FAI Inspection Checklist: A Comprehensive Guide

  1. Gather the necessary documentation
  2. Use AS9102 forms for the inspection
  3. Balloon the part drawing
  4. Fill out Form 1
  5. Fill out Form 2
  6. Fill out Form 3
  7. Manufacture the part
  8. Inspect the part
  9. Keep track of the measurement results
  10. Create a report
  11. Consider using software
  12. Continuously improve the FAI process

Gather the necessary documentation

Before conducting a First Article Inspection (FAI), it is crucial to gather all the necessary documentation. This includes engineering drawings, digital product definition data sets, bill of materials/raw materials list, specifications, manufacturing planning/routing/traveler/work order, and source/supplier information. These documents provide the necessary information for the inspection process and ensure that the part meets all the required specifications.

Use AS9102 forms for the inspection

AS9102 forms are widely used in the aerospace industry for conducting FAIs. These forms provide a standardized format for documenting the inspection process and ensure consistency across different inspections. The three main forms used in AS9102 are Form 1 (Part Number Accountability), Form 2 (Product Accountability), and Form 3 (Characteristic Accountability).

Balloon the part drawing

One of the essential steps in the FAI process is ballooning the part drawing. Ballooning involves identifying the requirements to be inspected by assigning a unique balloon number to each requirement. This helps in clearly identifying and referencing the inspection requirements throughout the inspection process.

Fill out Form 1

Form 1 is used to document the part number accountability. It includes information from the Bill of Materials and Specifications List, such as the reference location of the balloon requirements, units of measure, variable requirements with tolerances, and classifications. Filling out Form 1 accurately ensures that all the necessary information is captured for the inspection process.

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Fill out Form 2

Form 2 is used to document the product accountability. It includes information about material and process specifications, special processes, and functional testing defined as design requirements. This form ensures that all the necessary information about the product is captured and accounted for during the inspection process.

Fill out Form 3

Form 3 is used to document the characteristic accountability. It includes dimensions, tolerances, notes, and inspection tools required for each characteristic. This form provides a detailed breakdown of the inspection requirements for each characteristic and helps in ensuring that all the necessary measurements are taken during the inspection process.

Manufacture the part

Once all the necessary documentation is gathered and the forms are filled out, the next step is to manufacture the part. During the manufacturing process, it is important to document the processing and inspection results for the requirements. This documentation helps in tracking the progress of the part and ensures that all the necessary steps are followed during the manufacturing process.

Inspect the part

After the part is manufactured, it is time to conduct the actual inspection. The inspection should be carried out according to the inspection plan created in Step 2. It is important to use calibrated and certified inspection tools to ensure accurate measurements. The inspection process should be thorough and cover all the requirements specified in the documentation.

Keep track of the measurement results

During the inspection process, it is crucial to keep track of the measurement results. This includes recording the measured result(s), serial numbers of the tools used, and any non-conformance information. Keeping track of the measurement results helps in maintaining a record of the inspection process and provides valuable data for analysis and future reference.

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Create a report

Once the inspection is complete, it is important to create a report summarizing the findings. This report should include the measurement result data entered into Form 3, any non-conformance information, certificate of conformance, and functional test report. The report should be comprehensive and provide a clear overview of the inspection process and its results.

Consider using software

To simplify the process of preparing for and creating First Article Inspection Reports, it is worth considering the use of software. Software such as InspectionXpert can streamline the inspection process by automating the creation of inspection reports. This reduces the time spent typing and improves accuracy, ensuring that the inspection reports are of high quality and meet the necessary standards.

Continuously improve the FAI process

Finally, it is important to continuously improve the FAI process to ensure that quality parts go out the door. This can be done by analyzing the inspection results, identifying areas for improvement, and implementing corrective actions. Regularly reviewing and refining the FAI process helps in enhancing the overall quality of the parts and ensures that the inspection process is efficient and effective.

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