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RSC Cluster: AS9102 First Article Inspection and Net-Inspect

The AS9102 First Article Inspection and Net-Inspect Cluster breaks down how first articles are executed, reviewed, and submitted in real aerospace environments. It clearly explains Forms 1 through 3, partial FAI triggers, drawing changes, and inspection responsibility. The content also maps system handoffs between internal execution tools and Net-Inspect, helping teams avoid submission errors and audit findings. This cluster turns FAI from a recurring fire drill into a repeatable, auditable process.

  • FAI package

    An FAI package is the complete set of first article inspection documentation compiled for a specific part number or assembly, typically in accordance with AS9102 in aerospace and other regulated manufacturing. It groups the required forms and objective evidence needed to demonstrate that a production process can consistently make a part that meets all approved design requirements.

    What an FAI package usually includes

    The exact contents can vary by customer, contract, or internal procedure, but an FAI package commonly includes:

    • AS9102 Forms 1, 2, and 3 (or equivalent internal forms) covering part information, materials and special processes, and detailed characteristic results
    • Ballooned or numbered drawings and models that link each design characteristic to an inspection result
    • Inspection records and measurement data (e.g., CMM reports, gage readings, surface finish and hardness results)
    • Certificates of conformance and material certificates (e.g., raw material, special processes, heat treatment, coatings, welding, NDT)
    • Process documentation that may be required to support traceability (e.g., routers, travelers, control plans, or work instructions)
    • Change-control records when applicable (e.g., engineering change notices, configuration baselines, or revision history)
    • Evidence of approvals, sign-offs, and dates associated with the FAI review and completion

    In digital environments, an FAI package may be stored and managed as a single record in an MES, QMS, PLM, or specialized FAI tool, with links to controlled documents and data sources.

    How FAI packages are used in operations

    • Qualification of production processes: The package documents that the initial or changed production configuration can meet all drawing and specification requirements.
    • Customer and regulator evidence: Customers, primes, and auditors commonly review sampled FAI packages during audits or source inspections to verify process control and documentation practices.
    • Baseline for future builds: The approved FAI package becomes a reference for subsequent production runs, engineering changes, and recurring FAIs.
    • Traceability and genealogy: FAI packages contribute to overall part history by linking parts, lots, processes, and materials to verified design requirements.

    What an FAI package is not

    • It is not routine in-process inspection for every lot or shipment, although it may reuse similar inspection methods.
    • It is not a full product qualification or certification in a regulatory sense; it is focused on verifying conformity to design and process capability for a defined configuration.
    • It is not limited to a single form or report; the term refers to the complete, organized set of all relevant FAI documentation.

    Common confusion

    • FAI vs. FAI package: “FAI” often refers to the inspection activity itself, while the “FAI package” is the documented evidence set that results from that activity.
    • AS9102 forms vs. package: The AS9102 forms (1, 2, 3) are part of an FAI package, but a complete package also includes supporting documents such as ballooned drawings, inspection data, and certificates.

    Link to AS9102 audit context

    In AS9100 or AS9102-focused audits, reviewers commonly sample FAI packages to confirm that first article inspections were performed per requirements, that all characteristics are accounted for, and that supporting evidence such as drawings, records, and certificates is complete and properly controlled.

  • flowdown

    Flowdown commonly refers to the controlled passing of requirements from one level of a contract or organization to lower levels, such as from a customer to a prime contractor and then to suppliers and sub-tier suppliers.

    In industrial and regulated manufacturing environments, flowdown is used to ensure that all applicable requirements are clearly communicated and traceable throughout the supply chain and internal operations.

    What flowdown includes

    Flowdown typically covers:

    • Customer and contractual requirements, such as quality clauses, inspection and test expectations, and documentation needs.
    • Regulatory and standards-based requirements, for example references to aerospace or defense standards, export control obligations, or industry-specific quality standards.
    • Technical and configuration requirements, including drawings, specifications, revisions, key characteristics, and special process instructions.
    • Compliance and reporting obligations, such as nonconformance reporting, FAI/AS9102 expectations, record retention, and traceability.

    These requirements are usually embedded in purchase orders, contracts, supplier quality requirements, work orders, or internal procedures so that every party performing work is working to the correct and current expectations.

