The first part made after a new setup, design change or tooling change is the best opportunity to catch errors before they multiply. A wrong offset, an outdated drawing or an incorrect material can produce hundreds of bad parts if not caught early. First article inspection (FAI) and first-off approval are the controls that verify the process is right before production runs.
Two related practices
First article inspection
FAI is a full verification of a new or changed part against every requirement on its drawing and specification. It's typically required for new parts, design revisions, new processes, new tooling, supplier changes and production after long breaks. Many customers, especially in automotive, aerospace and medical sectors, require a formal FAI report before accepting production parts.
First-off approval
First-off approval is a routine check after each setup or changeover: the first part is checked against key characteristics before the operator continues. It's less extensive than FAI but happens much more often.
Preparing for FAI
- Confirm the correct drawing revision. See drawing revision control.
- Balloon the drawing: number every characteristic — dimensions, tolerances, notes, material, finish.
- Define the method: which gauge or instrument for each characteristic.
- Verify instruments are calibrated. See calibration management.
- Collect material and process evidence: material certificates, special process certificates such as heat treatment or plating.
Performing and recording FAI
Measure each ballooned characteristic and record the actual value, result and instrument used. Non-conforming characteristics are investigated and corrected before re-inspection. The FAI report collects results, evidence and approvals. Where customers specify a report format, follow it exactly.
First-off approval workflow
- Operator completes setup and produces the first part.
- Operator performs self-checks on defined characteristics.
- Inspector or qualified setter verifies critical characteristics.
- Result is recorded: approved, or rejected with reason and corrective action.
- Production continues only after approval.
Waiting for inspectors is a common setup loss. Clear priority rules, mobile notifications and qualified setters who can approve certain characteristics shorten the wait. See SMED.
Which characteristics to check at first-off
Focus on characteristics affected by the setup: dimensions set by tool offsets, fixture positions or program changes, plus critical-to-quality characteristics defined by the customer. A defined first-off checklist per part and operation keeps checks consistent and fast.
Digital FAI and first-off
Paper FAI reports and first-off registers are slow and hard to search. Digital systems help by:
- Storing ballooned characteristics per part and revision.
- Guiding inspectors through each characteristic on a tablet.
- Capturing measurements from digital gauges where they support it.
- Flagging out-of-tolerance values immediately.
- Notifying inspectors when first-off is waiting, and tracking wait time.
- Blocking production booking until approval, where required.
- Generating FAI reports in customer formats.
An example: reducing first-off delays
A machining company found that machines waited a long time for first-off approval after each setup, especially on night shift with fewer inspectors. It introduced tablet-based first-off with notifications, trained senior setters to approve non-critical characteristics, and tracked wait time per machine. Wait times fell substantially, and because results were recorded digitally against each job, the company could show customers first-off evidence for every batch.
Getting started
Define first-off checklists for your highest-volume parts, set up digital recording and notifications for inspectors, and measure wait time. For new parts, adopt a standard ballooned FAI process and report template.
Common mistakes
- Inspecting against an outdated drawing revision.
- Skipping first-off under time pressure.
- Vague first-off checks, different for each inspector.
- Long waits for approval, encouraging operators to continue without it.
- FAI reports that can't be found when customers ask.
How software helps
Quality management software holds characteristics, guides FAI and first-off inspection, records results, manages approvals and generates reports, linked to jobs, drawings and instruments. See quality management software.
Talk to us about digital first article inspection.
FAI for suppliers and outsourced processes
When parts or processes are outsourced, FAI applies to suppliers as well. Require suppliers to submit FAI reports for new parts and changes, review them before approving production and record approval status per supplier part. Parts from unapproved suppliers or revisions can then be blocked at incoming inspection. This closes a common gap where internal parts are well controlled but bought-out parts are not.
Partial FAI after changes
Not every change requires a full FAI. When a single feature changes on a drawing or a process change affects only some characteristics, a partial FAI covering affected characteristics may be enough, subject to customer requirements. Recording which characteristics were re-verified and why keeps the decision traceable.
Measuring the process
Track first-off wait time, first-off rejection rate by machine and part, and FAI cycle time for new parts. High rejection rates point to setup methods, programs or tooling that need improvement; long waits point to inspection capacity or notification problems.
Keeping records
Retain FAI reports for the life of the part and as long as customers require, linked to the drawing revision and job.
Frequently asked questions
What is the difference between first article inspection and first-off approval?
First article inspection usually refers to full verification of a new or changed part against its drawing, often reported to the customer. First-off approval is the routine check of the first part after each setup before production continues.
When is FAI required?
Typically for new parts, design changes, new processes, new suppliers or tooling, production restarts after long breaks and when customers require it.
What does FAI measure?
All drawing characteristics — dimensions, tolerances, materials, finishes, notes — with results recorded against each characteristic, often using a ballooned drawing.
How long should first-off approval take?
As short as possible while still verifying critical characteristics. Delays waiting for inspectors are a common setup loss.
Can FAI be digital?
Yes. Ballooned characteristics, measurement entry on tablets, gauge links where available, photos and approval workflows can all be digital.
