Best First Article Inspection Service in China | BSA GROUP

Looking for professional First Article Inspection (FAI) services in China? BSA GROUP provides comprehensive FAI services with accurate, certified inspection reports that ensure your products meet exact specifications from the first production run.

Receive precisely what you request with zero mistakes and no delays through expert First Article Inspection.

First Article Inspection Services at a Glance

• 5,000+ Inspection Projects Completed Successfully
• 4,000+ Satisfied International Clients
• 135 Countries Represented Worldwide
• 100+ Professional Quality Control Inspectors

Critical Issues BSA GROUP Helps You Discover

Incorrect Product Labeling

Eliminate labeling errors on product specifications, serial numbers, part numbers, and balloon drawings. We export all necessary data in standardized Excel reports, saving you significant time and effort while ensuring documentation accuracy.

Common Labeling Issues We Detect:

• Incorrect part numbers or serial numbers
• Mismatched specification labels
• Missing or illegible identification marks
• Non-compliant safety warnings
• Incorrect revision numbers
• Wrong balloon number references

Unsuitable Materials Used

We guarantee thorough inspection of all parts and components according to industry requirements and specifications. Our material verification process ensures your products use only the specified materials that meet the highest standards.

Material Verification Includes:

• Raw material composition analysis
• Material grade verification
• Supplier material certificates review
• Physical properties testing
• Chemical composition verification
• Compliance with material specifications

Wrong Component Placement

We verify that all component positionings strictly follow your design requirements and engineering drawings. Moreover, we ensure components fulfill industry standards including AS9102 (aerospace) and other relevant specifications, making your design vision 100% reality.

Placement Verification:

• Component orientation accuracy
• Assembly sequence validation
• Dimensional positioning checks
• Tolerance compliance verification
• Fit and clearance validation
• Interface alignment confirmation

Product Quality Consistency

We work closely with your manufacturer to ensure even complex parts and assemblies achieve 100% quality consistency from the first article through mass production. Our systematic approach maintains quality standards throughout the entire manufacturing process.

Quality Consistency Monitoring:

• Critical dimension verification
• Surface finish assessment
• Functional performance testing
• Repeatability validation
• Process capability analysis
• Quality trend monitoring

[Contact Our FAI Experts]

Key Advantages of First Article Inspection

Complete Documentation Inspection and Validation

We meticulously check every detail of essential parts, including all associated sub-assemblies and components. Save valuable time and leave the tedious, repetitive inspection work to our experienced professionals.

Comprehensive Documentation Review:

• Engineering drawings with annotations
• Bill of materials (BOM) verification
• Specification sheets validation
• Quality control plans review
• Process flow documentation
• Inspection and test plans

Benefits:

• Catch design errors before mass production
• Verify manufacturing capability
• Ensure complete traceability
• Validate supplier understanding
• Document baseline standards

Establishing the Manufacturing Plan of Record (POR)

We ensure optimal quality control using the latest inspection methodologies and industry best practices. Once the First Article Inspection is complete and approved, we establish your Plan of Record for consistent mass production.

Plan of Record Benefits:

• Documented manufacturing baseline
• Standardized production processes
• Quality benchmarks established
• Future production reference
• Continuous improvement foundation

No need to worry about any future production runs when you have a validated Plan of Record guiding manufacturing.

Significant Cost and Resource Savings

Conducting First Article Inspections ensures quality control when producing initial parts and components, preventing expensive mistakes during mass production.

Cost Savings Through FAI:

• Identify all issues in first production run
• Correct problems before mass production begins
• Avoid scrapping large quantities of defective parts
• Prevent costly production delays
• Reduce rework and repair expenses
• Minimize customer returns and complaints

ROI Example:

• FAI Investment: $500-2,000
• Cost of Defective Production Run: $50,000-500,000+
• Savings: Massive

Expert Consultation and Guidance

We document any problems discovered during the FAI process and provide professional recommendations to improve your drawings, designs, and manufacturing processes.

Expert Services Include:

• Design optimization suggestions
• Manufacturing process improvements
• Material selection guidance
• Tolerance analysis
• Cost reduction opportunities
• Quality enhancement recommendations

Why Partner With BSA GROUP for First Article Inspection?

Extensive Industry Experience

Professional expertise you can trust:

• Over 10 years of First Article Inspection experience
• Thousands of successful FAI projects completed
• Extensive testimonials from satisfied clients
• Comprehensive knowledge of industry standards
• Proven track record across multiple industries

We have solutions to virtually all inspection challenges and follow standardized procedures to meet your specific goals.

Excellence in Customer Support

Your requirements are our first priority:

• Always available for inquiries and support
• Rapid response times (within 24 hours)
• Problems solved promptly with quality solutions
• Dedicated account managers
• Clear communication throughout process
• Proactive issue identification and resolution

Professional Documentation Standards

Detailed, accurate FAI reporting:

• Professional First Article Inspection Reports (FAIR)
• Comprehensive details and drawings included
• Ballooned drawings clearly documented
• AS9102 compliant reports when required
• Digital and physical documentation options
• Easy-to-understand format for all stakeholders

Ballooned drawings and complex documentation are no longer a burden when working with BSA GROUP’s experienced inspection team.

Comprehensive Add-On Services

Beyond First Article Inspection:

If issues are discovered during FAI, we provide complete sourcing and supply chain solutions:

• Alternative supplier identification
• Product sourcing services
• Freight and logistics coordination
• Quality improvement consulting
• Manufacturing process optimization
• Supply chain management support

Get Your Professional First Article Inspection Now!

Partner with BSA GROUP for expert FAI services that protect your production investment.

Client Testimonials – First Article Inspection Services

“I’ve sourced all kinds of products for my company for about a year with BSA GROUP. Their First Article Inspection service is excellent, and their team is professional and trustworthy. I definitely recommend working with them.” – Levi

“I worked with BSA GROUP for 2-3 years to build my brand. They thoroughly inspect each item and handle quality control expertly. I love their FAI service—it saves me significant time. If you’re developing business in China, they’ll help you succeed smoothly.” – Belinda

“Working with BSA GROUP has been very positive. They’re honest and reliable with First Article Inspections. I recommend their services to anyone who needs professional quality control and inspection services from China.” – Julie

The Complete Guide to First Article Inspection (FAI)

Imagine completing an entire mass manufacturing production run, only to discover that every single unit fails to meet your industry standards—the worst tragedy that could happen in manufacturing!

