AS9102 First Article Inspection: Requirements & Process

In the high-stakes world of aerospace manufacturing, a single defective component can lead to catastrophic consequences and multi-million-dollar setbacks. According to the International Aerospace Quality Group (IAQG), the first article inspection standardizes FAI process requirements to the greatest extent possible and can be used at all levels of the supply chain by organizations around the world to provide consistent process and documentation requirements for the verification of aviation, space, and defense products. This critical quality assurance process ensures that your manufacturing capabilities can consistently produce parts that meet exact specifications before full-scale production begins.

For operations managers, quality assurance professionals, and compliance officers, understanding AS9102 First Article Inspection (FAI) is essential for maintaining aerospace quality standards, reducing costly production errors, and ensuring regulatory compliance. Whether you're implementing your first FAI process or upgrading existing quality management systems, this comprehensive guide will walk you through everything you need to know about AS9102 requirements and best practices.

What Is First Article Inspection (FAI)

First Article Inspection (FAI) is a comprehensive quality verification process that validates whether a newly manufactured or revised product meets all design, specification, and customer requirements before mass production begins. The purpose is to provide objective evidence that all engineering design and specification requirements are properly understood, accounted for, verified, and documented.

At its core, FAI involves selecting a representative sample from the first production run and conducting thorough verification against engineering drawings, specifications, and customer requirements. This process encompasses material verification, special processes validation, functional testing, and complete documentation of manufacturing process capabilities.

The FAI process provides objective evidence that production processes can consistently manufacture compliant products, validates that specifications are correctly interpreted, and creates a documented baseline for future production runs. For aerospace suppliers, conducting proper first article inspections is often a contractual requirement that demonstrates manufacturing accountability.

What Is the AS9102 Standard for First Article Inspection?

AS9102 is a unique standard updated by SAE to emphasize the value of the FAI process. Although AS9100 Rev D requires production process verification under Clause 8.5.1.3, AS9102, AS9102 itself is not explicitly mandated by AS9100; however, it provides a widely accepted and structured method for satisfying production process verification requirements, and many aerospace customers contractually require FAI to be performed in accordance with AS9102. The AS9102 standard, maintained by the Society of Automotive Engineers (SAE), establishes comprehensive documentation requirements specifically for aerospace first article inspections.

The AS9102 standard bridges the gap between AS9100 quality management requirements and practical FAI implementation, providing a structured framework that separates planning and evaluation activities and defines Digital Product Definition (DPD) requirements.

The current version, AS9102 Rev C, was released on June 28, 2023, and incorporates several enhancements over previous revisions, including clearer guidance on commercial off-the-shelf (COTS) component documentation.

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AS9102 FAI Requirements Explained

Understanding AS9102 FAI requirements is crucial for aerospace suppliers seeking to demonstrate manufacturing process capability. The standard establishes specific documentation requirements centered around three fundamental accountability areas: part number accountability, product accountability, and characteristic accountability.

The Organization should have a process to plan for the completion of First Article Inspection activities before the First Production Run. Key requirements include maintaining detailed documentation of all materials used, including material certifications and traceability records. Special processes must be documented with appropriate certifications and supplier approvals.

The AS9102 standard mandates that inspection equipment be calibrated and traceable, with records maintained for each measurement tool used. Personnel conducting inspections must be qualified and independent from those who manufactured the product. Any non-conformances identified during the FAI process must be properly documented.

Modern AS9102 requirements address digital product definitions, accommodating 3D model-based manufacturing environments with verification against CAD annotations and model-based specifications.

When Is a First Article Inspection Required?

Understanding when to conduct a first article inspection is critical for maintaining compliance. FAI should be repeated whenever there is a change in design that affects the fit, form, or function of the product.

