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A First Article Inspection is a design verification process for verifying that a new or modified production process produces conforming parts that meet the manufacturing specification detailed in technical or engineering drawings. Typically, a supplier performs the FAI and the purchaser reviews the report. The FAI process usually consists of fully testing and inspecting either the first part produced by the new process or a sample from the first batch of parts. First article inspection is typically a purchase order requirement of the purchaser for the supplier to complete. If the manufacture doesn't have the in-house capability or if the purchaser requests, the first article inspection may be conducted by an approved subcontract supplier such as a dimensional inspection/metrology laboratory.
Dimensional characteristics are normally inspected using calibrated tools such as Coordinate Measuring Machines , Vernier calipers,Go/no go gauges etc. It may also be a requirement for material testing to be completed, checking the hardness, conductivity and other other properties.
First article inspections are commonplace for military subcontractors. The protocol is, however, required for design verification, purchasing controls, from the supplier and the purchasers receiving inspection in many non-military industries, particularly aerospace, automotive and medical manufacturing.
Manufacturers delivering products to government bodies or in regulated industries such as medical device must typically meet more stringent requirements than international requirements. If there are special test requirements outside of the suppliers capability then test maybe subcontracted to a 3rd party accredited testing lab. This is normally called First Article Test and is a separate activity from FAI.