EN 9102:2024

Aerospace series - Quality systems - First article inspection requirements

1.1   General
This document establishes the requirements for performing and documenting FAI. It is emphasized the requirements specified in this document are complementary (not alternative) to customer and applicable statutory and regulatory requirements.
1.2   Purpose
The primary purpose of FAI is to verify and validate product realization processes are capable of producing characteristics that meet engineering and design requirements. A well-planned and executed FAI by a multi-disciplinary team (e.g. members from responsible functions) provides objective evidence the manufacturer’s processes can produce compliant product; having effectively understood and incorporated the associated requirements.
NOTE   A FAI is not a product acceptance document. While interrelated, FAI and product acceptance are separate activities. The focus of FAI is verification of production processes via assessment of product. FAI and supporting documentation do not provide assurance regarding conformance for product acceptance purposes; neither does the lack of a FAI necessarily imply product is nonconforming to engineering and design requirements.
FAI will:
-   provide confidence, through objective evidence, the product realization processes are capable of producing conforming product;
-   demonstrate the manufacturers and processors of the product have an understanding of the associated requirements;
-   provide assurance of product conformance at the start of production and after changes, as outlined in this document.
A FAI is intended to:
-   mitigate risks associated with production startup and process changes;
-   reduce future escapes;
-   help ensure product safety;
-   improve quality, delivery, and customer satisfaction;
-   reduce costs and production delays associated with product nonconformances;
-   identify product realization processes not capable of producing conforming characteristics and initiate and/or validate associated corrective actions.
-
1.3   Application
This document applies to organizations and their suppliers responsible for product realization processes that produce the design characteristics of the product. The organization shall flow down the requirements of this document to suppliers who produce design characteristics.
This document also applies to suppliers performing special process(es). A certificate of conformance (CoC) provided by processors attests to satisfying the requirements. External suppliers providing special process(es) can satisfy this document's requirements by either:
-   documenting the design characteristics and associated results on a first article inspection report (FAIR); or
-   documenting the design characteristics and associated results on a detailed CoC.
This document applies to assemblies, sub-assemblies, and detail parts including castings, forgings, and modifications to standard catalogue or commercial-off-the-shelf (COTS) items. Each of these items have a separate FAI.
Unless contractually required, this document does not apply to:
-   development and prototype parts that are not considered as part of the first production run;
-   procured standard catalogue item, COTS, or deliverable software. When these items are included in an assembly, they shall be documented in the index of part numbers in an assembly FAIR.
1.4   Informative
If there is a conflict between the requirements of this document, and customer or applicable statutory/regulatory requirements, the latter takes precedence.
In this document, the following verbal forms are used:
-   "shall" indicates a requirement;
-   "should" indicates a recommendation;
-   "may" indicates a permission;
-   "can" indicates a possibility or a capability.
Information marked as "NOTE" is for guidance in understanding or clarifying the associated requirement .

Luft- und Raumfahrt - Qualitätsmanagementsysteme - Anforderungen an die Erstmusterprüfung

Série aérospatiale - Systèmes qualité - Exigences pour la revue premier article

1.1   Généralités
Le présent document établit les exigences pour réaliser et documenter la FAI. Il est à souligner que les exigences spécifiées dans le présent document viennent compléter (sans les remplacer) les exigences du client et les exigences légales et réglementaires applicables.
1.2   Objet
L'objet principal de la FAI est de vérifier et de valider que les procédés de réalisation du produit sont à même de produire des caractéristiques qui satisfont aux exigences d'ingénierie et de conception. Une FAI bien planifiée et effectuée par une équipe pluridisciplinaire (par exemple : dont les membres occupent des fonctions à responsabilité) apporte les preuves objectives que les procédés du fabricant permettent de produire des produits conformes, pour autant que les exigences associées aient été bien comprises et incluses à la FAI.
NOTE   Une FAI n'est pas un document d'acceptation d'un produit. Si elles sont interdépendantes, la FAI et l'acceptation d'un produit sont toutefois des activités distinctes. L’objectif de la FAI est de vérifier les procédés de production via l'évaluation du produit. La FAI et la documentation associée ne fournissent aucune garantie quant à la conformité en vue de l'acceptation d'un produit. L'absence de FAI n'implique pas que le produit n'est pas conforme aux exigences d'ingénierie et de conception.
La FAI :
-   donne confiance, grâce aux preuves objectives, dans la capacité des procédés de réalisation du produit à fournir un produit conforme ;
-   démontre que les fabricants et les transformateurs du produit comprennent les exigences associées ;
-   garantit la conformité du produit au début de la production et après les changements, comme décrit dans le présent document.
Une FAI est destinée à :
-   réduire les risques associés au lancement de la production et aux modifications de procédé ;
-   réduire les futures dérives ;
-   garantir la sécurité du produit ;
-   améliorer la qualité, la livraison et la satisfaction client ;
-   réduire les coûts et les délais de production associés aux non-conformités du produit ;
-   identifier les procédés de réalisation du produit ne permettant pas de produire des caractéristiques conformes, et lancer et/ou valider les actions correctives associées.
1.3   Application
Le présent document s'applique aux organismes et à leurs fournisseurs responsables des procédés de réalisation du produit qui élaborent les caractéristiques de conception du produit. L'organisme doit transmettre les exigences du présent document aux fournisseurs qui élaborent les caractéristiques de conception.
Le présent document s’applique également aux fournisseurs en charge d’un ou plusieurs procédés spéciaux. Un certificat de conformité (CC) fourni par les transformateurs atteste que les exigences sont satisfaites. Les fournisseurs externes chargés d’un ou plusieurs procédés spéciaux peuvent satisfaire aux exigences du présent document :
-   en documentant les caractéristiques de conception et les résultats associés dans un rapport de revue premier article (FAIR) ; ou
-   en documentant les caractéristiques de conception et les résultats associés dans un CC détaillé.
Le présent document s'applique aux ensembles, aux sous-ensembles et aux pièces élémentaires, y compris aux pièces forgées ou moulées et aux modifications des articles catalogue standards ou des produits sur étagère (COTS). Chacun de ces articles dispose d’une FAI distincte.
Sauf exigence contractuelle, le présent document ne s'applique pas :
-   aux pièces prototypes et de développement qui ne sont pas considérées comme faisant partie de la première production de série ;
-   aux articles catalogue standards, aux COTS ou aux logiciels livrables achetés. Lorsque ces articles sont inclus dans un ensemble, ils doivent être documentés dans l'index des références articles d'un FAIR de l’ensemble.
[...]

