Standard Work · SOP

First Article Inspection (FAI) and Quality Sign‑Off

This procedure defines the mandatory steps for performing a First Article Inspection (FAI) on initial production parts or after any significant process change. It ensures that all dimensional, material, and process requirements are verified and formally approved before full production release, reducing scrap, rework, and customer non‑conformances.

Estimated Time

90 min

Difficulty

Advanced

Regulation

AS9102 / PPAP

Version

2.0

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Purpose

The purpose of this First Article Inspection (FAI) procedure is to establish a standardised method for verifying that the first produced part conforms to all engineering, material, and process specifications. A fully documented FAI provides objective evidence that the manufacturing process is capable of producing conforming parts, identifies potential issues before production ramps, and serves as a baseline for future process control. This procedure aligns with AS9102 / PPAP requirements for aerospace, automotive, and precision manufacturing environments.

Scope

This SOP applies to all first‑article parts produced in the machine shop, fabrication cell, or assembly line. It is mandatory:

Before production release of any new part number.
After any engineering change (ECN) that affects form, fit, or function.
After a change in manufacturing process, tooling, or fixture design.
After a machine relocation or major repair that may affect process capability.
After a hiatus of more than one year for a given part number.

This procedure does not replace in‑process inspections or final quality audits; it is a discrete first‑article verification gate.

Safety Precautions

LOTOBefore handling the first article on a live machine, perform a lockout/tagout (LOTO) if any power source must be isolated for measurement access. Verify zero energy state.
PPEWear required personal protective equipment: safety glasses with side shields, steel‑toe boots, and cut‑resistant gloves when handling sharp edges or burrs. Use gloves when cleaning surfaces with solvent.
CHEMWhen using marking fluids, dyes, or solvents for non‑destructive testing, ensure adequate ventilation. Read SDS for each chemical. No open flames or smoking in the inspection area.
LIFTFor heavy first articles (>20 kg), use a hoist or lift assist. Never lift alone. Ensure the part is securely supported on the surface plate or measurement fixture.

Required Tools & Materials

Approved part print / engineering drawing – current revision with sign‑off.
FAI check sheet (AS9102 Form 1 or customer‑specific format).
Calibrated micrometers (0–25 mm, 25–50 mm, etc.), digital calipers (150 mm / 300 mm), depth gage, and thread gages (GO/NO‑GO).
CMM (Coordinate Measuring Machine) – program verified against master if used for complex geometries.
Surface plate (Grade B or better), height stand, and dial indicator with 0.01 mm resolution.
Material cert (mill test report) or supplier certificate of conformance.
Process traveler / work instruction – current revision.
Digital camera (at least 5 MP) for photographing interfaces and critical features.
Marking pen (non‑transferable), inspection stamp, and red NCR flags.
Solvent (isopropyl alcohol or approved cleaner) and lint‑free wipes.

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Procedure: Step-by-Step

1 Revision Verification: Pull the current engineering drawing and process traveler. Confirm both are signed and match the work order. Check that the material certification references the same heat‑lot number. Place the part in a designated ‘UNDER FAI’ area and tag it with a red FAI label.

2 Dimensional Inspection: Using the calibrated equipment listed in the measurement plan, record every characteristic on the FAI check sheet. For each dimension, write the actual measured value and the tolerance. Flag any out‑of‑tolerance condition with a red NCR sticker and note the deviation magnitude. For CMM programs, run the first article program three times and average the results for critical features.

3 Material & Process Verification: Confirm the material grade, hardness (if specified), and surface finish. Attach the material cert or supplier report. If a coating or plating is required, verify the thickness with a calibrated gauge. Document the process parameters (speed, feed, temperature) from the machine controller and ensure they match the plan.

4 Fit & Functional Check: Assemble the first article to its mating part(s) (if applicable). Check for smooth fit, no binding, and proper alignment. For threaded features, run the GO gauge the full depth and the NO‑GO gauge to the maximum allowable turns. Photograph the assembly interface at two perpendicular angles.

5 Complete FAI Packet: Fill out the FAI summary section on the check sheet. List all non‑conformances and attach any deviation permits or MRB dispositions. The inspector (metrology technician or quality inspector) stamps and signs the check sheet. Assemble the packet in order: check sheet → drawing → material cert → photos → process records.

6 Quality Sign‑Off & Release: Present the complete FAI packet to the Quality Manager (or designated signatory). The signatory reviews all data, confirms that all dimensions are within tolerance or covered by an approved deviation, and marks the traveler with a green ‘FAI APPROVED’ stamp. Only after this stamp is applied may the first article be moved to the production bin and serial production begin.

7 Record Keeping: File the original FAI packet in the quality department’s archive (physical or digital) for the life of the part. Update the enterprise system (e.g., ShopDocs) with the FAI status. If any future change occurs, a partial or full re‑FAI must be initiated per revision control procedures.

First Article Inspection (FAI) and Quality Sign‑Off

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