test Verification | Materials, special processes, and functional tests that are defined as requirements, with specs, suppliers, and certificate references |
| Form 3 | Characteristic Accountability, Verification and Compatibility Evaluation | An actual result for every design characteristic on the drawing, including notes, matched to a ballooned drawing, with the measuring method identified and any nonconformances recorded |
In Revision C, the Form 1 field for the reason behind the FAI applies to every FAI, full or partial, and the bill of materials section is expected to list detail parts, subassemblies, and COTS items. If you still receive reports on older Rev B layouts, ask your supplier whether they have moved to the current forms.
Full FAI versus partial FAI
A full FAI covers every characteristic of a new part. A partial FAI, sometimes called a delta FAI, covers only the characteristics affected by a change, while the rest of the earlier FAI stays valid.
A full FAI is normally required for the first production run of a new part number from a supplier, and when the buyer asks for one. Some customers also require a full FAI after a long lapse in production or a move to a new site rather than a partial one, so check your own clauses.
A partial or new FAI is triggered by changes. Customer quality clauses that invoke AS9102 commonly list these events, as Lockheed Martin Aeronautics' quality clause Q2A does:
- A change in design affecting fit, form, or function
- A change in manufacturing or processing source, process, inspection method, location of manufacture, tooling, or materials that can affect fit, form, or function
- A change in the numerical control program, or its translation to another media, that can affect fit, form, or function
- A natural or man-made event that may affect the manufacturing process
- A lapse in production of two years, or as the customer specifies
Other primes' supplier training adds the implementation of a corrective action to that list. Your contract and your customer's clauses decide the final rule.
What buyers should check in an FAI report
Reviewing an FAI well takes less time than chasing a nonconformance later. Use this as a review checklist.
- Right part, right revision. Form 1 matches the PO part number and drawing revision, and the baseline FAI is identified for a partial.
- Every characteristic is accounted for. The ballooned drawing and Form 3 line up one to one, including notes, general tolerances, and flag notes, not only dimensions.
- Actual results, not "OK". Variable characteristics show measured values. Attribute checks name the method or gauge.
- Measurement method fits the tolerance. A tight position tolerance checked with calipers is a red flag.
- Material and processes are traceable. Form 2 lists each material and special process with its spec and a certificate reference, and the processor is approved where your clauses require it.
- Functional tests are documented where the drawing or spec requires them.
- Nonconformances are dispositioned. Any out-of-tolerance result is identified with a disposition, not buried.
- Sub-tier FAIs are included for detail parts or assemblies built by other suppliers, when your clauses require them.
- Signatures and dates are present per your requirements.
Common problems in FAI packages
- Drawing notes left off the characteristic list
- Results recorded as pass or fail where a measured value was needed
- Form 2 listing a material spec without the certificate behind it
- A partial FAI that does not reference the baseline it updates
- The FAI performed on a prototype or hand-made part instead of production methods
- A supplier changing a process, a sub-tier source, or an NC program without telling the buyer or redoing the affected FAI
The last item is the expensive one. Requiring suppliers to notify you before changes that affect the part, as many quality clauses do, keeps the FAI meaningful after the first delivery.
How to specify FAI on your RFQ and PO
Be explicit. State that an FAI to AS9102 is required, full or partial, whether it must be submitted for approval before production ships, and whether you need sub-tier FAIs. If your customer requires a digital FAI format or a specific system, say so. Attach or reference your quality clauses by number and revision.
If the supplier already has a valid FAI for the same part number and revision made at the same site with the same process, ask for that report instead of paying for a new one. If something has changed, a partial FAI covering the change is usually enough unless your clauses require more. See the aerospace RFQ checklist for where FAI fits among the other requirements.
What FAI does to cost and schedule
An FAI is real inspection labor. On a complex machined part with many characteristics, measuring and documenting everything can take longer than making the part, and CMM programming adds more. The first lot also waits on the FAI review before it ships if you require approval first.
Plan for it. Put the FAI on the RFQ so it is priced in, leave review time in your schedule, and turn your reviews around quickly. The aerospace machining cost guide shows how inspection compares with the other cost drivers.
Get parts delivered with the FAI you need
Use the inspection quote form to request parts with an AS9102 FAI, or inspection and FAI work on parts you already have. A person replies within 1 business day. We flow your FAI and quality clause requirements down to the supplier, check the paperwork before it reaches you, and ship every order with a certificate of conformance, plus other certs when your request requires them. For the parts themselves, see aerospace CNC machining.
Questions
What is an AS9102 first article inspection?
It is a documented verification, under SAE AS9102, that a supplier's production process can make a part meeting every requirement on the drawing and purchase order. The report uses three forms: part number accountability, product accountability for materials, special processes, and functional tests, and characteristic accountability with a result for every design characteristic. The current revision is AS9102C, released in June 2023.
When is a partial FAI enough instead of a full FAI?
A partial FAI covers only the characteristics affected by a change, such as a design revision, a new process, a new tooling set, or a change to the NC program, while the rest of the earlier FAI remains valid. A full FAI is normally needed for a new part from a supplier. Some customer clauses require a full FAI after a long production lapse or a site move, so check your contract.
How long is a first article inspection valid?
It stays valid until something changes that can affect the part. Customer clauses that invoke AS9102 commonly list design changes, changes in source, process, inspection method, location, tooling, materials, or NC program, a natural or man-made event affecting the process, and a lapse in production of two years, or as the customer specifies. Any of those can require a new full or partial FAI.
Is an FAI the same as accepting the parts?
No. An FAI shows that the production process can make conforming parts. It does not accept any particular lot. Each production delivery still needs inspection and acceptance under your normal requirements, and a certificate of conformance. Treating a passed FAI as a substitute for lot acceptance is a common mistake that lets later process drift go unnoticed.
Do commercial off-the-shelf parts need their own FAI?
Usually not, but they still belong in the report. In AS9102C, Form 1 is expected to list COTS items along with detail parts and subassemblies. Many customer clauses exempt standard hardware and COTS items from a separate FAI unless the buyer directs otherwise. Check your quality clauses, since some customers require more for specific items.
What should I reject in an FAI report?
Reject or return reports with missing characteristics, especially drawing notes, results written as OK where a measured value is needed, materials or special processes without certificate references, measurement methods too coarse for the tolerance, a partial FAI with no baseline reference, or undispositioned nonconformances. Also question any FAI done on a prototype rather than a part made with the production process.
Related
Sources
- SAE International, AS9102C Aerospace First Article Inspection Requirement
- BSI Knowledge, Aerospace series: First article inspection requirements (SAE AS9102C:2023 listing)
- Lockheed Martin Aeronautics, Quality Clause Q2A Rev 11, First Article Inspection
- HEICO Sunshine Avionics, AS9102 Supplier FAI Training
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