This catastrophic scenario is exactly why First Article Inspection (FAI) is essential before any mass production begins.

BSA GROUP is a quality control company with over 10 years of specialized experience in First Article Inspections. We’re dedicated to helping buyers solve quality control problems, save substantial money, and avoid costly time delays.

In this comprehensive guide, you’ll discover everything you need to know about First Article Inspection:

• What is First Article Inspection (FAI)?
• Why your business needs FAI
• How to conduct an efficient First Article Inspection
• Step-by-step FAI Report creation
• When FAI is required
• What should be included in an inspection plan
• Common FAI challenges and solutions
• Industry standards and compliance

Let’s dive into the world of professional First Article Inspection.

Table of Contents

• What is First Article Inspection?
• Why Your Business Needs First Article Inspection
• How to Conduct an Efficient FAI
• Creating a First Article Inspection Report (FAIR)
• When You Need First Article Inspection
• What to Include in an Inspection Plan
• FAI Standards and Compliance
• First Article Inspection Process Flow
• Common FAI Mistakes to Avoid
• FAI Frequently Asked Questions

What is First Article Inspection (FAI)?

First Article Inspection (FAI) is a formal, comprehensive verification process used to examine and validate that a manufacturer can produce parts or assemblies that meet all specified requirements before mass production begins.

FAI Definition and Purpose

Core Purpose: FAI is a thorough examination with stringent verification protocols applied to your production process, ensuring consistent manufacturing of components that meet correct specifications.

Inspection Scope: FAI encompasses the complete manufacturing chain:

1. Raw materials – Verification of material specifications
2. Conversion processes – Manufacturing method validation
3. Special processing – Heat treatment, coating, plating verification
4. Functional testing – Performance and functionality validation
5. Dimensional inspection – Complete measurement verification
6. Documentation review – Traceability and compliance confirmation

FAI Sampling Methodology

Standard Practice: Three to five random samples from the first production run are thoroughly inspected to ensure all requirements are met. This sampling provides statistical confidence while maintaining practical efficiency.

Sample Selection:

• Random selection from initial production batch
• Represents true manufacturing capability
• Includes all critical characteristics
• Tests manufacturing consistency
• Validates process repeatability

FAI vs. Other Inspections

How FAI Differs:

FAI is the most thorough inspection, examining 100% of specifications and characteristics rather than sampling-based verification.

Why Does Your Business Need First Article Inspection?

First Article Inspections are commonly required in aerospace, defense, automotive, medical devices, and other industries with strict quality requirements. Let’s explore why FAI is critical for business success.

The Aerospace Industry Example

Scenario:

Imagine securing a contract to produce engine components for a commercial airline—a significant business opportunity with substantial revenue potential.

You sign the contract promising:

• Timely delivery
• Full specification compliance
• Quality assurance
• Regulatory compliance

But you skip First Article Inspection…

The Costly Result:

After beginning mass production of 10,000 units, you discover:

• Critical dimensions are out of specification
• Material hardness doesn’t meet requirements
• Surface finish fails aerospace standards
• Components don’t pass functional testing

Consequences:

• ❌ All 10,000 defective components must be scrapped or reworked
• ❌ Manufacturing schedule severely delayed
• ❌ Raw materials wasted
• ❌ Labor hours lost
• ❌ Customer relationship damaged
• ❌ Contract penalties incurred
• ❌ Revenue lost to competitors
• ❌ Company reputation harmed

Financial Impact:

• Production costs wasted: $200,000+
• Rework/replacement costs: $150,000+
• Delay penalties: $50,000+
• Lost future business: Incalculable
• Total loss: $400,000+ for skipping a $2,000 FAI

Why FAI is Essential

An accurate First Article Inspection Report helps you:

1. Detect Errors Early

• Find problems when corrections are cheapest
• Identify design issues before tooling
• Catch material specification errors
• Discover manufacturing process flaws

2. Prevent Wrong Specifications

• Verify all dimensions and tolerances
• Confirm material properties
• Validate functional performance
• Ensure regulatory compliance

3. Save Time, Money, and Resources

• Avoid mass production of defective parts
• Prevent expensive scrapping
• Eliminate costly rework
• Reduce time-to-market delays

Supply Chain Impact

Repairing and replacement needs time, and customers suffer most from delays.

Supply Chain Risks Without FAI:

• Production delays cascade to customers
• Inventory shortages impact sales
• Delivery commitments missed
• Customer contracts jeopardized
• Business relationships damaged

Any supply chain disruption leads to business losses that far exceed FAI costs.

You can save your business from the most expensive mistakes by investing in professional First Article Inspection before mass production.

Industry Requirements

Many industries REQUIRE First Article Inspection:

Aerospace & Defense:

• AS9102 standard compliance mandatory
• FAA/EASA certification requirements
• NADCAP accreditation
• Government contract requirements

Automotive:

• PPAP (Production Part Approval Process)
• IATF 16949 requirements
• OEM specifications
• Tier supplier mandates

Medical Devices:

• FDA 21 CFR Part 820 compliance
• ISO 13485 requirements
• Design control verification
• Process validation documentation

Electronics:

• IPC standards compliance
• UL/CE certification requirements
• Customer quality agreements

Inspection, Supplier Audit, Product Testing in China & Asia

BSA GROUP, as a professional China sourcing agent, focuses exclusively on quality control excellence. Today, hundreds of international clients worldwide have selected BSA GROUP as their trusted partner for supply chain quality management and First Article Inspection services.

