First Article Inspection (FAI) is the detailed verification of the first part or batch produced from a new or changed manufacturing process. Every dimension, material property, and special characteristic called out on the engineering drawing is measured and documented. The FAI report provides objective evidence that the production process can produce conforming parts.
In aerospace manufacturing, FAI is formalized by AS9102, which defines the documentation requirements: Form 1 (Part Number Accountability), Form 2 (Product Accountability — materials and special processes), and Form 3 (Characteristic Accountability — every dimension with actual measured values). Automotive uses PPAP with similar intent, and medical device manufacturers perform process validation that includes first article verification.
FAI is triggered not only by new parts but also by changes: new suppliers, process changes, tooling changes, material changes, or production transfers between facilities. Manufacturers that integrate FAI data collection with their CMM and inspection equipment can generate FAI reports semi-automatically, reducing a process that often takes days of manual effort to hours.