Executive takeaway
AS9102 First Article Inspection (FAI) is not “extra inspection.” It is a structured evidence package that proves:
- the manufacturing process can produce the design,
- the supplier is controlling configuration,
- and all characteristics are accounted for.
If you cannot build a coherent FAIR package, you will lose time at receiving—even when parts are good.
What AS9102 demands in practice
A credible FAI system includes:
- drawing ballooning with characteristic IDs
- traceability to drawing revision and planning documents
- objective measurement evidence for every characteristic
- linkage to material and special process certifications where applicable
The most common reasons FAIR packages fail
- Unballooned or duplicated characteristics
- Missing revision control (drawing/spec mismatch)
- Missing evidence for special processes or outside processing
- Unclear measurement method and datum simulation
- Incomplete linkage between traveler, inspection, and certs
A production-ready workflow to build FAIR packages
Step 1 — balloon the drawing correctly
- Unique ID for each characteristic
- Avoid combining characteristics unless buyer allows
Step 2 — map each balloon to a measurement method
For each characteristic define:
- tool (CMM, pin, height gage, optical, functional gage)
- datum simulation and fixturing
- environmental conditions if critical
- decision rule policy for borderline values (when required)
Step 3 — build the evidence pack structure
A buyer-friendly FAIR binder typically includes:
- cover page with part number and revision
- process plan / traveler
- inspection results and data files
- material certs and traceability
- outside processing certs (anodize, passivation, heat treat, NDT, etc.)
- calibration traceability where required
Step 4 — define change triggers (delta vs full FAI)
Define what triggers a partial or full FAI:
- machine or process changes
- program/post changes
- tooling/fixture redesign
- material source changes
- drawing or spec revision
How to reduce receiving friction
- Present the FAIR package in a consistent, audit-ready format.
- Use buyer language: “characteristic accountability,” “revision control,” “traceability,” “special process evidence.”
- Provide clear contact paths for clarification during receiving.
Buyer evidence pack
- Standard FAIR template (repeatable)
- Revision control log and change trigger policy
- Example FAIR package from a representative program (redacted)
FAQ for buyers
- When do we need a full re-FAI vs a delta FAI?
- What causes the most common receiving rejections in AS9102 flows?
- How can a Vietnam CNC supplier reduce audit friction and delays?