A first article inspection is required for:

• Initial production of new parts or assemblies
• Design changes that could impact fit, form, or function
• Modifications to manufacturing processes, tooling, or equipment
• Supplier changes for raw materials or special processes
• Relocation of production facilities

The FAI part does not have to be the very first unit manufactured, but it must be representative of the first production run using intended production processes, tooling, and inspection methods.

Customer-specified intervals also trigger FAI requirements, with some aerospace customers requiring periodic updates even without changes to maintain ongoing supplier qualification.

The AS9102 First Article Inspection Process

The AS9102 first article inspection process follows a systematic approach designed to ensure comprehensive product validation. The Organization should have a documented process to plan for FAI. This process should identify the responsible functions and address the activities to be performed before the first production run.

The process begins with thorough planning, including reviewing customer requirements, engineering drawings, and specifications. Teams must gather all necessary documentation and ensure that measuring instruments are calibrated and qualified personnel are available to conduct inspections.

During manufacturing, the first article is produced using established production processes. Throughout this phase, teams document process parameters and maintain records of all materials and processes used. The person who verifies a First Article characteristic cannot be the same person who generated or produced that characteristic, as self-verification is not permitted.

The inspection phase involves systematic verification of all product characteristics against requirements, including dimensional measurements, material verification, and functional testing where applicable. Documentation compilation follows, where all inspection results and supporting documentation are assembled into the complete FAIR package.

The final phase involves review and approval of the completed FAIR package before submission to the customer. This multi-level review process helps prevent errors and ensures that all requirements have been adequately addressed.

The Three AS9102 First Article Inspection Forms

The AS9102 standard requires three specific forms to document the first article inspection comprehensively: Form 1 (Part Number Accountability), Form 2 (Product Accountability), and Form 3 (Characteristic Accountability).

AS9102 Form 1 – Part Number Accountability 

It serves as the foundational document that identifies and tracks all parts included in the FAI. This form captures essential identification information, including part numbers, part names, revision levels, and serial numbers. Recent updates in AS9102 Rev C have modified Field 17 from "Part Serial Number" to "Part Type."

AS9102 Form 2 – Product Accountability 

It documents all materials, special processes, and functional testing associated with the first article. This form requires detailed documentation of raw materials with appropriate material certifications and specifications, plus special processes such as heat treatment, coating, or plating.

AS9102 Form 3 – Characteristic Accountability

It represents the most detailed documentation, capturing every measurable characteristic of the first article. This form requires systematic documentation of all dimensional characteristics, tolerances, surface finishes, and geometric tolerances specified on engineering drawings with unique balloon numbers corresponding to inspection drawings.

AS9102 Certification and Compliance Requirements

While AS9102 itself does not require formal certification, it serves as a crucial component of aerospace quality compliance strategies. AS9102 compliance operates within the context of AS9100 certification, which does require a formal third-party assessment. During AS9100 audits, assessors evaluate the organization's FAI capabilities and documentation practices.

The compliance framework requires organizations to establish documented processes for FAI planning, execution, and record-keeping. Organizations must maintain competent personnel trained in AS9102 requirements and complete traceability documentation for materials and special processes.

Quality management system integration represents another critical compliance aspect. AS9102 processes must align with the organization's broader quality management system, including document control, corrective action, and management review processes.

Why AS9102 First Article Inspection Is Critical for Aerospace Quality

AS9102 first article inspection represents a cornerstone of aerospace quality assurance, providing essential verification that manufacturing processes can consistently produce conforming products. The critical nature of aerospace applications demands rigorous quality verification processes that prevent the propagation of manufacturing errors throughout production runs.

Risk mitigation represents a critical benefit of AS9102 implementation. By identifying potential manufacturing issues during the first article phase, organizations can implement corrective actions before they impact production schedules or product delivery, reducing warranty claims and field failures.

Customer confidence building through rigorous FAI processes creates competitive advantages in the aerospace marketplace. Organizations with robust AS9102 processes often receive preferential treatment in supplier selection and may qualify for reduced incoming inspection requirements.

