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.
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.
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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