TEMPLATESSETUP APPROVALFree Excel (.xlsx) download

First Piece Inspection Checklist

An Excel checklist for approving a setup before the run starts. Enter nominal and tolerance; the sheet works out the limits, marks each measurement PASS or FAIL, and returns APPROVED, INCOMPLETE or REJECTED for the first piece.

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Who this template is for

Machine operators, setup technicians and inspectors in machining, fabrication and molding shops, and the quality engineers who define which characteristics a first piece must check.

When to use it

At the start of every new job, and again after a tool change, program edit, fixture change, material lot change or machine repair, before parts are released for the full run.

Standards it supports

ISO 9001:2015 8.5.1 — Production runs under controlled conditions, including monitoring and measurement at suitable stages to confirm outputs meet acceptance criteria.
ISO 9001:2015 8.6 — Release only once planned verification is complete, and keep evidence of conformity and of who authorized release.
ISO 9001:2015 7.1.5.2 — Measuring equipment used for verification must be calibrated and identified, and earlier results reassessed if it is found unfit.
ISO 9001:2015 8.7 — Parts that fail must be identified and controlled to prevent unintended use.
IATF 16949:2016 8.5.1.3 — Requires verification of job set-ups for new runs and changes such as material or job change, first-off/last-off comparison where applicable, and retained records.

How to use this template

Fill the header — record part number, revision, work order, machine, the reason for the first piece, and who ran and inspected it.
List the characteristics — copy the characteristics to check from the drawing or control plan, with nominal and minus and plus tolerance.
Measure and record — measure the first piece with calibrated gauges and enter the value, or OK / NG for attribute checks, with the gauge ID.
Read the decision — any FAIL rejects the piece; adjust the setup and run a new first piece on a fresh sheet.
Release and file — when the decision reads APPROVED, the inspector signs and the run starts. Keep the sheet with the job record.

Tip: Enter the minus tolerance as a positive number (0.10, not −0.10). The sheet subtracts it from nominal to get the lower limit.

What's inside the template

Header

Part number, revision, work order, machine, reason for first piece, operator, inspector and date

Characteristics

Characteristic, nominal and minus/plus tolerance for each check

Limits

Lower and upper limits calculated from nominal and tolerance

Results

Measured value or OK/NG, gauge ID and calculated PASS/FAIL

Decision

Checks completed, failed and outstanding, and APPROVED / INCOMPLETE / REJECTED

Example: a completed template

Example First piece for Example Precision Co., a fictional machine shop, after a program edit on bracket 10-2240 Rev D. Dimensions and readings are invented for illustration.

Header

Part / revision	10-2240 / D
Work order	WO-5512
Machine	CNC cell 3
Reason	Program edit (ECN-2026-041)

First piece #1 (mm)

Characteristic	Nominal	Tol −/+	Limits	Measured	Result
Hole A diameter	6.80	0.10 / 0.10	6.70 – 6.90	6.83	PASS
Overall length	85.00	0.20 / 0.20	84.80 – 85.20	85.12	PASS
Slot width	12.00	0.00 / 0.05	12.00 – 12.05	12.07	FAIL
Thickness	6.35	0.05 / 0.05	6.30 – 6.40	6.33	PASS
Burrs and finish (visual)	—	—	—	OK	PASS
Part marking legible	—	—	—	OK	PASS

Outcome

Decision on piece #1: REJECTED (1 of 6 checks failed).
Slot cutter wear offset adjusted by 0.04 mm; piece #2 run on a new sheet.
Piece #2 slot width 12.03 (within 12.00 – 12.05), all other checks PASS: APPROVED and released.

The math in this Example

Hole A limits: 6.80 − 0.10 and 6.80 + 0.10 = 6.70 to 6.90; 6.83 is inside, so PASS
Slot width upper limit: 12.00 + 0.05 = 12.05; 12.07 is 0.02 over, so FAIL
Overall length limits: 85.00 ± 0.20 = 84.80 to 85.20; 85.12 is inside, so PASS
Piece #2 slot width: 12.07 − 0.04 offset = 12.03, inside 12.00 to 12.05, so PASS

How to fill in each field

Field	What to enter	Example
Reason	Why a first piece is needed: new job, tool change, program edit, fixture change, material lot or after repair.	Program edit (ECN-2026-041)
Characteristic	Each dimension or feature from the drawing or control plan that the setup can affect. Include key attributes such as marking.	Slot width
Nominal	The drawing value in the drawing’s units. Leave blank for attribute checks.	12.00
Tol − / Tol +	Both entered as positive numbers. For a one-sided tolerance, enter 0 on the other side.	0.00 / 0.05
LSL / USL	Calculated limits. Do not type over these cells.	12.00 / 12.05
Measured	The reading for variable checks, or OK / NG for attribute checks.	12.07
Gauge ID	The calibrated gauge used, so the reading can be traced if that gauge is later found out of tolerance.	CAL-031
Result	Calculated PASS or FAIL. CHECK LIMITS means a number was entered for a row with no limits.	FAIL
Decision	APPROVED only when every listed check is complete and none failed.	REJECTED

Common mistakes

Running parts while the first piece is being measured. Hold the machine, or quarantine everything made, until the decision reads APPROVED.
Checking only the easy dimensions. List every characteristic the setup can change, taken from the drawing or control plan, not just what fits on a caliper.
Entering minus tolerance as a negative number. The sheet subtracts it, so −0.10 would raise the lower limit. Enter 0.10.
No gauge ID. Record it on every row. If the gauge later fails calibration, you need to know which approvals relied on it.
Adjusting and re-measuring the same piece. After a FAIL, adjust the setup, run a new piece and record it on a new sheet.
Treating a first piece as a first article. A first piece approves a setup; a first article inspection verifies a new or changed design and process in full. Use the FAI form when that is required.
Throwing the sheet away after release. Keep it with the job record. It is the evidence that the setup was verified.

Frequently asked questions

What is the difference between first piece and first article inspection?

First piece inspection approves a setup at the start of a run or after a change, and is repeated often. First article inspection is a full verification of a new or changed part and process, usually done once per revision and in aerospace documented per AS9102.

When is a new first piece required?

Define it in your procedure. Common triggers are a new job, tool change, program edit, fixture change, new material lot and machine repair.

Which characteristics should be checked?

The ones the setup can affect, normally taken from the control plan or flagged on the drawing. Many shops check all dimensions for a new job and a defined subset after a tool change.

Who should approve the first piece?

Typically someone other than the setup person, such as an inspector or lead, so the approval is an independent check. Your procedure decides.

Should we also check the last piece?

Last-piece checks show the process stayed in tolerance through the run. IATF 16949 mentions first-off and last-off comparison where applicable; add a last-piece column if you use it.

First Piece Inspection Checklist

Who this template is for

When to use it

Standards it supports

How to use this template

What's inside the template

Example: a completed template

Header

First piece #1 (mm)

Outcome

The math in this Example

How to fill in each field

Common mistakes

Frequently asked questions

See also

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