Clarifying Full vs. Partial First Article Inspection Triggers
Published .
Applicable Standards
AS9102Applicable Sections
- ✓Form 1 — Part Number Accountability
- ✓Form 3 — Characteristic Accountability
Related
- AS9100
Topics
- fai
- first-article-inspection
- as9102
- sub-assembly
- partial-fai
- delta-fai
- quality-planning
A supplier introduced a new sub-assembly part number into production. Believing that the individual components had been previously verified, the supplier performed what they considered a 'partial FAI,' focusing only on the assembly-level characteristics. They submitted an incomplete FAI package, omitting forms or data for the component-level features.
The customer rejected the FAI package as it did not comply with the governing standard, which requires a complete FAI for any new part number, including sub-assemblies. A partial, or 'delta,' FAI is only applicable for documenting changes to a part with a previously completed and approved baseline FAI.
Key Takeaways
- The incomplete submission resulted in a product acceptance delay and a formal corrective action request.
- The supplier was required to perform a new, complete First Article Inspection, generating all required forms to account for all product characteristics, before the part could be accepted.
- The customer rejected the FAI package as it did not comply with the governing standard, which requires a complete FAI for any new part number, including sub-assemblies.
Common Mistakes
- Missing balloon numbers on the drawing.
- Title block requirements not accounted for on Form 3.
- Incorrect or incomplete Form 1 part number traceability.
- Treating a design change as a full FAI re-accomplishment instead of a partial/delta.
Best Practice
Ensure quality planning processes strictly adhere to AS9102 requirements, which mandate a complete baseline FAI for every new part number. Partial FAIs are not a substitute for a full FAI on a new assembly and should only be used to document the impact of specific changes against an established baseline.
Reflects the recommended position based on community discussion and expert review.
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