The FAI Workflow
A structured FAI workflow for aerospace quality execution.
Every engagement runs through the same operational backbone, predictable, traceable, and audit-ready.
Program Intake
Scope, drawings, contract flow-downs.
Inside each step
What goes in. What comes out.
The seven steps above are the spine of every FAIRQA program. Here's what we need from you at each stage, what we hand back, and the standards we're holding the work to.
- STEP 01
Program Intake
We scope the program against contract flow-downs, drawings, customer-specific QCRs, and your delivery schedule. Risk is mapped before a single characteristic is ballooned.
- Inputs
- Drawings, PO, contract clauses, prior FAI history
- Deliverable
- Program brief, risk log, intake checklist
- Standard
- AS9102 / Customer flow-downs
- STEP 02
Drawing & Requirements Review
Every engineering data set is validated for revision currency, spec roll-up, GD&T integrity, and flow-down traceability before characteristics are extracted.
- Inputs
- Latest drawing rev, spec list, QCRs
- Deliverable
- Requirements matrix, exception list
- Standard
- AS9102 §4 / GD&T Y14.5
- STEP 03
FAI Validation
Ballooning, characteristic accountability, and Forms 1-3 build, executed against the bubbled drawing with full bidirectional traceability to inspection records.
- Inputs
- Ballooned drawing, inspection data, material certs
- Deliverable
- Forms 1, 2, 3 with characteristic accountability
- Standard
- AS9102 Rev C
- STEP 04
Supplier Coordination
Submittals, dispositions, and corrective actions managed end-to-end with your suppliers. We close the loop so your team isn't chasing tier-1 paperwork.
- Inputs
- Supplier list, PO scope, submittal cadence
- Deliverable
- Disposition log, CAR tracker, readiness status
- Standard
- AS9100 §8.4 supplier control
- STEP 05
Compliance Review
Objective evidence, traceability links, and counterfeit-prevention checks reviewed by a second set of eyes before the package leaves the building.
- Inputs
- Inspection records, material certs, process certs
- Deliverable
- Compliance review sign-off, evidence index
- Standard
- AS9100 / AS5553 / DFARS 252.246-7008
- STEP 06
Submission Readiness
Audit-ready packages assembled, indexed, and formatted to the prime's expected delivery method: Net-Inspect, customer portal, or PDF book.
- Inputs
- Approved Forms 1-3, evidence bundle
- Deliverable
- Submission-ready FAI package
- Standard
- Prime-specific delivery requirements
- STEP 07
Reporting & Ongoing Support
Program-level dashboards, on-time submission tracking, and embedded engineering support so quality keeps pace with production.
- Inputs
- Program cadence, KPI targets
- Deliverable
- Live dashboards, monthly program report
- Standard
- Continuous improvement / AS9100 §9
What you can expect
Operational commitments, not marketing claims.
5-10 days
Typical first-article turnaround
From ballooned drawing to submission-ready package on most aerospace parts.
100%
Characteristic accountability
Every dimension, note, and spec callout traced and accounted for, no gaps at submission.
Audit-ready
Every package, every time
Built to survive prime audit, DCMA review, or customer source inspection without rework.
How we plug in
The questions we get before kickoff.
How do engagements start?
NDA first. Then a discovery call to understand your needs, a collaborative SOW, and a quote. Once approved, we run launch support and status reporting from day one.
Do you integrate with our existing QMS?
Yes. We work inside your AS9100-aligned QMS, your customer portals, and your data systems.
Who owns the data and the records?
You do. All FAI records, evidence bundles, and dashboards are your property. We maintain controlled working copies and hand over signed, indexed packages on completion.
What happens after the FAI is submitted?
We stay engaged. Disposition feedback, re-submittals, delta-FAIs on engineering changes, and ongoing dashboards are part of the program, not a separate scope.