First Article Inspection (FAI)
Review the first agreed production configuration before the next release decision. Make the inspected characteristics, supporting records and approval conditions explicit.
Make the first build a documented decision point.
First article inspection checks a defined initial production configuration against specified requirements and records the evidence. Formal 9102-based FAI is a structured verification process developed for aviation, space and defense products; it can also be applied elsewhere when agreed. [S07]
For a PCB or PCBA project, distinguish an ordinary first-piece or first-build review from a contractually required AS9102 package. Tell GlobalWellPCB which deliverable you need, which characteristics it covers and whether written customer approval is a hold point before further production.
Define the article, the evidence and the authority.
This is a proposed planning matrix, not a reproduction of controlled AS9102 forms. Use the customer-mandated forms and agreed standard revision when a formal FAI is required.
Scroll the table horizontally to see all columns.
| Review area | What to evaluate | What to agree |
|---|---|---|
| Article identity | Part number, serial or lot identity and the exact fabrication/assembly configuration. | Confirm whether the article comes from the intended production route. |
| Characteristic list | Dimensions, populated parts, polarity, labels, hardware and other applicable requirements. | Map each agreed characteristic to a drawing, BOM or specification reference. |
| Materials and process evidence | Requested material records, special-process evidence and approved deviations. | Identify records required for the actual contracted scope. |
| Inspection and test results | Actual measurements or accepted evidence for each listed characteristic. | State the method, units, limits and unverified items. |
| Findings and disposition | Nonconformities, missing evidence, corrective actions and approved exceptions. | Keep open items visible; do not present an incomplete review as full approval. |
| Release and repeat review | Authorized sign-off and conditions for reviewing subsequent changes. | Agree hold points and full/partial repeat-review requirements. |
Tell us which features need inspection, your sampling requirements and the reports you need. We will confirm these details in your quotation.
From a clear requirement to a documented decision.
- 01
Agree the FAI scope
Identify the governing document, required forms, characteristic coverage and sample selection. Define review and approval responsibilities before the initial build.
- 02
Build the identified article
Link the article to the intended released files and production route. Record deviations from the planned configuration instead of concealing them.
- 03
Compile the evidence
Record the results, attach the agreed reports and identify any missing or nonconforming characteristics. Make references easy to trace.
- 04
Close or hold the release
Resolve findings and obtain the required approvals. Record whether the next production step is released, conditionally approved or still on hold.
A useful FAI package can be traced both ways.
A reviewer should be able to move from a requirement to its result, and from a result back to the article and configuration that produced it.
- Configuration index
- Part, drawing, BOM, assembly and firmware revisions relevant to the article.
- Characteristic results
- Requirement identifier, nominal value or condition, limits, actual result and verification method.
- Supporting records
- Agreed material, inspection, programming and functional-test records with clear cross-references.
- Review disposition
- Nonconformity references, approved exceptions, signatures where required and release status.
An approved first article is not proof of every later unit.
FAI does not replace ongoing production controls or the required acceptance testing for subsequent lots. It is also not automatically a PPAP submission, design qualification or reliability demonstration. State these as separate deliverables when the customer requires them.
First Article Inspection (FAI) FAQs
Find answers about inspection methods, reports and approvals before placing your order.
Is a first assembled board automatically an AS9102 first article?
No. A first board is a physical item; a formal FAI includes an agreed verification and documentation process. Specify AS9102 applicability and the required package rather than assuming that any first-piece check meets it. [S07]
Must the whole batch wait for customer approval?
Only when the agreed order or quality plan establishes that hold point. Define the point of approval, the evidence to submit and what may proceed while review is open.
Can FAI include functional testing?
Yes, when functional requirements and the corresponding test evidence are included in the scope. Identify the test procedure, firmware, limits and article identity in the record.
When is a repeat FAI needed?
Use the governing standard and customer requirements to evaluate changes to design, materials, source, tooling, process or production conditions. Do not use an invented one-size-fits-all calendar rule.
What if a characteristic fails?
Record it as a finding, apply the authorized disposition and provide any required corrective or reinspection evidence. Keep the article and report status consistent with the unresolved condition.
Can a photograph replace the inspection results?
A photograph may support a visible characteristic, but it cannot replace dimensional measurements or electrical results that the requirement actually calls for. Match the evidence type to the characteristic.
Technical references
Explore the inspection and testing references below. Include the applicable standards, acceptance criteria and required records with your enquiry so we can confirm the inspection plan for your board.