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First Article Inspection (FAI) Tracker

Generate AS9102 forms for aerospace/automotive parts with balloon drawings, dimensional reports, and digital signature workflows.

Solution Overview

Generate AS9102 forms for aerospace/automotive parts with balloon drawings, dimensional reports, and digital signature workflows. This solution is part of our Quality category and can be deployed in 2-4 weeks using our proven tech stack.

Industries

This solution is particularly suited for:

Aerospace Automotive Medical Device

The Need

First Article Inspection (FAI) is a critical quality gate in aerospace, automotive, and medical device manufacturing. When a supplier or internal production line begins manufacturing a part for the first time, or after significant process changes, the customer requires documented proof that the part meets all specifications. Failure to complete FAI correctly results in production halts, customer audits, contract penalties, and program delays. The stakes are extraordinarily high: a missed dimensional specification or inadequate documentation can halt an entire aerospace production line, costing $10,000+ per day in downtime.

Currently, FAI processes rely on paper forms and manual coordination. Quality engineers print AS9102 forms, conduct inspections with manual measurement recording, create balloon drawings by hand or primitive CAD, and route forms through email for multiple approval signatures. Documents get lost in email chains, revision control is impossible to maintain, and questions about why a specific feature passed inspection require hunting through archived emails. Dimensional data is recorded in handwritten notebooks, later manually transcribed into forms, creating transcription errors. When customers request documentation, companies scramble to locate original signed forms and supporting measurement data, sometimes taking days to compile a single FAI package.

The AS9102 standard itself is complex. Part 1 requires design specification verification, Part 2 requires material and process verification, and Part 3 requires product conformance demonstration. Organizations struggle to ensure all required elements are included—material certifications, CMM (coordinate measuring machine) reports, microscopy photos, surface finish measurements, hardness testing results, and X-ray analysis when required. Missing documentation during a customer audit becomes a Non-Conformance Report (NCR) that damages supplier ratings and can result in contract loss.

Geographic and organizational complexity adds further challenges. For global manufacturers with suppliers across multiple continents, FAI data must be accessible in real-time, with approvals from engineering, quality, and procurement teams in different time zones. Suppliers cannot begin production until FAI is formally approved and documented. Delays in the approval process directly impact production schedules and customer delivery commitments.

The financial consequences are severe. A single missed FAI deadline can delay program launches by weeks, resulting in customer penalties of $100,000+ and reputational damage that takes years to recover. Rework due to dimensional issues discovered after production began costs exponentially more than issues caught during FAI. Excessive time spent compiling and managing FAI documentation diverts quality engineering resources from value-added activities like process improvement and problem-solving.

The Idea

A First Article Inspection (FAI) Tracker transforms the FAI process from scattered paperwork into a streamlined, digitally-native system where dimensional data flows directly from measurement equipment into standardized AS9102 forms, balloon drawings are created interactively within the system, and approvals follow defined workflows with immutable audit trails.

The system begins when a new part enters production. Quality engineers create a FAI record linked to the engineering drawing, customer contract, and any previous FAI history. The system automatically populates customer requirements, specification limits, and acceptance criteria from linked technical drawings. For each dimension or feature requiring verification, engineers can designate whether this is a design characteristic (Part 1), material/process characteristic (Part 2), or product characteristic (Part 3)—with the system automatically guiding completeness requirements for each part.

Dimensional measurement integrates directly with laboratory equipment. CMM machines, optical comparators, hardness testers, and surface finish gauges output raw measurement data. Rather than manually transcribing measurements from equipment displays into paper forms, integrations with metrology equipment feed measurements directly into the FAI system with timestamp and gauge identification. The system immediately validates measurements against specification limits, flagging out-of-spec results in real-time so measurements can be retaken if needed, rather than discovering issues weeks later when forms are reviewed.

Balloon drawings are created interactively within the system. Quality engineers upload the engineering drawing as a high-resolution image or PDF. The system provides an annotation interface where engineers directly mark features on the drawing—clicking to place numbered "balloons" (circles) that correspond to each measured feature. Hovering over a balloon shows the specification, tolerance, measurement value, and pass/fail status. Multiple balloon sets can be created for different material conditions, heat treatments, or post-processing states. The system generates both a visual marked-up drawing and a corresponding dimensional report showing every numbered balloon with its measurement data and acceptance status.

Material and process documentation is integrated directly. Rather than collecting certificates separately, the system provides a checklist of required certifications based on the specification: material mill certificates, heat treat certificates, hardness testing reports, surface analysis, chemical composition analysis, and any special process certifications (plating, anodizing, welding, etc.). Material certificates can be uploaded directly into the FAI record, and integrations with supplier management systems automatically pull supplier certifications. The system validates that all materials and processes referenced in the drawing are certified and documented.

