First Article Inspection
First Article Inspection (FAI) is a crucial part of quality control in manufacturing, ensuring that the first production piece (or sample) of a batch meets all specified requirements before full-scale production begins.
Let’s Start Work
Together
Please feel free to contact us. We will get back to you with 1-2 business days. Or just call us now.
What is First Article Inspection (FAI)?
FAI involves a detailed inspection and testing of the first item produced in a batch (the “first article”) to verify that it meets the technical drawings, specifications, and standards set by the client. This process ensures that all the manufacturing processes are capable of producing parts that meet the required quality criteria.
FAI typically includes:
Measurement and Inspection of Critical Dimensions
The dimensions and tolerances specified in the design drawings are verified against the first produced part to ensure they align precisely with the intended design.Material Verification
The material used in the production of the first article is inspected to confirm it meets the required material specifications.Appearance and Visual Inspection
The first article undergoes a thorough visual inspection to check for any surface imperfections, markings, or cosmetic flaws that do not meet the design requirements.Functional Testing
If applicable, the first article is subjected to functional testing to confirm that it performs as expected under its intended operating conditions.Verification of Manufacturing Processes
The manufacturing processes, such as machining, welding, assembly, or finishing, are assessed to ensure they are capable of consistently producing parts that conform to the design specifications.Documentation
An FAI report is generated that includes all the measurements, test results, material certifications, and a detailed analysis of the first article. This report is used as a reference throughout the production run to ensure consistency and quality control.
SMS Engineering FAI Process:
At SMS Engineering, we follow a systematic and precise approach to First Article Inspection, ensuring that every first part meets your exacting requirements before moving forward with mass production.
- Detailed Planning: We work closely with you to understand your design and specifications, defining critical inspection points.
- Inspection and Measurement: We employ a combination of manual and advanced inspection tools to measure key dimensions and ensure consistency.
- Report Generation: A comprehensive FAI report is provided, outlining the inspection results, including dimensional analysis, material verification, and functional tests.
- Corrective Actions: In case any issues are found, we work with you to implement corrective actions to ensure that production can proceed smoothly.
When is FAI Required?
New Product Introduction: When launching a new product or component, FAI ensures that the production process is set up to produce high-quality, compliant parts.
Changes to Design or Manufacturing Process: If there are significant design modifications or changes in the manufacturing process, FAI is necessary to confirm that the new process will still meet the required specifications.
Supplier Evaluation: When working with new suppliers, FAI helps to validate their ability to produce quality parts according to your standards.
Regulatory Compliance: In regulated industries, such as aerospace or medical devices, FAI is a critical step to ensure that products meet industry-specific regulations.
Why is First Article Inspection Important?
FAI ensures that the production processes are capable of meeting the design specifications. It confirms that any potential issues can be identified and resolved early, reducing the risk of defects later in the production process.
By catching errors or non-conformance early in the process, FAI helps avoid costly production delays, material wastage, and rework associated with non-compliant parts.
FAI ensures that the first batch of products meets the desired quality standards. This gives confidence to both the manufacturer and the customer that the production process is optimized for quality control.
Many industries, such as aerospace, automotive, and medical devices, require FAI as part of their regulatory compliance. Conducting a thorough FAI process helps ensure adherence to industry standards and regulatory requirements.
Catching and resolving issues during FAI can significantly reduce costs associated with rework, scrap, and shipping delays, ultimately making the production process more efficient.