Procurement Glossary
First Article Inspection (FAI): Definition, process and importance in Procurement
November 19, 2025
First Article Inspection (FAI) is a critical quality assurance process in procurement in which the first produced part of a new series is comprehensively inspected. This systematic initial inspection ensures that suppliers meet the agreed specifications before series production begins. Find out below what exactly FAI means, how the process works and what strategic importance it has for quality management in Procurement .
Key Facts
- FAI fully tests the first series part against all specifications and drawing requirements
- The process reduces quality risks and prevents costly reworking in series production
- FAI is an established standard, particularly in the automotive and aviation industries
- The documentation is standardized and serves as proof of process capability
- Successful FAI is a prerequisite for series release and start of production
Contents
What is First Article Inspection (FAI)?
First Article Inspection refers to the complete inspection and documentation of the first produced part of a new series or after significant process changes.
Core elements of the FAI
The FAI includes a systematic check of all critical features of the first series component. All dimensions, tolerances, material specifications and functional requirements are checked against the technical drawings and specifications. The initial sampling documents each test step in detail and provides complete proof of conformity.
FAI vs. incoming goods inspection
In contrast to routine incoming goods inspections, FAI only takes place once at the start of series production and checks 100% of all specified characteristics. While random sample inspections monitor ongoing quality, FAI validates the supplier's basic process capability.
Importance of FAI in Procurement
For purchasers, FAI is a crucial tool for supplier qualification. The process minimizes procurement risks and creates trust in new supplier relationships. Systematic validation avoids expensive quality problems in series production and reduces quality costs in the long term.
Procedure: How FAI works
The FAI process follows a structured sequence from planning to the final release of series production.
Preparation and planning
The FAI begins with the definition of all features to be tested based on technical drawings and specifications. A detailed control plan determines which test equipment is to be used and which tolerances are to be adhered to. The inspection planning also takes critical safety features and functional requirements into account.
Carrying out the audit
The first series part is fully measured and tested against all specifications. Calibrated test equipment is used, the suitability of which has been proven by MSA studies. Each test step is documented and the measurement results are recorded in standardized forms.
Documentation and release
The complete FAI documentation includes measurement reports, material certificates and process documentation. After successful testing, the customer approves the series production. In the event of deviations, corrective measures must be initiated and a new FAI carried out.
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Important KPIs and targets
Key figures on FAI performance enable the continuous improvement of quality assurance processes and supplier assessment.
FAI success rate
The rate of successful FAIs on the first attempt shows the quality of the supplier processes and preparation. High success rates of over 90% indicate stable processes and good cooperation. Low values require analysis of the causes and targeted improvement measures at the supplier.
Lead time FAI process
The time from the first part delivery to the final release directly influences the time-to-market of new products. Benchmark values are between 5-15 working days, depending on complexity. Delays due to incomplete documentation or rechecks should be systematically analyzed and reduced.
Costs per FAI
The total costs for FAI implementation, including internal and external expenses, enable efficiency comparisons between suppliers. Standardized processes and digital tools reduce the costs per FAI by up to 30%. The quality costs should be weighed against the avoided error costs in series production.
Litigation risks and countermeasures for FAI
Despite careful planning, various risks can affect the FAI process and lead to delays or quality problems.
Incomplete test specifications
Missing or unclear test instructions lead to inconsistent FAI results and room for interpretation. Incomplete technical drawings or contradictory specifications delay the approval process. As a preventative measure, all inspection characteristics should be clearly defined and agreed with the supplier.
Test equipment errors and measurement uncertainty
Uncalibrated or unsuitable test equipment falsifies FAI results and can lead to incorrect decisions. High measurement uncertainty makes limit value decisions difficult and increases the risk of quality problems. Regular test equipment calibration and Gage R&R studies minimize these risks.
Time pressure and lack of resources
Tight project deadlines lead to superficial FAI inspections and incomplete documentation. Staff shortages or a lack of expertise at the supplier's endanger the quality of the initial inspection. Early planning and sufficient resource allocation are crucial for successful FAI implementation.
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Practical example
An automotive supplier performs FAI on a new brake disk casting. The first production part is fully tested against 47 specified characteristics, including critical dimensions for braking performance and safety. The inspection is carried out using calibrated 3D coordinate measuring machines and documents each measured value in a standardized FAI report. After successful validation of all specifications, the OEM issues the series release for the monthly production of 50,000 units.
- Complete documentation of all 47 test characteristics with measured values and tolerances
- Material certificate confirms required cast iron specification GG-25
- Process verification of heat treatment with hardness values according to specification
Current developments and effects
Digitalization and new technologies are fundamentally changing FAI processes and creating new opportunities for more efficient quality assurance.
Digital FAI systems
Modern software solutions automate FAI documentation and enable paperless processes. Digital systems link measurement data directly with CAD models and automatically generate compliant reports. Integration into existing ERP systems significantly speeds up approval processes.
AI-supported quality inspection
Artificial intelligence is revolutionizing FAI through automated image evaluation and pattern recognition. AI systems can inspect complex geometries more precisely than conventional methods and identify potential quality problems at an early stage. Machine learning continuously optimizes inspection strategies based on historical data.
Blockchain for traceability
Blockchain technology creates immutable FAI documentation and improves traceability in complex supply chains. Smart contracts can automatically issue approvals if all FAI criteria are met. This technology strengthens trust between suppliers and customers in the long term.
Conclusion
First Article Inspection is an indispensable tool for quality assurance in procurement that minimizes risks and creates trust in supplier relationships. Systematic validation of the first series component prevents costly quality problems and ensures process capability. Modern digital technologies and AI support make FAI processes more efficient and precise. For buyers, FAI remains a strategic tool for sustainable quality assurance and supplier development.
FAQ
What distinguishes FAI from a normal quality inspection?
FAI inspects 100% of all specified characteristics of the first series component, whereas normal quality inspections are usually based on random samples. The FAI documentation is more comprehensive and serves as proof of the supplier's basic process capability for the entire series production run.
When is a new FAI required?
A new FAI is necessary in the event of significant process changes, tool changes, material changes or after longer production breaks. A complete FAI must also be carried out in the event of a change of supplier or relocation in order to validate process stability.
How long does a typical FAI take?
The lead time varies between 5-15 working days depending on the complexity of the part. Simple parts with few test features can be completed in 2-3 days, while complex assemblies with extensive functional tests can take up to 3 weeks.
What are the costs of FAI?
FAI costs are made up of testing costs, documentation and any external laboratory costs. Typical costs are between 500-5,000 euros per part, depending on the complexity and scope of testing. This investment is amortized by avoiding quality problems in series production.
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