First Article Inspection (FAI): Tudo o que precisa de saber

Industries like aerospace, automobile, electronics, and many more require components for their products that are highly accurate and precise.

They always start with thoroughly testing a sample for a new component before final approval. This process is known as First Article Inspection.

Learn about it in this guide below.

What is the First Article Inspection (FAI)?

First Article Inspection is a process that offers validation of the product. The process helps in testing the first part of the product, which is produced as a sample.

By inspecting this component, it will be confirmed whether the component matches the drawings of the engineer or not.

It is not a matter of just one component, in fact, it is a small batch that has multiple components and all of them are assessed.

However, the size of the order is not fixed and may vary, it may cover around 3 to 5 units which are chosen at random.

The process of the First Article Inspection uses a metrology equipment, which allows for the assessment of the component.

Some of the inspection methods will require using Coordinate Measuring Machining, and some will use gauges and calipers.

Materials are also tested in this process for instance to identify the relevant hardness and if any defects have formed in any part of the component.

This process is opted for testing new orders where the part is manufactured for the first time.

At the end of the First Article Inspection, a report is provided that indicates whether the component is a failure or a success.

Why Is the First Article Inspection Important?

Before placing the products in mass-volume production, it is important to evaluate the first batch.

It helps to ensure that there are no deviations in the product. However, some of the reasons why the First Article Inspection is important are the following:

• To carry out a verification of the documented requirements.
• To have the first article production documented.
• To ensure a high-quality production with consistency.

Who Performs First Article Inspections?

The First Article Inspection is conducted by the part supplier. While the order is placed, the inspection is also agreed upon because it offers quality assurance. The process of FAI can also be outsourced if there is no in-house setup.

The First Article Inspection Process

The first article's inspection process has different steps and each step has its own significance. These steps are given below:

1. Identification of Inspection Needs

The first step is to define what needs to be inspected, this includes the material, dimensions, and performance requirements of the component. In that case, you will have to review the specifications and industry standards in light of customer requirements.

2. Conduct the First Production Run

The process of production includes manufacturing the first batch of production under standard conditions. It consists of using the materials that have been approved and following a standard that is consistent throughout the entire production process in the future as well.

3. Select Samples

Select samples from the first production batch so that these parts can be inspected in detail. You can determine sampling methods based on the volume of production. Usually, random sampling is done.

4. Perform First Article Inspection

Inspect the samples that you have drawn out of the batch and measure them against the specific criteria. You can use the equipment for measuring the dimensions, check the properties of the material, and also assess the performance of the component.

5. Record Measurement Results

You have to document all your findings that you have identified through the process of inspection. This will consist of noting the measurements and deviations if any from the specifications.

6. Prepare the First Article Inspection Report

You will need to compile a report in detail which contains the details of the process of inspection followed by results.

7. Review and Approval

Make sure that the FAI report you have created is meeting all the requirements and submit it for review. You will have to respond to the feedback and also once you have got the formal approval, the full-scale production will be started.

When Should a First Article Inspection be Performed?

In usual circumstances, the main purpose of performing the First Article Inspection is when a part is manufactured for the very first time.

However, there are some cases where the inspection may be required and these are given below.

• A component has an update in its design.
• There is a change in the process of manufacturing or a machine is replaced.
• There is a change in the location of the manufacturer.
• In case when a lot of time has passed between the orders.

First Article Inspection is conducted for the industries where the parts require tight tolerance. These industries include automobile, defense, aerospace, etc.

What Should an Inspection Plan Include?

The inspection plan must contain the following:

• You must indicate the purpose of inspection, which features are required to be examined must be laid down first.
• List down all the requirements that must also have the measuring units and any specifications that may differ based on tolerance.
• Specify the criteria as well which is significant and crucial before the inspection plan ends.

What Happens if a Part Passes or Fails FAI?

The First Article Inspection helps to identify the flaws before the actual manufacturing starts.

Hence, if the product fails in the First Article Inspection, the production will stop and the measures to make corrections will be taken.

These issues may be composed of any difference in colors, flaws in the component or design, or some functional issues.

However, in the case where the part passes the FAI, a further production run would take place producing the bulk volume of parts.

Conclusão

If you are also looking to take advantage of this process for your new parts, you can contact DEK. We provide you with reliable First Article Inspection services, which will help you identify the flaws in your components, if there are any, before you move forward with further manufacturing.

FAQs

What are the differences between FAI and PPAP?

The process of FAI is conducted on the parts that are the first ones or are produced after a change in design. Whereas, PPAP is a comprehensive process in which the evaluation of parts is taken from the entire production run.

How to find a reputable First Article Inspection services provider?

There are various considerations to make for choosing a reputable First Article Inspection service provider. The major factors are expertise, experience, and a reputable name. Someone who has the relevant skills and equipment required for the inspection should be chosen.