First Article Inspection Checklist

First Article Inspection (FAI) is a critical process in manufacturing, particularly in industries where quality control and assurance are paramount, such as aerospace, automotive, and medical device manufacturing.

FAI involves the comprehensive examination and validation of the first production unit of a new part or assembly against engineering drawings, specifications, and other requirements. The purpose of FAI is to ensure that the manufacturing process is capable of consistently producing parts that meet the customer’s requirements and specifications.

Here’s an overview of the key steps involved in First Article Inspection:

1. Planning: Before production begins, a detailed plan for the FAI process is developed. This plan outlines the scope of the inspection, the sampling procedure, inspection methods, acceptance criteria, and documentation requirements.
2. Documentation Review: The engineering drawings, specifications, and other relevant documents are reviewed to ensure that the inspection process will accurately verify compliance with all requirements.
3. Part Identification: The first production unit, known as the “first article,” is identified and separated from the rest of the production run.
4. Physical Inspection: The first article is subjected to a thorough physical inspection, which may include dimensional measurements, material composition analysis, visual inspection, and functional testing.
5. Measurement and Testing: Precise measurement tools and testing equipment are used to verify that the dimensions, features, and properties of the first article match the requirements specified in the engineering drawings.
6. Documentation: Detailed records of the inspection results, including measurements, observations, and any non-conformities identified, are documented in a First Article Inspection Report (FAIR). The FAIR serves as a formal record of compliance with customer requirements.
7. Approval Process: Once the FAI is complete and all requirements have been verified, the first article is submitted for approval by the customer or a designated authority. Approval indicates that the manufacturing process is capable of producing parts that meet the required specifications.
8. Production: Upon approval of the first article, production can proceed according to the established process.

FAI is a critical step in ensuring product quality, reducing the risk of defects and non-conformities, and maintaining compliance with customer requirements and industry standards. By thoroughly inspecting the first production unit, manufacturers can identify and address any issues early in the production process, preventing costly rework and potential quality issues down the line.

Creating a comprehensive First Article Inspection (FAI) checklist is essential to ensure that all necessary steps are followed and that the inspection process is thorough and effective. Here’s a structured checklist that can be adapted based on specific industry requirements and the complexity of the part or assembly being inspected:

Pre-Inspection Preparation:

1. Review Documentation
   • Engineering drawings
   • Specifications
   • Purchase orders
   • Quality control plans
2. Verify Equipment and Tools
   • Calibration status of measurement tools
   • Availability of testing equipment
   • Functionality of inspection software (if applicable)
3. Identify First Article
   • Ensure clear identification and separation from the production run

Physical Inspection:

4. Dimensional Inspection
   • Verify critical dimensions
   • Measure tolerances
   • Check geometric features
5. Visual Inspection
   • Surface finish evaluation
   • Presence of defects (e.g., scratches, dents, burrs)
6. Material Inspection
   • Material composition analysis
   • Material properties verification (e.g., hardness, density)
7. Functional Testing
   • Perform tests to verify functionality according to specifications
   • Operation of moving parts (if applicable)

Documentation and Reporting:

8. Document Inspection Results
   • Record measurements and observations
   • Note any non-conformities or discrepancies
9. Complete First Article Inspection Report (FAIR)
   • Include inspection results
   • Attach supporting documentation (e.g., measurement reports, test records)
10. Review FAIR for Accuracy
    • Ensure all information is accurately documented
    • Cross-reference with engineering drawings and specifications

Approval Process:

11. Submit FAIR for Approval
    • Send FAIR to the customer or designated authority
    • Include any required certifications or documentation
12. Address Non-Conformities
    • If non-conformities are identified, address and resolve them
    • Obtain approval for any corrective actions taken

Post-Approval:

13. Implement Corrective Actions (if necessary)
    • Address any issues identified during the FAI process
    • Update processes or procedures as needed
14. Proceed with Production
    • Once the first article is approved, proceed with production according to established processes

Additional Considerations:

• Regulatory Compliance: Ensure compliance with industry standards and regulations (e.g., AS9102 for aerospace, ISO 9001)
• Customer-Specific Requirements: Consider any additional requirements specified by the customer
• Record Keeping: Maintain thorough records of the FAI process for future reference and audits

By following a structured checklist like this, manufacturers can systematically conduct First Article Inspections, ensuring that all aspects of the inspection process are covered and that the final product meets the required specifications and quality standards.

First Article Inspection (FAI) checklist using eAuditor Audits & Inspections can streamline the inspection process, enhance efficiency, and improve accuracy. Here’s a simplified outline of how such a checklist:

1. Pre-Inspection Preparation:

• Document Review
  • Upload and review engineering drawings, specifications, and quality control plans within eAuditor Audits & Inspections.
• Equipment Verification
  • Check calibration status and availability of measurement tools and testing equipment.

2. Identification and Setup:

• Identify First Article
  • Scan or photograph the first article and assign a unique identifier within the eAuditor Audits & Inspections.
• Set Inspection Parameters
  • Input inspection criteria, including critical dimensions, tolerances, and inspection methods.

3. Physical Inspection:

• Visual Inspection
  • Capture images of the first article to document surface finish and identify any visual defects.
• Material Inspection
  • Input material composition analysis results or upload documents/images related to material properties.

4. Functional Testing:

• Conduct Tests
  • Use eAuditor Audits & Inspections to log results of functional tests and operations, including any observed issues or malfunctions.

5. Documentation and Reporting:

• Record Inspection Results
  • Input inspection data directly into the eAuditor Audits & Inspections, with fields for measurements, observations, and non-conformities.
• Generate FAI Report
  • Automatically generate a First Article Inspection Report (FAIR) within the eAuditor Audits & Inspections based on the recorded inspection results.

6. Approval Process:

• Submit for Approval
  • Send the completed FAI report electronically for review and approval by the customer .

7. Post-Approval Actions:

• Implement Corrective Actions
  • Log any identified non-conformities or discrepancies within the eAuditor Audits & Inspections.
• Update Documentation
  • Make any necessary updates to inspection parameters or procedures based on feedback from the FAI process.

Additional Features:

• Customization Options
  • eAuditor Audits & Inspections allows users to customize checklist templates, inspection criteria, and report formats to accommodate specific industry requirements.
• Integration with ERP Systems
  • eAuditor Audits & Inspections can integrate with enterprise resource planning (ERP) systems for seamless data transfer and record-keeping.

By using eAuditor Audits & Inspections  with these features, manufacturers can modernize and streamline their FAI processes, reducing manual paperwork, minimizing errors, and improving overall efficiency.