How to Conduct an Efficient First Article Inspection

Familiarizing yourself with the FAI process flow is the key to successful implementation. Here’s the complete procedure before mass production:

Phase 1: Supplier Selection

Critical First Step:

Research and choose your ideal supplier based on:

• Manufacturing capabilities
• Quality control systems
• Industry certifications
• Past performance record
• Technical expertise
• Production capacity
• Cost competitiveness

BSA GROUP Services:

• Supplier identification and vetting
• Factory capability assessments
• Quality system audits
• Technical capability verification

Phase 2: Pre-Production Planning

Preparation Stage:

Your first production batch begins manufacturing after:

• Design finalization
• Material procurement
• Tooling completion
• Process planning
• Quality plan approval
• Operator training

Key Activities:

• Review engineering drawings
• Verify material specifications
• Confirm manufacturing processes
• Establish inspection checkpoints
• Prepare measurement equipment
• Train inspection personnel

Phase 3: First Article Inspection Execution

Comprehensive Verification:

Conduct thorough functional testing and dimensional inspection:

Inspection Activities:

• Dimensional measurement (100% of characteristics)
• Material verification
• Functional performance testing
• Visual inspection
• Surface finish evaluation
• Assembly verification
• Documentation review

Quality Criteria:

• Compare to engineering drawings
• Verify against specifications
• Check industry standards compliance
• Validate customer requirements

Phase 4: First Article Inspection Report Summary

Documentation Stage:

List all specifications and inspection results in formal FAI Report:

Report Contents:

• Part identification information
• Material verification results
• Dimensional measurement data
• Functional test outcomes
• Non-conformance documentation
• Corrective action plans
• Approval signatures

Phase 5: Corrective Action (If Required)

Problem Resolution:

If functional tests reveal issues or materials don’t comply with design characteristics:

Corrective Actions Required:

1. Manufacturer reviews all findings
2. Root cause analysis performed
3. Corrective measures implemented
4. Process adjustments made
5. Tooling modifications completed
6. Re-inspection scheduled

Re-Inspection Process:

• Address all non-conformances
• Verify corrections effective
• Conduct new FAI
• Document improvements
• Obtain final approval

Goal: Meet all design characteristics and standards before mass production authorization.

Best Practices for Efficient FAI

Tips for Success:

1. Standardize Your Inspection Process

• Use consistent checklists
• Follow industry standards (AS9102, PPAP)
• Maintain standard procedures
• Document best practices
• Train inspectors consistently

2. Avoid Manual Data Entry Errors

• Use digital measurement tools
• Implement automated data collection
• Utilize inspection software
• Reduce transcription mistakes
• Improve data accuracy

3. Leverage Mobile Assessment Apps

• Real-time data capture
• Photo documentation capability
• Cloud-based storage
• Instant report generation
• Remote collaboration tools

4. Determine Optimal Inspection Frequency

• Risk-based approach
• Critical characteristics focus
• Process capability consideration
• Statistical sampling when appropriate
• Full inspection for first articles

BSA GROUP’s FAI Expertise

Our experienced team guides you through:

• Complete FAI process management
• Supplier coordination
• Technical consultation
• Documentation preparation
• Report generation
• Approval facilitation

In my professional experience, your sourcing company should guide you through these processes seamlessly. BSA GROUP provides expert guidance at every stage, ensuring efficient First Article Inspection execution.

Simple Steps to Create a First Article Inspection Report (FAIR)

Creating a comprehensive, compliant First Article Inspection Report follows a systematic five-step process:

Step 1: Pre-Plan Your FAI

Collect Required Documentation:

Before starting the First Article Inspection, gather all necessary documentation:

Engineering Drawings

• Complete technical drawings with dimensions
• Drawing notes and specifications
• Revision history and dates
• Geometric dimensioning and tolerancing (GD&T)
• Surface finish requirements

Balloon Drawings

• Ballooned engineering drawings showing each characteristic
• Numbered reference points
• Clear characteristic identification
• Traceability to Form 3 data

Digital Product Definition (DPD)

• CAD models and files
• 3D drawings
• Model-based definition (MBD)
• PMI (Product Manufacturing Information)

Material Documentation

• Raw materials specifications
• Material certificates
• Heat treatment requirements
• Special processing specifications
• Material test reports

Manufacturing Process Planning

• Process flow diagrams
• Manufacturing instructions
• Tooling requirements
• Equipment specifications
• Quality control plans

Supplier Information

• Supplier contact details
• Facility location
• Certifications held
• Quality system information
• Previous performance data

Pre-Planning Benefits:

All documentation and pre-planning significantly improves decision-making quality. The FAI process becomes easier and smoother when you have all details organized beforehand.

Documentation Checklist:

• ☐ Engineering drawings (latest revision)
• ☐ Balloon drawings prepared
• ☐ Material specifications
• ☐ Process plans
• ☐ Inspection equipment list
• ☐ Customer requirements
• ☐ Industry standards references
• ☐ Previous FAI reports (if applicable)

Step 2: Create an Inspection Plan

Complete the three forms required for First Article Inspection Report (FAIR):

These forms follow AS9102 standard (aerospace) or similar industry-specific formats:

Form 1 – Part Number Accountability

Purpose: Identifies the part and documents organizational responsibility.

Required Information:

• Part number and revision
• Part name/description
• Manufacturer name and code
• Purchase order number
• Quantity inspected
• Manufacturing process
• Organization details
• Approval signatures

Key Fields:

• Drawing number and revision
• Organization information
• Manufacturing location
• Dates and personnel

Form 2 – Product Accountability

Purpose: Documents the manufacturing process and special processes.

Required Information:

• Manufacturing process flow
• Special processes (heat treat, plating, coating)
• Sub-tier suppliers
• Functional testing performed
• Inspection equipment used
• Certifications and qualifications

Details Captured:

• Process sequence
• Equipment identification
• Personnel qualifications
• Sub-supplier information
• Test equipment calibration

Form 3 – Characteristic Accountability

Purpose: Documents detailed dimensional and functional inspection results.

Required Information:

• Characteristic number (from balloon drawing)
• Characteristic description
• Specification requirement
• Actual measurement results
• Inspection method used
• Results (Pass/Fail)
• Non-conformance documentation

Data Elements:

• Each characteristic from drawing
• Measurement data
• Statistical analysis (if required)
• Non-conformance details
• Corrective actions

Step 3: Manufacturing

Document Production Process:

Ensure comprehensive recording of processing and inspection outcomes:

Manufacturing Documentation:

• Production start date/time
• Machine and equipment used
• Operator identification
• Process parameters (temperature, pressure, speed)
• Material lot numbers
• Tool identification numbers
• Setup verification records

Handmade Products: Details become more sensitive regarding craftsmanship:

• Artisan/craftsman identification
• Techniques employed
• Quality control checkpoints
• Visual inspection criteria
• Skill level verification

Process Control:

• In-process measurements
• Statistical process control (SPC)
• First-piece inspection results
• Process adjustments documented
• Quality alerts recorded

Step 4: Collect Measurement Data

Comprehensive Inspection Execution:

Examine the part following the inspection plan created in Step 2.

