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First article inspection (FAI) report template
A first article inspection (FAI) is a full inspection of one part from the first production run, checking every characteristic on the drawing before production goes ahead. It proves the process, tooling and materials can make the part as drawn. This template follows the common structure of an FAI report: part information and the reason for the FAI, then a table of every characteristic with its balloon number, nominal, tolerance, measured result, pass or fail and inspection method, then the material and special process certificates, functional tests and sign-off. The Excel version works out the limits from the nominal and tolerances, flags any value outside them as a fail, and gives an overall result. It is a general template; it does not claim to meet any particular FAI standard, so use your customer's format if they specify one.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Fields for part number, name, revision, drawing and FAI number, tick boxes for the reason, and a table with columns for balloon number, characteristic, nominal, tolerances, measured result, pass or fail, method, gauge ID and notes.Part information and reasonBallooned characteristic tableNominal and tolerancesMeasured result, pass or failMethod and gauge IDMaterial and process certificatesResult and sign-off
When to use it
When to use a first article inspection report
- For a new part, before the first production run is released.
- After a drawing revision, for the characteristics that changed.
- When the part moves to a new supplier, site, machine or process, or the tooling changes.
- After a long gap in production, or when your customer asks for one.
How to fill it in
- 1
Balloon the drawing
Number every characteristic on a copy of the drawing: dimensions, tolerances, notes, finishes and materials.
- 2
Fill in the part information
Part number, name, revision, drawing number, supplier or process, the order and the serial or lot of the part inspected.
- 3
List each characteristic
One row per balloon: the characteristic, the nominal and the minus and plus tolerance.
- 4
Measure and record
Measure each characteristic and write the actual result, the method or gauge and the gauge ID. Circle pass or fail.
- 5
Check the certificates
List each material and special process with its certificate number and check it against the specification on the drawing.
- 6
Decide and sign
Accept, accept with a deviation, or reject and fix. A reject means a new FAI on a new part after the fix.
A filled-in example
Illustrative, not a benchmarkAn example: an FAI on a new aluminum housing with 42 ballooned characteristics (illustrative).
The example FAI: one failed characteristic rejects the part
- Pass: 41 characteristics
- Fail: 1 characteristic
- Balloon 7: bore, over 32.000 mm (limit +0.025)+0.018 mmpass
- Balloon 15: flatness (limit 0.05)0.07 mmfail
41 of 42 characteristics passed and 1 failed. Balloon 7, the bore, measured 0.018 millimeters over nominal against an allowance of 0.025: pass. Balloon 15, flatness, measured 0.07 against a limit of 0.05: fail.
- Balloon 7: bore diameter 32.000 mm, tolerance −0.000/+0.025. Measured 32.018 on a bore gauge. Pass.
- Balloon 15: flatness 0.05 mm. Measured 0.07 on the CMM. Fail.
- Balloon 31: anodize, clear, to the finish specification on the drawing. Certificate checked against the specification. Pass.
- Result: 41 pass, 1 fail. Rejected: the fixture was clamping the part too hard.
The fixture clamping was changed, a second part was machined and inspected for all 42 characteristics, and that FAI was accepted.
Common mistakes
Skipping characteristics
An FAI covers every characteristic on the drawing, including notes and finishes, not only the dimensions that seem critical.
Measuring with the wrong gauge
The gauge must be able to measure to the tolerance. Record the gauge ID.
Not checking certificates
Material and special process certificates are part of the FAI. Check them against the drawing.
A part from a trial setup
Inspect a part made with the production process, tooling and materials, or the FAI proves nothing.
Download the template
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Run this template in LeanSuite
In LeanSuite quality checks run as digital checklists with number limits, required photos and signatures, and an out-of-spec answer can raise a tag or start a CAPA automatically.
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FAQ
First article inspection (FAI) report template: common questions
A full inspection of one part from the first production run against every characteristic on the drawing, done before production is released to prove the process can make the part as drawn.
For a new part, after a drawing change, when production moves to a new supplier, site or process, when tooling changes, after a long gap in production, or when the customer asks for one.
A copy of the drawing with a numbered balloon next to each characteristic. The numbers match the rows of the FAI report, so every characteristic is accounted for.
It is not presented as meeting AS9102 or any other standard. It follows the common structure of an FAI report. If your customer specifies a standard or form, use theirs.