    Operational meaning in manufacturing

    Operationally, flowdown is about how requirements are translated into day-to-day activities. Examples include:

    • A prime aerospace customer specifying that AS9102 FAI is required, and the manufacturer flowing that requirement down to its machining and special-process suppliers.
    • An OEM including export control language that is then flowed down to any supplier handling controlled technical data or hardware.
    • Drawing revision changes being reflected in ERP/MES, work instructions, and supplier purchase orders so that all production uses the correct revision.

    Digital systems such as ERP, MES, PLM, and supplier portals are often used to manage and document flowdown, helping maintain configuration control, version governance, and traceable acknowledgment of requirements.

    Flowdown in aerospace and regulated supply chains

    In aerospace and other highly regulated sectors, flowdown is a key part of demonstrating that customer and regulatory requirements are consistently applied across multiple tiers of suppliers. For example, the applicability of AS9102 first article inspection, special process approvals, or record retention periods is frequently established by customer contracts and then flowed down to relevant internal processes and external suppliers.

    What flowdown is not

    • It is not limited to quality requirements; it can include commercial, schedule, and technical conditions, though quality and compliance are most emphasized in regulated manufacturing.
    • It is not the same as casual communication; effective flowdown is controlled, documented, and traceable to specific contract or regulatory sources.
    • It is not a guarantee of supplier compliance; it is the mechanism used to communicate what compliance is expected.

    Common confusion

    • Flowdown vs. delegation: Flowdown is about communicating requirements; delegation is about assigning authority or decision-making. A company can delegate some tasks without changing the underlying requirement flowdown.
    • Flowdown vs. internal procedures: Internal procedures describe how an organization works. Flowdown links specific customer or regulatory requirements into those procedures and into supplier documents.

    Connection to the source context

    In the context of AS9102 and first article inspection, flowdown describes how a customer or prime manufacturer formally includes AS9102 and related requirements in contracts, purchase orders, or quality clauses so that suppliers know when and how to perform and document first article inspections.

  • First Article Inspection (FAI)

    First Article Inspection (FAI) is a formal, documented process used to verify that a new or significantly changed manufacturing process can consistently produce a part or assembly that meets all specified design, drawing, and specification requirements. It is typically performed on the first production run (or an early representative piece) and results in an inspection record that links measured characteristics to the design authority.

    Key elements of First Article Inspection

    In regulated and aerospace-oriented manufacturing, FAI commonly includes:

    • A defined inspection part (the “first article”) produced using standard production tools, methods, materials, and operators.
    • Complete verification of all design requirements on drawings, models, and specifications, often using ballooned characteristics.
    • Recorded inspection results for each characteristic, including dimensions, notes, material or process requirements, and special characteristics.
    • Traceability to manufacturing processes, work instructions, tooling, gages, and material lots used.
    • Approval and retention of an FAI report as part of the quality record set.

    FAI may be required for:

    • New part introduction or first production use of a part number.
    • Significant design changes that affect fit, form, function, or safety.
    • Major changes to manufacturing processes, locations, tooling, equipment, or suppliers.
    • Reinstating production after a prolonged lapse, depending on customer or internal criteria.

    FAI vs routine inspection

    FAI is broader than routine or in-process inspection. It verifies the complete set of design requirements and associated manufacturing process capability at a defined point in time, rather than sampling a subset of characteristics on an ongoing basis. Routine inspection focuses on ongoing product acceptance; FAI focuses on initial and change validation of the process and its documentation.

    FAI in aerospace and regulated industries

    In aerospace, FAI is commonly aligned with the AS9102 standard, which defines a structured methodology and forms for conducting and documenting First Article Inspections. Many OEMs and primes require FAI from their suppliers, and digital FAI workflows are often integrated with MES, PLM, or quality systems to maintain traceability, revision control, and audit readiness.

    In other regulated and high-reliability sectors, similar practices exist under different standards or internal procedures, but the core purpose remains: to show that the manufacturing process, as implemented, can produce conforming parts and that this is documented in a way that can be reviewed and audited.

    Operational use

    Operationally, FAI shows up as:

    • A required step in new product introduction workflows or engineering change processes.
    • A gate in supplier approval or production release, often linked to purchase order and work order milestones.
    • A set of digital or paper forms containing characteristic listings, measured values, and pass/fail status.
    • A controlled quality record maintained for traceability, customer review, and audits.