The approval workflow enforces completeness before sign-off becomes possible. When an engineer marks FAI as "ready for review," the system validates: - All Part 1 design characteristics have measurements and balloon markings - All Part 2 material/process characteristics have supporting documentation - All Part 3 product characteristics have conformance data - Material certificates are current and valid - All special processes have required certifications

If any required element is missing, the system lists what's incomplete and prevents submission. Once complete, the FAI record routes to Quality Manager for review and approval, then to Engineering for final sign-off, then to Customer Quality Representative if customer sign-off is contractually required. Each reviewer can see the complete package: engineering drawing, balloon-marked drawing, dimensional measurements, material certificates, and all supporting test data in a single unified view.

Digital signatures are embedded with timestamps and reviewer identity, creating an immutable audit trail compliant with 21 CFR Part 11 (FDA) and equivalent aerospace/automotive standards. Comments and revision histories are preserved, enabling traceability if later questions arise about why a particular acceptance decision was made.

Once approved, the FAI becomes the reference standard for production. Any future part from the same supplier or process must conform to approved FAI requirements. The system generates FAI compliance checklists for production receiving inspections, reducing inspection time by providing a pre-populated measurement plan and acceptance criteria derived directly from the FAI approval.

For organizations with multiple suppliers or multiple production sites, the system provides visibility into FAI status across the supply chain. Dashboards show which FAI records are pending, which approvals are outstanding, and which suppliers are trending toward FAI delays or failures.

How It Works

flowchart TD A[New Part
Engineering Drawing] --> B[Create FAI
Record] B --> C[Link Specifications
& Requirements] C --> D[Designate
Part 1/2/3
Characteristics] D --> E[Upload Technical
Drawing] E --> F[Create Balloon
Drawings
Mark Features] F --> G[Define Measurement
Plan] G --> H[Conduct Inspection
Measure with Equipment] H --> I[Equipment Data
Flows to FAI System] I --> J{Measurements
Within Spec?} J -->|No| K[Flag Out-of-Spec
Re-Measure or
Request Deviation] K --> H J -->|Yes| L[Collect Material
Certifications] L --> M[Attach Test Reports
CoA & Certificates] M --> N[System Validates
Completeness
All Parts 1/2/3] N -->|Incomplete| O[List Missing
Elements] O --> P[Complete Missing
Documentation] P --> N N -->|Complete| Q[Submit for
Quality Review] Q --> R[Quality Manager
Reviews & Approves] R --> S[Engineering
Manager
Final Sign-Off] S --> T{Customer
Approval
Required?} T -->|Yes| U[Route to
Customer Quality
Team] U --> V[Customer
Digital Signature] T -->|No| W[FAI Approved
& Archived] V --> W W --> X[Generate AS9102
Documents] X --> Y[Release to
Production] Y --> Z[Create Receiving
Inspection Checklist
from FAI Data]

End-to-end First Article Inspection workflow from engineering drawing through measurement, documentation collection, multi-stage approvals, and production release with AS9102 compliance.

The Technology

All solutions run on the IoTReady Operations Traceability Platform (OTP), designed to handle millions of data points per day with sub-second querying. The platform combines an integrated OLTP + OLAP database architecture for real-time transaction processing and powerful analytics.

Deployment options include on-premise installation, deployment on your cloud (AWS, Azure, GCP), or fully managed IoTReady-hosted solutions. All deployment models include identical enterprise features.

OTP includes built-in backup and restore, AI-powered assistance for data analysis and anomaly detection, integrated business intelligence dashboards, and spreadsheet-style data exploration. Role-based access control ensures appropriate information visibility across your organization.