Measurement Requirements:

Dimensional Inspection:

• Measure 100% of characteristics on balloon drawing
• Use calibrated inspection equipment
• Record actual measurements
• Calculate tolerances
• Document method used

Functional Testing:

• Perform all specified functional tests
• Record test results
• Document test equipment used
• Verify performance criteria
• Note any deviations

Visual Inspection:

• Surface finish verification
• Cosmetic quality assessment
• Marking and labeling check
• Color verification (if applicable)
• Overall workmanship evaluation

Equipment Traceability:

Keep track of all certified inspection tools:

• Equipment identification numbers
• Calibration certificates
• Calibration due dates
• Measurement uncertainty
• Traceability to standards

Reference for Responsible Personnel: Document which equipment was used for each measurement so the person in charge can verify traceability and accuracy.

Step 5: Create the FAI Report

Data Entry and Report Generation:

Enter your measurement result data into Form 3 and complete all documentation:

Report Compilation:

Form 1 Completion:

• Fill in all part identification fields
• Obtain required signatures
• Document approval dates
• Include organization stamps

Form 2 Completion:

• Detail manufacturing processes
• List all special processes
• Document sub-tier suppliers
• Identify inspection equipment
• Include certifications

Form 3 Completion:

• Enter all measurement data
• Document pass/fail for each characteristic
• Note any non-conformances
• Attach supporting documentation
• Include corrective actions

Supporting Documentation:

Attach all relevant supporting materials:

• Material certificates
• Heat treatment reports
• Plating/coating certifications
• Functional test results
• Calibration certificates
• Sub-supplier documentation
• Non-conformance reports
• Corrective action plans
• Photos of critical features

Review and Approval:

Internal Review:

• Quality manager review
• Engineering review
• Manufacturing review
• Completeness verification

Customer Submission:

• Submit complete FAI package
• Provide electronic and/or hard copies
• Include all supporting documentation
• Await customer approval

Approval Process:

• Customer reviews submission
• May request additional information
• Provides approval or rejection
• Documents approved baseline

BSA GROUP’s FAI Report Services

Professional FAIR Creation:

BSA GROUP provides complete First Article Inspection Report preparation services:

• Expert data collection
• Professional report formatting
• AS9102 compliant documentation
• Industry-specific standards followed
• Quality review before submission
• Customer coordination support

Benefits:

• Ensures report completeness
• Meets industry standards
• Reduces rejection risk
• Saves significant time
• Professional presentation

When Do You Need a First Article Inspection?

Understanding when FAI is required ensures compliance with customer requirements and industry standards.

Two Types of First Article Inspection

First Article Inspections are required when introducing new products or making significant changes:

1. Full FAI (Complete First Article Inspection)

Definition: Comprehensive inspection of all characteristics and requirements for the first production run of a new part.

Required When:

• Brand new component introduced
• New part number created
• First time manufacturing this design
• No previous FAI exists
• Customer requires full baseline

Inspection Scope:

• 100% of characteristics inspected
• All three FAIR forms completed
• Complete supporting documentation
• Full traceability established
• Comprehensive testing performed

2. Partial FAI (Focused First Article Inspection)

Definition: Targeted inspection focusing on specific changes that affect the product’s form, fit, or function.

Scope Difference: In Partial FAI, the inspection focuses on the previous or latest change and its related impacts. The inspector tests all functions affected by that specific change rather than re-inspecting unchanged characteristics.

Required When:

• Design modifications made
• Process changes implemented
• Tooling revised
• Material source changed
• Manufacturing location moved

When to Conduct Full FAI

Full First Article Inspection is required when one or more of the following occurs:

1. New Component Introduction

• Part never manufactured before
• New design released
• Initial production setup
• First article baseline needed

Why: Establishes complete manufacturing baseline and validates all specifications.

2. Manufacturing Source Change

• Different factory location
• New supplier selected
• Production line moved
• Manufacturing transferred

Why: New location must prove capability to meet all specifications.

3. Material Source Change

• Raw material supplier changed
• Material specification modified
• Alternative material substituted
• Material grade changed

Why: Different materials may affect dimensions, properties, and performance.

4. Extended Production Gap

• Production resumed after long shutdown
• Typically after 2+ years dormant
• Tooling may have degraded
• Personnel may have changed

Why: Verifies continued manufacturing capability after extended periods.

5. Design Engineering Change

• Significant design modifications
• Drawing revision changes specifications
• New features added
• Critical dimensions altered

Why: Validates manufacturer can produce updated design.

6. Manufacturing Process Change

• Production method modified
• New equipment introduced
• Process parameters changed
• Manufacturing sequence altered

Why: Process changes may affect product characteristics.

7. Customer Request

• Customer requires FAI
• Contract specifies FAI requirement
• Quality agreement mandates FAI
• Industry regulation requires FAI

Why: Customer/regulatory compliance obligation.

When to Conduct Partial FAI

Partial First Article Inspection is required when one or more of the following occurs:

1. Design Modification Affecting Form, Fit, or Function

• Dimension changes
• Tolerance revisions
• Feature modifications
• Interface changes

Inspection Focus: Changed characteristics and related features only.

2. Manufacturing Process Modification

• Process parameter changes
• Equipment settings adjusted
• Tooling modifications
• Sequence changes

Inspection Focus: Characteristics potentially affected by process change.

3. Media Program Changes

• CNC program revisions
• Programming software updates
• CAM changes
• Control system modifications

Inspection Focus: Features controlled by changed programs.

4. Minor Material Changes

• Material grade slight variation
• Supplier change within same specification
• Heat treatment modification

Inspection Focus: Properties and characteristics affected by material change.

FAI Trigger Decision Matrix

Use this decision tree to determine FAI requirement:

START
│
├─ Is this a brand new part? → YES → Full FAI Required
│                          → NO → Continue
│
├─ Has production been idle 2+ years? → YES → Full FAI Required
│                                    → NO → Continue
│
├─ Did manufacturing location change? → YES → Full FAI Required
│                                    → NO → Continue
│
├─ Did material source change? → YES → Full FAI Required
│                              → NO → Continue
│
├─ Were design changes made? → YES → Evaluate significance
│                           → NO → Continue      │
│                                                ├─ Major change → Full FAI
│                                                └─ Minor change → Partial FAI
│
└─ Did process/tooling change? → YES → Partial FAI Required
                               → NO → No FAI needed (routine production)

What Should Be Included in an Inspection Plan?

