First article inspection (FAI) is a full, documented check of every design characteristic on a part from a new or changed production process. It proves the process can make the design, and it is done once per part number and revision, or again after a significant change. First piece inspection (FPI) is a shorter check of the first part after each setup, shift start or job change. It proves today’s setup is right before the run continues. FAI qualifies the process; FPI verifies the setup. Aerospace FAI usually follows AS9102; first piece inspection follows your own procedure.
| First article inspection (FAI) | First piece inspection (FPI) | |
|---|---|---|
| Purpose | Prove the production process can make the design | Prove this setup makes a good part before the run |
| Trigger | New part, design change, new process, new location or supplier, long production gap | Every setup, job start, shift change, tool change or restart after a stop |
| Scope | Every characteristic on the drawing and specifications: dimensions, notes, materials, special processes, tests | The characteristics a setup can affect, as listed in the control or inspection plan |
| Frequency | Once per part number and revision, repeated after significant changes | Many times per part number, every time the trigger occurs |
| Standard | AS9102 in aerospace; customer requirements elsewhere | Your own procedure; IATF 16949 requires job set-up verification |
| Record | FAI report with ballooned drawing and characteristic-by-characteristic results | Setup or first-piece checklist signed before release |
| Who | Quality inspector, often with a CMM; may need customer review | Operator or setup technician, checked by inspection |
An FAI verifies everything the drawing and its referenced specifications require, on a part made by the real production process, tooling and people. In aerospace, AS9102 sets out the record in three forms: part number accountability (the part and its sub-assemblies), product accountability (materials, special processes and functional tests, with certificates), and characteristic accountability (each design characteristic with its result). The AS9102 FAI template follows that structure, and the first article inspection guide goes deeper.
A partial or delta FAI covers only what a change affects: a new revision that moves one hole needs the affected characteristics re-verified, not the whole part. AS9102 also calls for a new FAI after a lapse in production; check the current revision and your customer’s requirements for the period.
A first piece inspection is about the setup, not the design. It checks the characteristics a setup can change: offsets, fixture position, program version, tool wear, material lot, and the critical dimensions most likely to move. It must be done and signed before the run continues, and the parts made while waiting for the result should be held until it passes.
Many shops also check the last piece of a run, so that if the last part is bad they know to sort back to the previous good check. The first piece inspection checklist has a header for the reason (new setup, shift, tool change) and a row per characteristic.
FAI tells you the process works. The control plan then says which characteristics to check at setup and during the run, and first piece inspection carries that out every time. Measurement matters for both: a gauge R&R study shows whether the setup gauge can see the tolerance, and positional tolerances are easier to check with the true position calculator. The measurement and inspection guide, the pillar for this cluster, ties the inspection steps together.
Write one procedure for each, or one procedure with two clearly separate sections. For FAI, define the triggers, the record format (AS9102 forms if you supply aerospace), who measures, who approves, and when the customer must review the report. List what counts as a significant change: new revision, new program, new fixture, new machine, new material source, new supplier for a special process, and a move to a new location.
For first piece inspection, define the triggers (setup, shift start, tool change, restart after a crash or a long stop), the characteristics to check for each part, the gauges to use, and the rule for parts made while the result is pending. Put the characteristic list on the first piece inspection checklist for each part number rather than leaving it to memory. Decide what happens when a first piece fails: adjust and re-inspect, and record the number of attempts, because repeated first-piece failures on the same feature are a sign the setup method itself needs work. Those records also feed the CAPA process when a trend appears.
Keep both records together with the job. An auditor or customer tracing a shipped lot should be able to find the FAI that qualified the process at that revision and the first piece record for the setup that made the lot, without searching several systems. File the FAI under the part number and revision, and file first piece records with the work order or router so each lot carries its own evidence.
Example: Inspection load for a fictional bracket: one FAI, then first pieces
Result: Example result: the FAI is a large one-time effort (42 characteristics), while first piece inspections are small but add up to 30 hours a year. That is why first piece checks should be limited to setup-sensitive features and kept fast. All numbers are example values.
Not by name. ISO 9001 requires release of product only after planned verification. AS9100 references first article inspection, and many customers require an AS9102 or similar report.
Another name for first piece inspection: checking the first part made after a setup before the run continues.
It depends on your procedure. Often the operator or setup technician measures, and an inspector or lead verifies and signs before release.
No. A first piece check covers only setup-sensitive characteristics, so it does not show that the process meets every requirement on the drawing.
Usually yes, or at least a partial FAI, because the production process changed. Check AS9102 and your customer’s requirements.
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