The short answer
FAI is not extra inspection for the sake of paperwork. It is a structured check that the part, process, and documentation agree before you trust repeat production.
What FAI covers
A proper first article inspection confirms the first run matches the drawing, the revision, the material and process specs, and the required records. In aerospace, AS9102-style forms are common. Outside aerospace, the structure may be simpler, but the logic is the same.
The goal is to catch mismatches while they are still cheap.
When to require it
Require FAI on new parts, major revision changes, supplier transfers, process changes that affect form-fit-function, and programs where downstream risk is high. Do not require full FAI on every low-risk repeat lot just to feel safe.
Quality requirements should match consequence, not habit.
What buyers get wrong
They often ask for 'FAI' without saying whether they want dimensional results only, a ballooned print package, material certs, process certs, and special-process evidence, or a named format. Suppliers then guess. Guessing is bad.
Another mistake is requesting FAI after the quote, as if it were free.
A useful FAI requirement
Good requirements state trigger condition, format, sample quantity, and approval expectation. They also say whether the first article must be approved before the production balance ships.
That clarity keeps FAI a control tool instead of a schedule trap.
What an experienced buyer does next
Related reading: CMM inspection explained: what procurement teams need to know.
The right move is usually to define the real functional requirement, remove the decorative requirements, and let the supplier build a route around what actually matters.
Comparison table where relevant
| FAI question | Good practice | Bad practice |
|---|---|---|
| What is included? | State dimensions, certs, and format | Just writing 'FAI required' |
| When is it needed? | New part or meaningful change | Every lot without reason |
| Who approves it? | Defined customer path | No approval rule |
| Does it block shipment? | State yes or no | Leave it ambiguous |
How to specify this in your RFQ
State whether FAI means AS9102-style package, dimensional report only, or a custom format. Include the approval path and whether the balance of the order waits for FAI approval. That prevents the most common first-article argument before it starts.
A clean RFQ does not just list requirements. It separates must-haves from preferences so the supplier can optimize where it is safe.
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