First Article Inspection (FAI)
A first article inspection (FAI) checks the very first pieces made with the series tooling and process, before mass production. The inspector compares them with your drawings, specification sheet and approved sample: you only launch production once they conform.
Also called
- First piece inspection
- First-off inspection
- FAI
- First article check
Approve the series before it starts
A defect on the first piece is repeated on every piece that follows.
The sample you approved was often made separately, by hand or in a sample room. Series production comes out of a mould, tooling and a production line: dimensions, material or finish can drift along the way.
A first article inspection verifies that the pieces coming out of the final tooling match what you ordered, before the factory produces thousands of them.
What the inspector checks
- Dimensions, measured against the drawings and their tolerances
- Materials, colours and finishes, against the specification sheet and the approved sample
- Assembly and function of the product
- Markings, labels and packaging, if they are already available
Every deviation is recorded with photos and measurements in an illustrated report, sent within 24 hours. You then decide: start production, have the tooling corrected or ask for new pieces.
First article inspection or initial production check?
One follows the other. The first article inspection takes place before series production and looks at the first pieces: do they match the drawings? The initial production check takes place when 1 to 20% of the goods are produced and looks at materials, the process and how well operators understand your requirements: is the series staying compliant?
For a new product, doing both secures the start of production; the final random inspection then checks the finished lot.
First Article Inspection: at a glance
- When
- Before mass production, on the first pieces from the series tooling
- Compared with
- Drawings and tolerances, specification sheet, approved sample
- Verdict
- Start production, correct the tooling or make new pieces
- Report
- Illustrated, online, within 24 hours
- Booking
- At least 48 hours ahead
What does it cost?
from US$ 268
per inspector-day, excluding tax
Inspections are charged per inspector-day, with travel in Asia and the illustrated report included. The number of days depends on quantity, AQL level, number of models and on-site tests: it is fixed in the quotation, before anything is booked.
See prices and termsHow a first article inspection runs, step by step
- DocumentsWe review your drawings, tolerances and specification sheet, and list the characteristics to measure.
- Pieces from the final toolingThe inspector checks that the pieces come from the series mould, tooling and line, not from the sample room.
- MeasurementsEvery characteristic on the list is measured and compared with its tolerance.
- Materials, colours, finishesCompared with the specification sheet and the approved sample.
- Assembly and functionThe product is assembled and tested as the end user will use it.
- VerdictThe report lists every deviation with photos and measurements: you decide whether production can start.
What the factory must have ready
- Pieces made with the final tooling and process
- Dimensioned drawings and the specification sheet
- The approved (golden) sample
- Measuring equipment suited to the tolerances
Defects that are built into the design or the tooling
Products often reported in the EU for defects that come from dimensions or construction, which a first article inspection can catch before the series starts.
| Product | EU alerts | Defects most often reported | What the inspector checks at this stage |
|---|---|---|---|
| Childcare articles | 31960% China | Openings and gaps measured, locking mechanisms, stability. | |
| Magnetic toys | 8093% China | How magnets are enclosed, size of parts, construction. | |
| Ladders | 3586% China | Profile sections and wall thickness, rung fixing, dimensions. | |
| Children’s furniture | 1926% China | Gaps and openings, rounded edges, stability. |
Source: Safety Gate, the EU rapid alert system for dangerous non-food products, January 2023 to October 2026; figures updated every week in our Quality Observatory. For your own product, see the Product Defects Monitor.
What a first article inspection cannot tell you
- Whether the series stays compliant: the initial production check and the during production inspection follow the run.
- Compliance with a standard (CE, EN 71, RoHS), which needs a laboratory test.
The six inspections compared
Each inspection answers a different question at a different moment of the order. Most importers start with the pre-shipment inspection, then add earlier checks for new products, new suppliers or large orders.
| Inspection | When | The question it answers | Best for |
|---|---|---|---|
| First Article Inspection | Before mass production, on the first pieces from the series tooling | Do the first pieces match the drawings and the approved sample? | New product, new mould or tooling, new material |
| Initial Production Check | 1 to 20% of the goods produced | Are the materials right, and has the factory understood the requirements? | First order, new supplier |
| During Production Inspection | About 15 to 20% of the goods produced | Is the run staying compliant, and will the shipping date hold? | Large quantities, tight schedules |
| Production Monitoring | Every day, at each stage of production | Are defects removed and reworked as soon as they appear? | Supplier that failed an early check, critical orders |
| Final Random Inspection | Production finished, goods packed | Does the finished lot meet the agreed AQL: ship, rework or sort? | Every order, before the balance payment |
| Container Loading Supervision | Loading day, goods packed and ready to leave | Are the right goods, in the right quantity, loaded safely? | Mixed or fragile loads, several suppliers |
Frequently asked questions
When should I order a first article inspection?
Before mass production of any new product, and whenever something changes: a new mould or tooling, a new supplier, a new material or a modified process. It is the last moment when a correction only costs a few pieces.
Which documents do you need for a first article inspection?
Dimensioned drawings with tolerances, the specification sheet (materials, colours, finishes) and, if you have one, the approved golden sample. The more precise these documents are, the clearer the verdict.
What happens if the first pieces do not conform?
The report details every deviation, with photos and measurements. The factory corrects the tooling or the process and produces new pieces, which are checked again before mass production starts.
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- Minimum notice: 48 hours
- Full illustrated report within 24 hours
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