A comprehensive First Article Inspection plan ensures thorough, organized verification. Here are the essential elements:

1. Use an Appropriate Inspection Form Template

Select Suitable Template:

Choose or create a template that suits your project and industry:

Standard Templates Available:

• AS9102 forms (aerospace and defense)
• PPAP forms (automotive)
• ISO 13485 formats (medical devices)
• Custom industry-specific formats

Template Requirements:

• Must include all details that matter to you
• Quality verification sections
• Specific feature measurement fields
• Pass/fail determination criteria
• Non-conformance documentation areas
• Signature and approval blocks

2. List All Task Inspections

Comprehensive Inspection Checklist:

Fill out your form by listing all inspection tasks in sequence:

Dimensional Inspections:

• Every dimension on drawing
• Critical characteristics highlighted
• Tolerance requirements noted
• Measurement method specified

Functional Tests:

• Performance tests required
• Test procedures referenced
• Acceptance criteria defined
• Test equipment specified

Visual Inspections:

• Appearance standards
• Surface finish requirements
• Marking and labeling checks
• Workmanship criteria

Special Inspections:

• Non-destructive testing (NDT)
• Material verification
• Chemical/physical testing
• Environmental testing

3. Include All Reference Documents

Essential Documentation:

Having comprehensive documentation ensures a smooth and efficient FAI process:

Production Part Approval Process (PPAP) Documentation

• Design records
• Engineering change documents
• Design FMEA
• Process flow diagrams
• Process FMEA
• Control plans

Contract Requirements

• Customer purchase order
• Quality requirements
• Delivery specifications
• Packaging requirements
• Regulatory compliance needs

FAIR Forms

• Form 1 – Part Number Accountability
  • Part identification
  • Organization information
  • Manufacturing process overview
• Form 2 – Product Accountability
  • Detailed process information
  • Special process certifications
  • Sub-tier supplier documentation
  • Inspection equipment list
• Form 3 – Characteristic Accountability
  • Individual characteristic data
  • Measurement results
  • Non-conformance documentation
  • Corrective actions

Supporting Technical Documents

• Engineering drawings (latest revision)
• Specifications and standards
• Material certifications
• Test procedures
• Calibration certificates
• Quality manual references

4. Define Inspection Responsibilities

Clear Role Assignment:

Clarify who is responsible for specific inspection activities and documentation:

Responsibility Matrix:

Supplier Responsibilities:

• Manufacturing the first article
• Conducting dimensional inspection
• Performing functional tests
• Preparing FAIR documentation
• Providing material certificates
• Obtaining special process certifications
• Submitting complete FAI package

Buyer/Customer Responsibilities:

• Providing clear specifications
• Supplying current drawings
• Defining acceptance criteria
• Reviewing FAI submissions
• Providing timely feedback
• Approving or rejecting FAIR

Third-Party Inspector Responsibilities (BSA GROUP):

• Independent verification inspection
• Objective measurement validation
• Documentation review and verification
• Unbiased reporting
• Technical consultation
• Facilitating communication

Terms of Engagement: Discuss and agree upon responsibilities with all parties before documenting them in the inspection plan. Clear communication prevents confusion and delays.

5. Display Times and Dates of Inspections

Timeline Management:

Document inspection schedule to keep manufacturing on track:

Key Dates to Include:

Planning Phase:

• Inspection plan creation date
• Drawing release date
• Manufacturing start date

Execution Phase:

• Scheduled inspection date
• Actual inspection date
• Re-inspection dates (if applicable)

Reporting Phase:

• Report completion date
• Submission date to customer
• Customer review deadline
• Approval/rejection date

Follow-Up Actions:

• Corrective action due dates
• Re-inspection scheduled dates
• Mass production authorization date

Timeline Benefits:

• Maintains accountability
• Tracks manufacturing progress
• Identifies delays early
• Enables proactive problem-solving
• Supports on-time delivery
• Documents historical timeline

6. Establish Acceptance Criteria

Clear Pass/Fail Standards:

Define specific criteria for accepting or rejecting the first article:

Dimensional Criteria:

• All dimensions within tolerance
• Critical characteristics 100% compliant
• GD&T requirements met
• Form, fit, function verified

Material Criteria:

• Material certificates provided
• Correct material grade confirmed
• Heat treatment requirements met
• Chemical/physical properties verified

Functional Criteria:

• All performance tests passed
• Operating parameters within limits
• Safety requirements met
• Reliability demonstrated

Documentation Criteria:

• All forms completed
• Supporting documents attached
• Traceability established
• Signatures obtained

7. Define Non-Conformance Handling

Problem Resolution Process:

Establish procedures for addressing non-conformances:

Documentation Requirements:

• Non-conformance description
• Root cause analysis
• Corrective action plan
• Implementation timeline
• Verification method

Approval Authority:

• Who can authorize deviations
• Disposition options (use-as-is, rework, scrap)
• Customer notification requirements
• Re-inspection requirements

FAI Standards and Compliance

Understanding applicable standards ensures your First Article Inspection meets industry and customer requirements.

AS9102 Standard (Aerospace)

Industry Standard for Aerospace FAI:

AS9102 Requirements:

• Three-form documentation (FAIR)
• 100% characteristic verification
• Ballooned drawings required
• Complete traceability
• Approved special processes
• Statistical analysis when specified

Compliance Benefits:

• Industry acceptance
• Customer approval facilitation
• Reduced audit risk
• Professional credibility

PPAP (Automotive)

Production Part Approval Process:

PPAP Elements:

• FAI is one component of PPAP
• Design records required
• Process flow documentation
• FMEA completion
• Control plan development
• Measurement system analysis
• Initial process capability study

PPAP Levels:

• Level 1: Warrant only
• Level 2: Warrant + limited supporting data
• Level 3: Warrant + complete supporting data (most common)
• Level 4: Warrant + supporting data + witness
• Level 5: Warrant + supporting data + on-site review

ISO 13485 (Medical Devices)

Medical Device Quality Requirements:

FAI Elements:

• Design verification
• Process validation
• Traceability establishment
• Risk management documentation
• Sterilization validation (when applicable)
• Biocompatibility verification

Industry-Specific Requirements

Electronics (IPC Standards):

• IPC-A-610 (Acceptability of Electronic Assemblies)
• IPC-6012 (Rigid Printed Boards)
• Visual inspection criteria
• Electrical testing requirements

Defense (MIL Standards):

• MIL-STD requirements
• Government source inspection
• First article testing (FAT)
• Qualification testing

Common First Article Inspection Mistakes to Avoid

Learn from common errors to ensure successful FAI execution:

Mistake 1: Incomplete Documentation

Problem: Missing forms, certificates, or supporting documents.