    Common confusion

    • FAI vs Production Part Approval Process (PPAP): PPAP is a broader automotive-focused approval framework that can include dimensional results similar to FAI, along with additional documentation such as process flow diagrams, control plans, and capability studies. FAI is more narrowly focused on verifying conformance of the part and associated process at first production or after change.
    • FAI vs first piece inspection: First piece inspection often refers to a shop-floor practice where the first part of a shift or setup is checked for conformance. FAI is a more formal, fully documented process typically tied to new parts, major changes, or customer/standard requirements.

  • FAI (First Article Inspection)

    First Article Inspection (FAI) is a formal, documented process used to verify that the first production run of a part or assembly meets all specified design, drawing, and process requirements. It is most commonly associated with aerospace and other highly regulated manufacturing sectors, but the concept is used across many industries.

    What FAI includes

    In a regulated manufacturing context, an FAI typically involves:

    • Inspecting a representative production part (or parts) produced using normal production tools, methods, and conditions
    • Verifying all defined characteristics, such as dimensions, tolerances, materials, finishes, and notes from the engineering drawing or model
    • Documenting inspection results in a structured report, often linked to ballooned drawings or characteristic lists
    • Capturing evidence of process controls, tooling, and key manufacturing steps used to produce the inspected article
    • Reviewing and signing off the results by appropriate quality and engineering personnel

    In aerospace, FAIs are commonly performed in accordance with the AS9102 standard, which defines a specific format and content for First Article Inspection Reports (FAIRs). Digital FAI solutions often integrate with MES, PLM, or QMS systems to pull design data, manage revisions, and store inspection evidence.

    When FAI is typically performed

    Although timing can vary by customer or internal procedure, an FAI is commonly required when:

    • Producing a new part number for the first time
    • Moving production to a new facility, line, or supplier
    • Making significant design or process changes that may affect form, fit, or function
    • Restarting production after a long interruption, if required by contract or procedure

    FAI is generally performed on production-intent hardware, not prototypes, and is distinct from routine in-process or final inspection. It serves as an initial validation that the manufacturing process, as set up, can consistently produce conforming parts.

    Operational use in manufacturing systems

    In industrial operations, FAI information may be:

    • Linked to work orders, routings, and travelers within an MES
    • Associated with specific part revisions in PLM or engineering systems
    • Managed in QMS or dedicated FAI software for document control and audit trails
    • Shared with customers or suppliers as part of qualification and source approval workflows

    Digital workflows can help control which lots or serial numbers require FAI, ensure the correct revision of drawings is inspected, and retain evidence for audits or customer reviews.

    Common confusion

    • FAI vs. FAIR: FAI refers to the inspection process itself. FAIR (First Article Inspection Report) is the resulting documented record of that inspection.
    • FAI vs. production inspection: FAI is a one-time or event-driven verification tied to initial production or significant change, while in-process and final inspections are ongoing checks during regular manufacturing.
    • FAI vs. PPAP: In automotive and some other sectors, Production Part Approval Process (PPAP) serves a similar qualification purpose but uses a different structured set of documents and requirements. FAI in aerospace is often governed by AS9102.

    Relation to AS9102 and aerospace

    In aerospace manufacturing, FAI commonly refers to the AS9102-defined process and forms. Under this usage, every design characteristic must be accounted for, typically using ballooned drawings and characteristic numbering, with results recorded on standardized AS9102 forms. Many organizations use digital tools and portals (such as Net-Inspect) to manage AS9102 FAIs, share data with customers, and maintain traceable records.

  • Form 3 (Characteristic Accountability)

    Form 3 (Characteristic Accountability) is one of the three standard forms defined in AS9102 for First Article Inspection (FAI) in the aerospace and defense industry. It is used to list each design characteristic from the drawing or model and to record how that characteristic was verified, the results of the inspection, and whether it conforms to requirements.

    What Form 3 typically includes

    While exact layouts may vary by organization or software, Form 3 commonly contains:

    • A complete list of drawing or model characteristics (often linked to balloon numbers)
    • Reference to the associated drawing zone or feature ID
    • Specification or tolerance limits for each characteristic
    • Measurement or verification method and gage or instrument used
    • Actual measured values or pass/fail indication
    • Status of each characteristic (e.g., acceptable, nonconforming, not applicable)
    • Links or references to any approved deviations, concessions, or waivers

    In digital FAI workflows, Form 3 is often generated from ballooned drawings or 3D models, with each characteristic tied to an inspection record and, in some cases, to upstream routing steps or operation plans.