Frequently Asked Questions

What is First Article Inspection (FAI) and why is it required? +
First Article Inspection is a mandatory quality verification process required by aerospace, automotive, and medical device manufacturers before a supplier or production line can begin mass manufacturing a part. FAI proves that the first article produced meets all engineering specifications, material requirements, and customer contractual obligations. It's typically required when a supplier is new, when manufacturing begins at a different location, or after significant process changes. Skipping or delaying FAI can halt entire production lines, trigger customer audits, and result in penalties up to $100,000+ per program. Essentially, FAI is the customer's proof that the supplier understands the requirements and can consistently produce compliant parts.
What is AS9102 and what are the three parts of FAI documentation? +
AS9102 is the aerospace quality standard that defines the First Article Inspection process and documentation requirements. It consists of three distinct parts, each addressing different aspects of manufacturing compliance. Part 1 verifies design specifications—dimensional measurements, tolerances, and functional performance of the part as designed. Part 2 verifies material and process specifications—confirming that materials meet certifications, heat treatments are documented, and special processes (plating, welding, anodizing) are certified. Part 3 verifies product conformance—demonstrating that the actual production part meets all specifications and is ready for regular production. A complete FAI document must address all three parts with supporting evidence: CMM reports, material mill certificates, heat treat documentation, hardness testing results, and specialized testing like X-ray analysis or microscopy when required by the drawing.
How long does FAI typically take and what causes delays? +
FAI typically takes 4-8 weeks from initial measurement to final customer approval, but delays are common. The biggest time wasters are manual processes: manually recording measurements from equipment into forms, creating balloon drawings by hand, hunting for material certificates scattered across email, and routing paper forms through multiple approval chains where they get lost or forgotten. Each revision cycle adds 1-2 weeks as documents are resubmitted and re-reviewed. Digital FAI systems eliminate these bottlenecks by automatically capturing measurement data from equipment, enabling interactive balloon drawing creation, centralizing all supporting documentation, and enforcing approval workflows that prevent incomplete submissions. Organizations using integrated FAI systems typically achieve approval in 2-3 weeks, enabling faster production releases and eliminating customer delivery delays.
What are the common reasons FAI gets rejected or requires rework? +
FAI rejections fall into four categories. First, incomplete documentation—missing material certificates, undocumented special processes, or test reports that don't match drawing requirements. Second, out-of-specification measurements—dimensions that fall outside tolerance limits, usually caught too late after hours of manual measurement entry and manual transcription. Third, non-conforming approvals—FAI submitted by someone who isn't authorized, missing required signatures from engineering or quality managers, or approval workflows that don't match the customer's contractual requirements. Fourth, inadequate traceability—balloon drawings that don't clearly reference features, measurement data disconnected from specifications, or missing evidence for why a feature was accepted. Modern FAI systems prevent most rejections by validating completeness before submission, flagging out-of-spec measurements immediately during inspection, automating approval routing, and creating clear visual connections between drawings, specifications, and measurements.
How do I integrate FAI with measurement equipment and avoid manual data entry? +
Manual transcription of measurement data is one of the largest sources of FAI errors and delays. Most modern metrology equipment—CMM machines (ZEISS, Mitutoyo, Hexagon), optical comparators, hardness testers, and surface finish gauges—can output measurement data in digital formats. An integrated FAI system accepts these data feeds directly, eliminating manual transcription. Measurements flow automatically from instruments with timestamp and equipment identification, are immediately validated against specification limits, and flag out-of-spec results in real-time so measurements can be retaken during the inspection session rather than discovered weeks later. For equipment without automated data output capability, mobile FAI apps enable inspectors to enter measurements directly during physical inspection, with offline-first architecture supporting unreliable manufacturing floor connectivity. The result is faster inspection cycles, zero transcription errors, and immediate visibility into whether FAI can proceed or if re-inspection is needed.
Can FAI be managed across multiple suppliers and global production sites? +
Yes, and global FAI management is critical for multinational manufacturers. Distributed FAI management requires a centralized system accessible across time zones where suppliers or remote production sites can create FAI records, but approvals follow centralized workflows defined by the customer. Each supplier or production location creates their FAI record with local measurement data and documentation, which then routes to central quality teams—perhaps in the US or Europe—for review and approval before production is released globally. Role-based access control ensures suppliers can only access their own FAI data while customers and quality teams can view across the entire supply chain. Dashboards show real-time FAI status: which locations have pending FAI, whose approvals are outstanding, which suppliers have trending FAI delays or frequent rework. This visibility enables proactive escalation—contacting suppliers with delayed FAI before they miss production commitments, or identifying training needs if certain suppliers consistently fail initial approval.
What happens after FAI is approved and how does it drive production? +
Once FAI is approved and digitally signed, it becomes the reference standard for all future production from that supplier or process. The approved FAI generates a receiving inspection checklist that receiving quality teams use for every incoming shipment—rather than reinventing acceptance criteria for each part, the system provides a pre-populated measurement plan derived directly from the approved FAI. This reduces incoming inspection time and ensures consistency. The approved FAI is also archived with full audit trail and immutable signatures, meeting regulatory requirements for aerospace quality (AS9100), FDA compliance (21 CFR Part 11), and customer audit requirements. If the customer later questions why a particular feature was accepted, you can retrieve the exact measurement data, balloon drawing markings, and approver signatures from the archived FAI. Many ERP systems integrate with FAI systems—FAI approval status automatically feeds back to production work orders, preventing production from starting until FAI is formally approved, and supplier scorecards automatically incorporate FAI performance metrics like time-to-approval and rework rates.

Deployment Model

Rapid Implementation

2-4 week implementation with our proven tech stack. Get up and running quickly with minimal disruption.

Your Infrastructure

Deploy on your servers with Docker containers. You own all your data with perpetual license - no vendor lock-in.

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