Solution:

• Use comprehensive checklist
• Review before submission
• Verify completeness
• Include all attachments

Mistake 2: Using Outdated Drawings

Problem: Inspecting to superseded revision.

Solution:

• Confirm latest revision
• Check engineering change notices
• Verify drawing date
• Update documentation

Mistake 3: Inadequate Measurement Uncertainty

Problem: Inspection equipment not capable of required accuracy.

Solution:

• Verify equipment capability
• Ensure 10:1 measurement ratio (preferred)
• Use appropriate instruments
• Document measurement uncertainty

Mistake 4: Missing Calibration Certificates

Problem: Inspection equipment calibration not verified.

Solution:

• Maintain calibration system
• Include calibration certificates
• Verify calibration current
• Document traceability

Mistake 5: Insufficient Sampling

Problem: Inspecting only one sample when multiple required.

Solution:

• Follow industry standards (typically 3-5 samples)
• Customer requirements drive quantity
• Document sample selection method
• Inspect sufficient quantity

Mistake 6: Poor Communication

Problem: Unclear expectations between parties.

Solution:

• Pre-FAI kickoff meeting
• Clear requirement documentation
• Regular status updates
• Prompt issue escalation

Looking for a Reliable Chinese Supplier?

BSA GROUP, as a professional China sourcing agent, helps you:

✓ Find qualified factories and manufacturers
✓ Negotiate competitive prices
✓ Monitor production progress
✓ Conduct professional First Article Inspections
✓ Ensure consistent quality
✓ Deliver products to your door

Frequently Asked Questions About First Article Inspection

1. Who is responsible for the First Article Inspection?

Primary Responsibility:

Typically, the supplier/manufacturer is responsible for conducting the First Article Inspection and providing concrete evidence of compliance.

Supplier Responsibilities:

• Perform dimensional inspection
• Conduct functional testing
• Complete FAIR documentation
• Gather supporting certificates
• Submit FAI package for approval

Quality Evidence Required:

• Measurement data
• Test results
• Material certificates
• Process certifications
• Calibration documents
• Traceability records

Third-Party Verification Options:

You can also choose independent third-party organizations (like BSA GROUP) to perform verification inspection:

Benefits of Third-Party FAI:

• Objective, unbiased verification
• Expert inspection capability
• Customer confidence increased
• Reduced supplier bias
• Professional reporting
• Independent quality assurance

BSA GROUP Third-Party FAI Services:

• Independent verification inspection
• Complete documentation review
• Measurement validation
• Professional FAIR preparation
• Objective reporting
• Customer advocacy

Collaborative Approach:

Best Practice: Supplier conducts FAI, third-party verifies

• Supplier performs initial inspection
• BSA GROUP validates measurements
• Both parties review documentation
• Complete transparency maintained
• Higher confidence level achieved

2. What are FAI samples?

Definition and Purpose:

Products or parts selected as FAI samples are also called approval samples, golden samples, or master samples. These are carefully selected, flawlessly crafted units produced before mass production authorization.

Characteristics of FAI Samples:

Perfect Quality:

• Manufactured to exact specifications
• No defects or non-conformances
• Representative of ideal production
• Meet all quality requirements
• Pass all functional tests

Documentation:

• Complete inspection records
• Full traceability
• Measurement data recorded
• Test results documented
• Approved by customer

Purpose:

• Establish quality baseline
• Reference standard for production
• Comparison benchmark for future units
• Training reference for operators
• Audit reference sample

How FAI Samples Are Used:

During Inspection:

• Inspector measures FAI samples completely
• Compares to engineering specifications
• Documents all characteristics
• Verifies compliance

During Production:

• Production units compared to approved samples
• Golden sample serves as visual reference
• Operators understand quality expectations
• Quality inspectors use for comparison
• Maintains consistency

Long-Term Reference:

• Stored securely for future reference
• Used during audits
• Referenced for clarification
• Comparison for repeat orders
• Historical quality record

Sample Quantity:

Typical Requirements:

• Aerospace: 3-5 samples typical
• Automotive: Per PPAP requirements (often 3-5)
• Medical devices: Customer specified
• Electronics: 3-10 samples depending on complexity

Sample Retention:

Storage Requirements:

• Secure storage location
• Controlled environment
• Clear identification labels
• Traceability maintained
• Access controlled

Retention Period:

• Throughout production lifetime
• Customer-specified duration
• Regulatory requirements
• Typically minimum 3-5 years

3. What is the difference between PPAP and FAI?

Understanding the relationship between Production Part Approval Process (PPAP) and First Article Inspection (FAI):

PPAP (Production Part Approval Process)

Definition: PPAP is a comprehensive quality process used primarily in the automotive industry to demonstrate that a supplier can consistently meet all customer requirements.

Scope: PPAP is much broader than FAI and includes multiple elements:

PPAP Elements (18 Total):

1. Design Records
2. Engineering Change Documents
3. Customer Engineering Approval
4. Design FMEA (Failure Mode Effects Analysis)
5. Process Flow Diagrams
6. Process FMEA
7. Control Plan
8. Measurement System Analysis (MSA)
9. Dimensional Results
10. Material/Performance Test Results
11. Initial Process Studies
12. Qualified Laboratory Documentation
13. Appearance Approval Report (AAR)
14. Sample Production Parts
15. Master Sample
16. Checking Aids
17. Customer-Specific Requirements
18. Part Submission Warrant (PSW)

Sample Quantity:

• Requires hundreds to thousands of production parts
• Statistical sample size
• Capability studies (Cpk analysis)
• Production run verification

FAI (First Article Inspection)

Definition: FAI is a detailed inspection process verifying that manufactured parts meet all engineering specifications.