The FAI is rejected, or accepted with a deviation if the customer or engineering approves one. After the fix, a new part is made and inspected, at least for the characteristics affected.
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- RCM worksheet (failure mode and task selection)Failure modes classed as hidden, safety, operational or non-operational, then a task chosen for each: condition-based, discard, failure-finding, redesign or run to failure.
- Training matrix template with expiry datesPeople by required trainings with expiry dates, OK, due, expired and missing flags, compliance by person and area, cover per training and a renewal list.
- Downtime reason codes template26 starter codes mapped to the six big losses, a log with drop-downs, a Pareto by code and by loss, and a code card for the line.
- Kaizen event preparation checklistEverything that has to be ready before a kaizen event and done after it: 44 items with owners and due dates from 6 weeks before day 1 to 30 days after, five go or no-go gates and a day-by-day agenda.
- Critical spare parts list and stocking levelsAssets ranked by consequence, each part classed and given a stocking policy, and min and max worked out from usage and lead time, with the downtime each stock-out would cost.
- Tier 2 meeting agenda and escalation sheetA 15-minute tier 2 agenda in ten timed blocks, fixed roles and rules, escalation triggers with time limits, and a log that ages every escalation and sends the answer back down.
- Forklift operator training and evaluation recordPer-operator training and evaluation record, a register with three-year due dates and refresher triggers, and a weighted practical evaluation scoresheet.
- REBA worksheet (Rapid Entire Body Assessment)Score up to six postures with REBA: body-part drop-downs, Tables A, B and C as lookups, final score and action level, and a before and after comparison.
- ISO 45001 internal audit checklist44 audit questions for the plant floor in 16 safety topics, each with its ISO 45001:2018 clause, the evidence to look for and the sample to take, plus 12 worker interview prompts, a findings log and a summary by clause.
- Plan for every part (PFEP) templateOne row per part: supplier, pack, container, usage, lead time and locations, with ABC classes, market and line kanban counts and a lineside space check.
- Changeover matrix templateA from-to matrix of changeover minutes with the clean each transition needs (allergen, colour, format), and a weekly planner that totals the order and suggests a shorter one.
- Overhead crane inspection checklist: frequent and periodic34 crane checks tied to OSHA 1910.179: an operator's pre-shift card, frequent and periodic inspections with signed records, a deficiency and tag-out log, and a register of next due dates.
- Maintenance job plan templateOne job planned on one sheet: steps and craft hours, parts checked against stock, tools, lockout and permits, documents, a ready check for the schedule, and technician feedback.
- Video time study filming checklistA pre-shoot checklist and shot log for filming a time study on video: camera, light, people, settings, power and review.
- Reorder point and safety stock sheet (many parts)Safety stock, reorder point, order quantity and an order list for up to 500 parts, worked out from each part's own demand and lead time history.
- OSHA compliance calendar (general industry)37 recurring federal OSHA duties with the paragraph, interval, owner, next due date and an overdue flag, plus a 12-month view and counts by owner.
- TRIR and DART rate trackerMonthly hours, OSHA 300 case counts and near misses in; rolling 12-month TRIR and DART rate, a case budget against your target and a trend chart out.
- Energy use and EnPI trackerMonthly electricity, gas and fuel in one unit, a 12-month regression baseline, expected against actual energy for each month, an EnPI ratio, the running saving and the tests that say whether the model can be trusted.
- FIFO lane sizing sheetThe maximum for a FIFO lane from the stop it must cover, in whole containers, with length, refill and wait checks for up to eight lanes.
- Pugh matrix templateCompare up to 8 concepts with a datum as better, same or worse on up to 12 criteria, flag must-haves, and carry the strongest into a second round.
- Machine guarding inspection sheetA machine register with due dates and a status per machine, 21 checks tied to OSHA 1910.212, .219 and .147, a guard opening check against Table O-10, and an action log.
- Condition monitoring route sheetA route of measuring points with baselines, alert and alarm limits, a check interval from the P-F interval, readings with rising and overdue flags, and an exceptions list worst first.
- Fire extinguisher inspection logOne row for every portable extinguisher: hydro test interval from OSHA Table L-1, annual and 6-year due dates, a 12-month check grid and open issues.
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A shift handover sheet, a red tag log, a changeover checklist for one machine: if your team uses it on the floor, ask.