A First Article Inspection Report is the document that certifies that each sample was produced and inspected according to the customer's specifications. First Article Inspection is the process of planning, manufacturing, and verifying a production process.
AS9102 is a standard updated by the SAE to emphasize the value of the FAI process, and a common reporting format for manufacturers in aerospace and defense industries. AS9102 itself is not a formal requirement – it is a guidance document, not something requiring certification.
Step 1: Pre-planning FAI
Before beginning, gather documentation needed for your First Article Inspection:
Digital product definition data sets
Bill of materials/raw materials list
Manufacturing planning/routing/traveler/work order
Step 2: Create inspection plan
Balloon part drawing: identify the requirement to be inspected with a balloon number.
Fill out the AS9102 Form 1 (Part Number Accountability) and Form 2 (Product Accountability) with information from the Bill of Materials and Specifications List.
Document reference location of the balloon
Requirements including units of measure, variable requirements with tolerances
Classifications (Critical, Major, Key)
Step 3: Manufacture the part
Build the product and ensure you are documenting/recording processing and inspection results for the requirements during the manufacturing process.