Scope: FAI focuses specifically on inspection and verification:

FAI Requirements:

• Inspection of individual characteristics
• Typically 3-5 sample parts
• Three-form documentation (FAIR):
  • Form 1: Part Number Accountability
  • Form 2: Product Accountability
  • Form 3: Characteristic Accountability

Focus:

• Dimensional verification
• Material confirmation
• Functional testing
• Characteristic accountability

Key Differences Summary

Relationship Between FAI and PPAP

FAI is PART of PPAP:

In automotive PPAP:

• Element #9 (Dimensional Results) includes FAI-type inspection
• Element #10 (Material/Performance Test Results) similar to FAI testing
• Element #14 (Sample Production Parts) are like FAI samples

Key Distinction:

• FAI can stand alone as an inspection method
• PPAP always includes FAI-like inspection plus much more
• PPAP is a complete approval process
• FAI is an inspection methodology

When to Use Each

Use FAI When:

• Aerospace/defense customer requirements
• AS9102 compliance needed
• Verifying manufacturing capability
• Simple inspection documentation required
• Quick approval needed

Use PPAP When:

• Automotive customer requirements
• IATF 16949 compliance needed
• Complete process approval required
• Statistical validation needed
• Comprehensive documentation required

BSA GROUP Expertise:

We provide both FAI and PPAP services:

• AS9102 compliant FAI reports
• Complete PPAP submissions
• Industry-specific expertise
• Professional documentation
• Customer approval facilitation

4. How long does a First Article Inspection take?

Timeline varies based on product complexity and inspection scope:

Standard FAI Duration

Simple Parts (Mechanical, Low Complexity):

• Inspection time: 4-8 hours
• Report preparation: 4-8 hours
• Total turnaround: 1-2 business days

Moderate Complexity Parts:

• Inspection time: 1-2 days
• Report preparation: 1 day
• Total turnaround: 2-3 business days

Complex Parts (Aerospace, Medical):

• Inspection time: 2-5 days
• Report preparation: 1-2 days
• Total turnaround: 3-7 business days

Assemblies with Multiple Components:

• Inspection time: 3-10 days
• Report preparation: 2-3 days
• Total turnaround: 1-2 weeks

Factors Affecting Timeline

1. Product Complexity:

• Number of characteristics to inspect
• Technical measurement difficulty
• Functional testing requirements
• Documentation complexity

2. Special Testing Requirements:

• Material testing (lab analysis)
• Environmental testing
• Life cycle testing
• Performance validation

3. Documentation Completeness:

• Drawing clarity
• Specification availability
• Prior documentation existence

4. Equipment Availability:

• Specialized measurement equipment
• CMM (Coordinate Measuring Machine) access
• Test equipment availability
• Calibrated instruments ready

5. Supplier Cooperation:

• Sample availability
• Information provision
• Access to manufacturing area
• Technical support

BSA GROUP Timeline Commitment

Standard Service:

• Simple parts: 2-3 days
• Complex parts: 5-7 days
• Very complex: 7-14 days

Rush Service Available:

• Priority scheduling
• Expedited reporting
• Additional fees apply
• 50% time reduction typical

5. How much does professional First Article Inspection cost?

BSA GROUP’s transparent FAI pricing:

Standard FAI Inspection Fees

Basic Mechanical Parts:

• Simple parts (< 20 characteristics): $300-500
• Moderate complexity (20-50 characteristics): $500-800
• Complex parts (50-100 characteristics): $800-1,200
• Very complex (100+ characteristics): $1,200-2,000+

Assemblies:

• Simple assemblies: $600-1,000
• Complex assemblies: $1,000-2,500
• Multi-level assemblies: $2,500-5,000+

Factors Affecting Cost

1. Number of Characteristics:

• More dimensions = higher cost
• Each characteristic requires measurement
• Form 3 data entry time increases

2. Measurement Complexity:

• Simple dimensions: Base rate
• GD&T measurements: +20-30%
• Complex surface profiles: +50-100%
• Reverse engineering needed: +100-200%

3. Functional Testing:

• Visual inspection only: Base rate
• Basic functional tests: +$100-300
• Complex performance testing: +$300-1,000
• Environmental testing: +$500-2,000

4. Special Testing Requirements:

• Material analysis: +$200-500
• NDT (Non-Destructive Testing): +$300-800
• Metallurgical testing: +$400-1,000
• Chemical analysis: +$300-600

5. Documentation Level:

• AS9102 basic report: Base rate
• Full PPAP package: +50-100%
• Customer-specific formats: +20-50%
• Extensive photography: +$100-200

6. Urgency:

• Standard (5-7 days): Base rate
• Rush (2-3 days): +50%
• Urgent (next day): +100%

What’s Included in BSA GROUP FAI Service

Comprehensive Package:

• ✓ Complete dimensional inspection
• ✓ Functional testing (as specified)
• ✓ Material verification
• ✓ All three FAIR forms completed
• ✓ Professional report formatting
• ✓ Digital and hard copy delivery
• ✓ Supporting documentation review
• ✓ Technical consultation
• ✓ Customer coordination support

Value Comparison

Cost vs. Risk Analysis:

FAI Investment: $500-2,000 typical
Cost of Defective Production Run: $50,000-500,000+
Return on Investment: Massive protection

One prevented defective production run pays for hundreds of FAI inspections.

Volume Discounts

Multiple FAI Projects:

• 3-5 FAIs: 10% discount
• 6-10 FAIs: 15% discount
• 11-20 FAIs: 20% discount
• 20+ FAIs: 25% discount (annual contract)

Long-Term Partnerships:

• Preferred pricing
• Priority scheduling
• Dedicated project manager
• Streamlined processes

6. Can BSA GROUP help with AS9102 compliance?

Yes, absolutely! BSA GROUP specializes in AS9102-compliant First Article Inspections.

AS9102 Expertise

What We Provide:

Complete AS9102 Form Package:

• Form 1 (Part Number Accountability) – properly completed
• Form 2 (Product Accountability) – all processes documented
• Form 3 (Characteristic Accountability) – full measurement data

Ballooned Drawings:

• Professional balloon drawing creation
• Characteristic numbering
• Clear traceability to Form 3
• Customer-acceptable format

Supporting Documentation:

• Material certificates organized
• Special process certifications included
• Calibration certificates attached
• Test reports compiled
• Sub-tier documentation gathered

AS9102 Compliance Verification:

• Review customer requirements
• Ensure complete documentation
• Verify format compliance
• Check traceability
• Validate signatures

Industry Expertise:

• Aerospace industry experience
• Defense contractor familiarity
• NADCAP understanding
• AS9100 quality system knowledge

Customer Approval Support:

• Pre-submission review
• Format verification
• Completeness check
• Customer question handling
• Revision coordination

7. What happens if the First Article fails inspection?

Failure is not the end—it’s an opportunity for improvement before expensive mass production.