    Role in manufacturing and quality workflows

    Within an AS9102 FAI package, Form 3 connects design data to inspection evidence. It is used to:

    • Demonstrate that every required characteristic has been identified and accounted for
    • Provide traceable inspection results for each characteristic
    • Support internal and customer reviews of FAI completeness and accuracy
    • Feed nonconformance, MRB, or CAPA workflows if any characteristic does not meet requirements

    Operationally, Form 3 may be integrated with MES, QMS, or specialized FAI software so that inspection results, gage IDs, operator IDs, and timestamps are captured electronically, supporting traceability and audit readiness.

    What Form 3 is not

    • It is not the cover sheet for the FAI; that is typically Form 1 (Part Number Accountability).
    • It is not the record of material, special processes, or functional tests; those are normally captured on Form 2 or in attached certifications and reports.
    • It is not a process control plan or control chart, although information from Form 3 can be used to inform those documents.

    Common confusion

    • Form 3 vs. ballooned drawing: The ballooned drawing visually numbers each characteristic. Form 3 is the structured list and inspection record for those numbered characteristics.
    • Form 3 vs. inspection report: Many organizations use Form 3 as their primary FAI inspection report, but routine in-process or final inspection reports outside of FAI may use different formats.

    Link to AS9102 and characteristic accountability

    Within AS9102 workflows, Form 3 is the central instrument for characteristic accountability. It provides evidence that the manufacturer has identified all applicable design characteristics, verified them using defined methods and equipment, and recorded the results in a way that can be reviewed, retained, and traced for future builds, changes, or audits.

  • Partial FAI

    Partial FAI commonly refers to a First Article Inspection that is intentionally limited in scope to selected characteristics, features, or operations rather than the entire part or assembly. It is used in regulated and aerospace manufacturing environments when only a portion of the design, process, or tooling has changed and a full, from-scratch FAI is not required by the applicable procedures.

    What a Partial FAI Includes

    A partial FAI typically focuses on:

    • Characteristics directly affected by a design change, drawing revision, or engineering change notice
    • Features impacted by changes to manufacturing methods, tooling, fixtures, material source, or key process parameters
    • Operations moved to a new machine, line, or supplier that require verification of conformity
    • Specific nonconforming dimensions or features that were previously corrected and now need re-verification

    In this context, only the affected characteristics are re-ballooned, inspected, and documented, while unchanged characteristics from the baseline (previous full FAI) are referenced rather than re-inspected.

    What a Partial FAI Does Not Include

    A partial FAI does not normally include:

    • Re-verification of every drawing characteristic from scratch
    • Re-documentation of unchanged processes, materials, or suppliers, except as required by internal or customer procedures
    • Replacement of the original full FAI record, which remains the baseline

    Instead, it supplements the original FAI by documenting the specific changes and their verification results.

    Operational Use in Manufacturing Systems

    In MES, QMS, and digital inspection tools, a partial FAI may appear as:

    • A follow-on FAI record linked to the original full FAI for the same part number or configuration
    • An inspection plan that reuses the prior FAI ballooning but only activates a subset of characteristics for re-measurement
    • A workflow triggered by a drawing or process change where the system flags only affected operations or features for FAI-level inspection

    In aerospace contexts aligned with AS9102 practices, partial FAIs are often documented using the same core forms or data structures as a full FAI, but with clear identification that the submission is partial and which characteristics or sections are being updated.

    Common Confusion

    • Partial FAI vs. Full FAI: A full FAI covers all drawing requirements for a defined configuration of a part or assembly. A partial FAI covers only the characteristics affected by changes, with the original full FAI still serving as the baseline.
    • Partial FAI vs. Routine Production Inspection: Routine inspections or in-process checks may sample features to control quality. A partial FAI is a formal, documented verification tied to a change event and typically controlled under customer or standard requirements, not just internal sampling plans.

    Context in Regulated and Aerospace Environments

    In aerospace and other highly regulated sectors, partial FAIs are often used to maintain traceability of design and process changes without repeating a full qualification of the part each time. Organizations typically define when a partial FAI is allowed, how it must reference the baseline FAI, and how to manage records so that auditors can trace which configuration each FAI (full or partial) applies to.

  • FAIR (First Article Inspection Report)

    A First Article Inspection Report (FAIR) is the documented record of a formal First Article Inspection (FAI). It captures evidence that an initial production part or assembly has been manufactured and measured against all applicable design, drawing, and specification requirements, and that the results meet those requirements within defined tolerances.

