First Article Inspection (FAI) demonstrates that a part produced using the current revision, material, process and tooling meets the design requirements. Production inspection monitors continuing control. FAI commonly covers every drawing characteristic and traceability item; production frequency follows CTQ, risk and capability. A passed FAI does not eliminate process control.
Values in this article support engineering screening during design review, RFQ and prototyping. They do not replace formal calculations, material data sheets, qualified procedures or contractual standards.
FAI PACKAGE
A ballooned drawing should map one-to-one to results, supported by material/heat certificates, outsourced finish certificate/thickness, process/tool revision, gauge ID/calibration status, nonconformity/deviation approval, photos and functional tests. Use AS9102 format only when contractually required for aerospace; ordinary industrial parts can use a leaner traceable form without importing unnecessary industry cost.
WHEN TO REPEAT
Risk-based full or partial FAI is appropriate for a new part, drawing revision, material/source change, major process/tool change, long production gap, equipment relocation or major corrective action. Production uses first-off, in-process and last-off checks: first-off prevents bad starts, patrol detects drift, last-off confirms the lot endpoint and provides a reference for the next setup.
CAPABILITY AND REACTION
For stable approximately normal CTQs, track Cp/Cpk; Cpk≥1.33 is a common organizational starting point, while safety/regulatory features may require more. Capability indices do not apply to unstable processes and do not replace gauge R&R. The control plan must define stop, quarantine since last good check, reinspection, correction and release responsibility.