What exactly is a First Article Inspection Report and why is it so crucial to the process from Phyllis Lucius's blog

Inspections of first articles are required in the aerospace and defense industries. According to the AS9102 standard, they are performed in order to ensure that products are manufactured in accordance with the specified specifications. An organization's ability to demonstrate compliance is also essential; the First Article Inspection Report serves this purpose. A First Article Inspection Report, on the other hand, is exactly what it sounds like.

This short guide will provide you with an overview of First Article Inspection Reports (FAIR) and why compliance with this standard is important for your organization. Let's start at the beginning, with the First Article Inspection (FAI), in order to gain a thorough understanding of what a FAIR is.

What is a First Article Inspection, and why first article inspection important?
A First Article Inspection (FAI) is a quality control procedure that evaluates the quality of one to five items from the first mass production run that are selected for testing. All of the items are selected at random and serve as a sample for the remainder of the production run. If the parts under inspection are produced in accordance with the exact specifications of the customer, it can be assumed that every other part will be correct as well.

FAIs are extremely meticulous in their work. In order to meet the needs of their customers, manufacturers will examine factors such as measurements and dimensions, equipment, design, and materials, and compare them with those requirements. If a product is being manufactured for the first time, or if elements of the product's design have been changed, the manufacturer's location has changed, production of the part has resumed after an absence of at least two years, the manufacturing process has changed, or a customer has requestedfirst article inspection, inspections will need to be performed.

If a part fails the FAI, the product will be returned to pre-production so that the issues can be resolved. However, if everything goes according to plan and the FAI is approved, the mass production run can resume.

What is an FAI report, exactly?
In the manufacturing industry, a First Article Inspection Report (FAIR) is documentation that demonstrates that a product has been manufactured according to the specifications specified.

When first article inspection service comes to the aerospace and defense industry, the report must take three different forms. Let's break down the purpose of each form and the information that should be included in them.

Form 1: Identification of the component Responsibility – describes the product part that is being examined during the FAI, along with any associated subassemblies or detail parts.

Specify all materials, specifications, processes, and any functional tests that are stipulated as a design requirement in Form 2: Product Accountability (also known as the Product Accountability Form).

Form 3: Accountability for Design Characteristics – summarizes each design characteristic of the FAI parts in a single document. Dimensions, tolerances, drawing notes, measurements, and the results, among other things, are recorded in this section. On this form, you must also include a drawing of a balloon.

Balloon Drawings – also known as Bubble Drawings, these drawings provide support for Form 3 by confirming each design characteristic complies with the requirements. On Form 3, the drawings are each assigned a number that corresponds to one of the design characteristic numbers listed on the sheet.

Additional information included in a FAI report will typically include the part name and number, the name and signature of the individual who conducted the FAI, the date that the form was completed, and whether or not the customer has approved the report.

What is the significance of a First Article Inspection Report?
Consider the following scenario: a commercial airline has requested that you manufacture a part for one of their aircraft engines. Precision and accuracy are required in the manufacturing of this part; if the dimensions or any other aspect of the design does not meet the airline's specifications, the part will be deemed unsuitable for use.

Consider the scenario in which you did not inspect any of the parts from the first production batch. There is a problem with the measurements, which you discover later in the process. All of the parts are deemed unacceptably flawed and must be remade, causing significant delays throughout the entire manufacturing process. Not only that, but resources have also been squandered as a result.

Failure to conduct an inspection resulted in a costly mistake, which is why an in-depth FAI is critical for your organization's success. In this way, you can detect errors in the manufacturing process early on and prevent products from being manufactured to incorrect or insufficient standards. This saves you time, money, and resources in the long run.

Producing an accurate FAI report will also provide customers with the peace of mind in knowing that their products will be manufactured efficiently and precisely to their specifications. Moreover, you can have confidence in your mass production process – and the requirements of the industry, as defined by AS9102, will be satisfied as well.