    What a FAIR typically includes

    In regulated and aerospace-focused manufacturing, a FAIR commonly contains:

    • Identification of the part, revision level, drawing number, and related specifications
    • Manufacturer and supplier details, including lot or batch information
    • Ballooned (numbered) drawing characteristic list linking each requirement to an inspection result
    • Measured values for dimensional, material, and functional characteristics
    • Notes on special processes, treatments, or key characteristics when applicable
    • References to supporting records (e.g., material certs, process certifications, test reports)
    • Signatures or approvals from responsible quality and/or engineering representatives

    Where FAIR is used in operations

    Operationally, a FAIR is used to document that the manufacturing process for a new or changed part is capable of producing results that conform to requirements. It is often required:

    • For new part numbers or first-time builds
    • After significant design changes or drawing revisions
    • After major process, tooling, or manufacturing location changes
    • When required by customer, contractual, or industry standards such as AS9102

    In many plants, FAIRs are generated or managed within quality systems, MES, or dedicated FAI software and may be exchanged electronically with customers or prime contractors.

    Relationship to AS9102 and aerospace

    In aerospace, FAIR commonly refers to the standardized reporting format aligned with AS9102 First Article Inspection requirements. AS9102 describes typical forms and data elements for documenting FAIs on aviation, space, and defense products, but organizations may implement FAIRs in paper or digital formats as long as contractual and standard requirements are addressed.

    What FAIR is not

    • It is not routine in-process or final inspection for every lot, although it may reference those controls.
    • It is not a statistical process capability study, even though it can trigger further analysis.
    • It is not a general nonconformance report, although nonconformances found during FAI may be documented separately and referenced by the FAIR.

    Common confusion

    • FAI vs. FAIR: FAI refers to the inspection activity; FAIR is the documented report of that activity.
    • PPAP vs. FAIR: In automotive, Production Part Approval Process (PPAP) covers a broader submission package. A FAIR in aerospace is more narrowly focused on first article inspection results, though it can serve a similar verification role.

  • Ballooning and characteristics

    Ballooning and characteristics commonly refer to the practice of marking engineering drawings or models with numbered “balloons” and defining each unique, inspectable requirement as a discrete characteristic. This is widely used in first article inspection (FAI), production inspection, and ongoing quality control in regulated manufacturing such as aerospace.

    What ballooning is

    Ballooning is the process of visually annotating an engineering drawing or 3D model so that every requirement that must be verified is identified with a unique reference number (the balloon). Each balloon typically corresponds to a specific line item in an inspection report.

    In practice, ballooning may include:

    • Dimension callouts (linear, angular, GD&T features)
    • Notes and specifications that require verification (material, finish, treatments)
    • Hole sizes, locations, patterns, and thread details
    • Form, fit, and function requirements that can be inspected
    • Referenced standards or process requirements that must be confirmed

    Ballooning can be performed manually on paper, in 2D CAD/PDF, or through digital tools that link the balloons directly to a characteristic database or FAI software.

    What characteristics are

    Characteristics are the individual, measurable or otherwise verifiable requirements extracted from the drawing or model and associated with a balloon number. In AS9102 and similar frameworks, these are often called inspection characteristics or product characteristics.

    A characteristic definition usually includes:

    • The balloon or item number
    • Description of the requirement (for example, diameter of hole, surface finish)
    • Nominal value and tolerances, or acceptance criteria
    • Units of measure
    • Associated drawing zone or reference
    • Type of characteristic (for example, key, critical, major, minor) when applicable
    • Planned inspection method and frequency where defined

    Characteristics provide the structure needed to build inspection plans, first article inspection forms, and ongoing in-process or final inspection records.

    Role in AS9102 and FAI

    In aerospace, ballooning and characteristics are tightly linked to AS9102 first article inspection:

    • The ballooned drawing defines the complete set of product requirements that must be verified.
    • Each ballooned item is translated into a characteristic line on the AS9102 Form 3 (characteristic accountability and verification list) or equivalent digital record.
    • Inspection results, tools used, and any nonconformances are recorded per characteristic, enabling traceable evidence of conformance to drawing requirements.

    Digital FAI systems typically use structured characteristic data to automate form population, result capture, and traceability back to specific drawing requirements and revisions.

