Full FAI commonly refers to a complete First Article Inspection performed in accordance with AS9102 or similar aerospace and defense requirements. It involves verifying and documenting every design characteristic on the drawing or model for a part or assembly, rather than a limited subset of features.
What Full FAI includes
In regulated and aerospace manufacturing environments, a Full FAI typically includes:
- Ballooned drawings or models identifying all required characteristics (dimensions, notes, material, finishes, special processes, etc.)
- A completed first article inspection report covering every ballooned characteristic
- Objective evidence such as measurement records, certifications, and process documentation
- Traceability to the specific part, lot, configuration, and manufacturing process used to produce the first article
- Signatures or electronic approvals from responsible functions (for example, quality and engineering)
Operationally, performing a Full FAI usually occurs when a part is produced for the first time, after significant design or process changes, or when required by customer or regulatory flowdown. In digital MES or FAI tools, a Full FAI workflow will drive collection of all required data elements rather than allowing partial coverage.
What Full FAI does not include
Full FAI does not typically refer to:
- Routine in-process or final inspections performed on every batch
- Sampling inspections that only check a portion of characteristics or units
- Capability studies or process validation activities, unless specifically tied into the FAI package
Common confusion
“Full FAI” is often contrasted with:
- Partial FAI: Only characteristics affected by a specific change (for example, drawing revision, tool change, or new supplier) are re-inspected and documented.
- Delta FAI: A limited update to an existing FAI, documenting only the changes since the last approved FAI.
Unlike general incoming or in-process inspections, a Full FAI is a structured, traceable, and usually one-time or event-driven activity intended to demonstrate that the manufacturing process can produce a part that meets all specified requirements.
Tie to AS9102 context
Within AS9102 programs, a Full FAI usually means completing the entire AS9102 FAI package (all forms and associated evidence) for every applicable drawing characteristic. Digital FAI solutions, Net-Inspect workflows, or MES-integrated FAI modules often distinguish between initiating a Full FAI versus a partial or delta FAI to align with customer and regulatory expectations.