Immediate Actions

1. Comprehensive Documentation:

• Detailed non-conformance report
• Photos of defects
• Measurement data showing failures
• Root cause analysis
• Impact assessment

2. Supplier Notification:

• BSA GROUP contacts manufacturer immediately
• Share all inspection findings
• Discuss non-conformances
• Identify root causes
• Propose solutions

Resolution Options

Option 1: Corrective Action and Rework

• Manufacturer analyzes failures
• Implements corrective actions
• Reworks first article samples
• Addresses root causes
• Re-inspection scheduled

Timeline: 1-2 weeks typical
Cost: Usually absorbed by supplier

Option 2: Design Revision

• Engineering reviews findings
• Design modified if needed
• Drawings updated
• New samples produced
• New FAI conducted

Timeline: 2-4 weeks typical
Cost: Shared based on cause

Option 3: Process Modification

• Manufacturing process adjusted
• Equipment settings changed
• Tooling modified
• Operator training updated
• New samples produced

Timeline: 1-3 weeks typical
Cost: Supplier responsibility

Option 4: Supplier Change

• If supplier cannot meet requirements
• Find alternative manufacturer
• Start new FAI process
• Delay but ensures quality

Timeline: 4-8 weeks typical
Cost: Finding new supplier

Re-Inspection Process

After Corrections:

1. Supplier notifies completion
2. Schedule re-inspection
3. BSA GROUP verifies corrections
4. Measure all affected characteristics
5. Review corrective actions
6. Approve if compliant
7. Authorize mass production

Re-Inspection Scope:

• Full FAI if major changes
• Partial FAI if minor corrections
• Focus on non-conformances
• Verify related characteristics

BSA GROUP’s Support During Failures

We manage the entire resolution:

• Technical root cause analysis
• Solution recommendations
• Supplier coordination
• Timeline management
• Re-inspection scheduling
• Customer communication
• Documentation updates

Goal: Resolve issues efficiently while maintaining quality standards and timeline commitments.

8. Do I need FAI for every production batch?

No, FAI is not required for every production batch—only in specific situations.

When FAI IS Required

Required Situations:

• First-time production of new part
• Manufacturing location changes
• Significant design modifications
• Extended production gaps (2+ years)
• Process changes affecting product
• Material or supplier changes
• Customer specifically requests FAI

When FAI is NOT Required

Routine Production:

• Repeat orders of same part
• No design changes
• Same manufacturing location
• Same processes used
• Continuous production
• Previously approved FAI exists

Use Standard Inspections Instead:

• In-process inspection during production
• Final inspection before shipment
• Statistical process control (SPC)
• Regular quality audits
• Periodic verification

Partial FAI Situations

When Minor Changes Occur:

• Small design modifications
• Process parameter adjustments
• Tooling refinements
• Minor material variations

Partial FAI Focuses On:

• Only changed characteristics
• Features affected by change
• Related dimensions
• Not complete re-inspection

Best Practices

Risk-Based Approach:

• Assess change significance
• Evaluate quality risk
• Consider customer impact
• Balance cost vs. benefit

Documentation:

• Maintain approved FAI baseline
• Update for changes
• Keep historical records
• Track change history

BSA GROUP Recommendation:

• Full FAI for significant changes
• Partial FAI for minor modifications
• Standard inspection for routine production
• Consult with quality team when uncertain

What’s Next? Start Professional First Article Inspection

Ready to Protect Your Manufacturing Investment?

Partner with BSA GROUP for expert First Article Inspection services that ensure quality from the very first unit.

Comprehensive FAI Services

BSA GROUP provides complete First Article Inspection solutions:

Inspection Services:

✓ Full First Article Inspection – Complete verification of all characteristics
✓ Partial FAI – Focused inspection for changes
✓ AS9102 Compliant Reports – Aerospace standard documentation
✓ PPAP Support – Automotive approval assistance
✓ Ballooned Drawing Creation – Professional characteristic identification
✓ Dimensional Measurement – Precision verification with calibrated equipment
✓ Functional Testing – Performance validation
✓ Material Verification – Certificate review and testing

Documentation Services:

✓ FAIR Form Completion – Professional three-form package
✓ Supporting Documentation – Complete certificate compilation
✓ Customer-Specific Formats – Tailored to requirements
✓ Technical Review – Engineering analysis
✓ Approval Coordination – Customer communication support

Why Choose BSA GROUP for First Article Inspection?

🏆 10+ Years FAI Experience
🏆 5,000+ Successful FAI Projects Completed
🏆 AS9102 Compliant Reporting Expertise
🏆 PPAP Support Available
🏆 Multiple Industries Served (Aerospace, Automotive, Medical, Electronics)
🏆 Professional Certified Quality Inspectors
🏆 Fast Turnaround – 2-7 Days Standard
🏆 Competitive Transparent Pricing
🏆 Customer Approval Facilitation Support

Industries We Serve

Expert First Article Inspection across all manufacturing sectors:

• ✓ Aerospace & Defense Components
• ✓ Automotive Parts & Assemblies
• ✓ Medical Devices & Equipment
• ✓ Electronics & Electrical Products
• ✓ Industrial Machinery Parts
• ✓ Precision Machined Components
• ✓ Sheet Metal Fabrications
• ✓ Plastic Injection Molded Parts
• ✓ Die Cast Components
• ✓ Custom Assemblies

Don’t Risk Mass Production Without FAI

One defective production run costs more than dozens of First Article Inspections.

Protect your manufacturing investment, prevent costly mistakes, and ensure quality from the first unit with BSA GROUP’s professional FAI services.

BSA GROUP – Your Trusted First Article Inspection Partner in China

Over a decade of professional FAI experience. Thousands of successful first article inspections completed. AS9102 and industry standards expertise. Contact us now for expert First Article Inspection services.