    Operational use in manufacturing systems

    In day-to-day operations, ballooning and characteristics may feed multiple systems:

    • PLM/CAD: Source of the design, where requirements originate.
    • FAI or quality systems: Store and manage the characteristic list, inspection results, and evidence.
    • MES: Use characteristics to drive in-process inspection steps and operator checks.
    • ERP/QMS: Reference characteristics for nonconformance records, deviations, and certificates of conformance.

    Consistent ballooning and characteristic definitions help align what is designed, what is manufactured, and what is inspected across different systems and locations.

    Common confusion

    • Ballooning vs. general markup: Ballooning is a structured, numbered system tied to inspection characteristics, not just informal comments or highlights on a drawing.
    • Characteristics vs. process parameters: Characteristics are typically product requirements on the drawing or model. Process parameters (for example, machine settings) may be controlled and recorded, but are not always defined as characteristics unless they appear as specific requirements.
    • Characteristics vs. critical characteristics only: While some organizations focus on key or critical characteristics, ballooning and characteristic listing usually cover all inspectable requirements, not only the critical subset.

    Relation to digital FAI preparation

    When preparing for advanced digital FAI capabilities, manufacturers often focus on cleaning and standardizing ballooning practices and characteristic data. This can include using consistent numbering rules, ensuring every inspectable requirement is captured as a characteristic, and structuring the data so it can be exchanged between PLM, ERP, MES, and quality systems without rework.

  • Delta FAI

    Delta FAI commonly refers to a partial or incremental First Article Inspection (FAI) that documents and verifies only the changes from a prior, approved baseline FAI. It is typically used in aerospace and other regulated manufacturing environments that follow AS9102 or similar requirements.

    Instead of repeating a full FAI on an unchanged part, a Delta FAI focuses on characteristics, features, or process steps that are affected by a design change, process change, tooling change, supplier change, or other defined trigger. The intent is to show objective evidence that the impact of the change has been understood and that the affected characteristics still meet requirements.

    What Delta FAI includes

    In practice, a Delta FAI usually includes:

    • Reference to the original, full FAI report used as the baseline
    • Identification of the specific change drivers (for example, engineering change order, revised drawing, new machine or program)
    • Updated ballooned drawings or characteristic listings limited to affected features
    • Measurement results and inspection records only for the affected characteristics
    • Updated process or routing references when manufacturing steps have changed
    • Signoff and date stamps that clearly differentiate Delta FAI from the original submission

    Delta FAIs can be recorded using the same forms or digital tools as a full FAI, with the scope and coverage clearly marked as incremental to an earlier report.

    What Delta FAI is not

    • It is not a full, start-to-finish First Article Inspection on every feature of the part.
    • It is not intended to bypass FAI triggers that would require a full re-FAI, as defined by customer or standard-specific rules.
    • It is not a generic in-process inspection; it is tied to configuration-controlled changes relative to a known baseline.

    Operational use in manufacturing

    On the shop floor and in quality systems, a Delta FAI typically appears as:

    • An additional FAI package linked to the same part number and revision, but associated with a new change notice or revision level
    • A focused inspection plan generated by MES, QMS, or FAI software containing only the impacted characteristics
    • A referenced attachment in customer portals or FAI management tools (for example, a new Delta FAI submission in Net-Inspect that points back to an earlier FAI record)

    Digital workflows often manage Delta FAI by versioning FAI records, preserving traceability between the original FAI and each incremental update so that auditors and customers can reconstruct the complete inspection history of a part or assembly.

    Common confusion

    • Delta FAI vs. full FAI: A full FAI covers all drawing characteristics and applicable requirements. A Delta FAI limits coverage to characteristics impacted by a defined change, with the original FAI serving as the baseline for everything else.
    • Delta FAI vs. routine inspection: Routine in-process or final inspection may occur on every lot or shipment, but a Delta FAI is a formal, documented event tied to configuration changes and often controlled by customer or standard-driven criteria.

    Context in AS9102 and aerospace

    In aerospace, customer specifications or quality agreements often define when a new full FAI is required versus when a Delta FAI is acceptable. Organizations typically maintain procedures that:

    • Define change events that trigger a Delta FAI (for example, drawing revision that affects only certain dimensions)
    • Describe how to identify and document affected characteristics
    • Ensure that both the original and Delta FAI records are retained and traceable for audits and customer review

    Although the exact term “Delta FAI” may not be formally defined in every standard, it is widely used in industry practice to describe this incremental FAI approach.