First Article Inspection (FAI) Checklist
Ensure flawless production with our comprehensive First Article Inspection (FAI) Checklist for Manufacturing. Downloadable & customizable, this checklist guarantees quality, compliance, & prevents costly errors - your key to manufacturing excellence!
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General Information
Basic details about the FAI, part, and supplier. This section establishes the context for the inspection.
FAI Report Number
Part Number
Revision Level
Supplier Name
FAI Date
Quantity of First Article
Order Number / PO Number
FAI Status
Document Review
Verification that all applicable drawings, specifications, process documentation, and other related documents are current and correct.
Drawing Revision Level Verified?
Specification Document Verified?
List of Documents Reviewed (e.g., Drawing, Specification, Process Plan)
Upload of Reviewed Document(s)
Document Review Date
Document Control Number (if applicable)
Are there any discrepancies between drawing and purchase order?
Material Verification
Confirmation that the materials used conform to specified requirements, including traceability and certifications.
Material Certification Received?
Material Certificate (e.g., Mill Certificate)
Material Lot Number
Material Supplier Name
Material Conforms to Specification?
Discrepancy Details (If Material Doesn't Conform)
Material Hardness (if applicable)
Material Traceability Verified?
Process Verification
Assessment of the manufacturing processes used to produce the first article, ensuring adherence to documented procedures.
Describe the Manufacturing Process Sequence
Machine ID (e.g., Milling Machine 1)
Process Control Plan Availability?
Used Inspection Gauges/Tools
Date of Process Run
Deviations from Standard Operating Procedures (SOPs)
Operator Qualification Status?
Dimensional Verification
Measurement of critical dimensions to ensure they meet drawing tolerances and geometric dimensioning and tolerancing (GD&T) requirements.
Length (Dimension A)
Width (Dimension B)
Height (Dimension C)
Diameter (Dimension D)
Wall Thickness (Dimension E)
GD&T Compliance - Position
GD&T Compliance - Parallelism
Dimensional Measurement Report
Functional Verification
Testing of the first article to confirm it performs its intended function(s) as defined in the requirements.
Describe the Functional Test Procedure Followed
Test Result: Voltage Output (V)
Test Result: Pressure Output (PSI)
Operating Temperature During Test
Functional Tests Performed (Check all that apply)
Overall Functional Test Result
Attach Video of Functional Test (if applicable)
Surface Finish & Appearance
Evaluation of surface finish, appearance, and any special treatments applied to the first article.
Ra Value (Microns)
Rz Value (Microns)
Surface Coating Type (if applicable)
Surface Coating Specification (if applicable)
Color Match (if applicable)
Description of Appearance Discrepancies (if any)
Appearance Photographs (Multiple)
Surface Defects Observed?
Assembly Verification (if applicable)
Inspection of any assembled components to ensure correct assembly, fit, and function.
Confirm all fasteners are present and correctly installed.
Number of Sub-Assemblies Verified (e.g., 100%)
Alignment/Fit of Components (Overall)
Detailed observations of component fit and alignment.
Upload photos of critical assembly points.
Torque Verification (if applicable)
Torque Values Used (Record Actual Values)
Checklist of Specific Sub-assemblies to be verified (Select All That Apply)
Non-Destructive Testing (NDT) (if applicable)
Performance of required non-destructive tests, such as X-ray, dye penetrant, or ultrasonic testing, as specified in the requirements.
NDT Method Required?
Selected NDT Method(s)
Specific NDT Requirements (from drawing/specification)
NDT Procedure Documentation
Ultrasonic Thickness Measurement (if applicable)
NDT Results & Anomalies Observed
Acceptance Criteria Met?
Deviation from Acceptance Criteria (if applicable)
NDT Inspector Signature
Documentation & Traceability
Verification of proper documentation, including inspection records, test results, and traceability of components and materials.
FAI Report Number
FAI Completion Date
Summary of Deviations & Corrective Actions (if any)
Calibration Certificates for Measuring Equipment
Material Certificate Status
Lot Number (if applicable)
Traceability Records Verified?
Supplier Part Number
Inspector Signature
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