Supply chain optimization benefits from standardized AS9102 processes that create consistency across multiple suppliers and manufacturing locations, supporting aerospace quality metrics that drive continuous improvement.

How Does BPRHub Help with AS9102 First Article Inspection?

BPRHub's AI QCG for Aerospace provides predictive, connected, and audit-ready compliance specifically designed for the aerospace industry. Our intelligent platform addresses the unique challenges of AS9102 FAI processes through automation and risk prediction.

Key Features:

• Streamlined Documentation: Instantly locate critical aerospace documents, including quality manuals and supplier certifications, with AI-powered document control
• Predictive Risk Assessment: Early warnings on quality escapes and supply chain delays that could impact FAI processes
• Supplier Monitoring: Real-time visibility into supplier capabilities affecting FAI success
• OCTO Compliance Assistant: 24/7 AI-powered expert answering AS9102 questions and providing guided workflows
• Comprehensive Standards Support: Built-in intelligence for AS9100 and other aerospace compliance requirements

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Key Takeaways

→ AS9102 First Article Inspection provides critical verification that manufacturing processes can consistently produce conforming aerospace products before full-scale production begins

→ The standard requires three comprehensive forms documenting part accountability, product accountability, and characteristic accountability with complete traceability

→ AS9102 Rev C (June 28, 2023) clarifies assembly-level documentation, Digital Product Definition usage, and form content, but organizations should avoid attributing all historical form field changes solely to Rev C

→ FAI is required for new parts, design changes affecting fit/form/function, process modifications, supplier changes, and customer-specified intervals

→ Proper AS9102 implementation reduces production risks, builds customer confidence, and supports regulatory compliance within the AS9100 quality framework

→ BPRHub provides expert consulting services to help aerospace organizations implement, optimize, and maintain effective AS9102 first article inspection processes

FAQ

What is the difference between AS9102 Rev B and Rev C? 

AS9102 Rev C, released on June 28, 2023, includes significant updates such as mandatory COTS documentation in the bill of materials, removal of signature requirements from Forms 2 and 3, updated field names like "Part Type" instead of "Part Serial Number," and enhanced alignment with AS9100 production process verification requirements. Rev C also introduces clearer guidance on digital product definitions and ballooned design requirements.

Is AS9102 certification required for aerospace suppliers?

AS9102 itself does not require formal certification, as it is a guidance standard rather than a certifiable requirement. However, AS9102 compliance is typically necessary for AS9100 certification, which is often required by aerospace customers. Organizations must demonstrate effective production process verification capabilities, which usually include AS9102-compliant FAI processes during AS9100 audits.

When must a first article inspection be repeated? 

A first article inspection must be repeated whenever design changes are affecting fit, form, or function, modifications to manufacturing processes or tooling, changes in materials or suppliers, relocation of production facilities, or at customer-specified intervals. Additionally, some customers require periodic FAI updates even without changes to maintain ongoing supplier qualification.

What are the most common AS9102 FAI rejection reasons? 

Common rejection reasons include incomplete or missing forms from the three-form package, missing signatures or dates, incorrect or missing information on key fields, inadequate documentation of special processes, missing material certifications, insufficient characteristic documentation on Form 3, and failure to address customer-specific flow-down requirements properly.

How long does an AS9102 first article inspection typically take? 

The duration varies significantly based on part complexity, manufacturing processes involved, and organizational capabilities. Simple parts may require 2-4 weeks, while complex assemblies with multiple special processes can take 6-8 weeks or longer. Proper planning, adequate resource allocation, and efficient documentation systems can significantly reduce cycle times while maintaining quality standards.

What software tools can help with AS9102 compliance? 

Various specialized software tools support AS9102 compliance, including quality management systems with built-in FAI modules, measurement data collection systems, digital documentation platforms, and automated report generation tools. These tools help streamline data collection, ensure documentation completeness, maintain traceability, and reduce the risk of human error in FAI processes.