Aeronavtika - Sistem vodenja kakovosti - Zahteve za prvi pregled vzorcev

1.1 Ta dokument postavlja zahteve za izvedbo in dokumentiranje za prvi pregled vzorcev (FAI). Poudariti je treba, da zahteve iz tega standarda dopolnjujejo (niso alternativna možnost) zahteve odjemalcev in ustrezne zakonske ter regulativne zahteve.
V primeru neskladnosti med zahtevami iz tega dokumenta in zahtevami odjemalcev ali ustreznimi zakonskimi ali regulativnimi zahtevami, imajo prednost ustrezne zakonske ali regulativne zahteve.
V tem dokumentu so uporabljene naslednje glagolske oblike:
– »treba je« ali »mora« označuje zahtevo;
– »naj« označuje priporočilo;
– »sme« označuje dovoljenje;
– »lahko« označuje možnost ali sposobnost.
Informacije, označene kot »OPOMBA«, so namenjene usmerjanju pri razumevanju ali pojasnjevanju pripadajoče zahteve.
1.2 Namen
Primarni namen prvega pregleda vzorcev je preveriti in potrditi, da procesi realizacije izdelka omogočajo ustvarjanje lastnosti, ki izpolnjujejo zahteve inženiringa in projektiranja. Prvi pregled vzorcev ni dokument o sprejemljivosti proizvoda. Dobro načrtovan in izveden prvi pregled vzorcev, ki ga izvede večdisciplinarna skupina (npr. člani z odgovornih funkcij), zagotovi objektivne dokaze, da proizvajalčevi procesi lahko proizvedejo skladen izdelek ob razumevanju in upoštevanju povezanih zahtev.
OPOMBA: Čeprav sta med seboj povezani, sta prvi pregled vzorcev in sprejemljivost izdelka ločeni dejavnosti. Prvi pregled vzorcev se osredotoča na preverjanje proizvodnih procesov z ocenjevanjem izdelka. Prvi pregled vzorcev in spremni dokumenti ne dajejo zagotovila glede skladnosti za namene sprejemljivosti izdelka; prav tako odsotnost prvega pregleda vzorcev ne pomeni nujno, da je izdelek neskladen z inženirskimi in projektantskimi zahtevami.
Prvi pregled vzorcev bo:
– zagotovil zaupanje, da procesi realizacije izdelka omogočajo proizvodnjo skladnega izdelka;
– pokazal, da proizvajalci in obdelovalci izdelka razumejo z izdelkom povezane zahteve;
– zagotovil objektivne dokaze o zmožnosti procesa;
– zmanjšal tveganja, povezana z začetkom proizvodnje in/ali spremembami procesa;
– zagotovil skladnost izdelka ob začetku proizvodnje in po spremembah, opredeljenih v tem dokumentu.
Prvi pregled vzorcev je namenjen:
– zmanjšanju prihodnjih napak, tveganj in skupnih stroškov;
– v pomoč pri zagotavljanju varnosti izdelka;
– izboljšanju kakovosti, dobave in zadovoljstva strank;
– zmanjšanju stroškov in zastojev proizvodnje, povezanih z neskladnostjo izdelka;
– ugotavljanju procesov realizacije izdelka, ki ne omogočajo proizvodnje skladnega izdelka, in sprejemanju in/ali potrjevanju povezanih korektivnih ukrepov.
1.3 Uporaba
Ta dokument se uporablja za organizacije in podrejene entitete, ki so odgovorne za proizvodnjo projektnih lastnosti izdelka (tj. za realizacijo izdelka). Organizacija bo zahteve tega dokumenta posredovala dobaviteljem, ki proizvajajo konstrukcijske lastnosti.
Ta dokument se uporablja za zunanje dobavitelje, ki izvajajo posebne procese. Potrdilo o skladnosti, ki ga zagotovijo obdelovalci, dokazuje skladnost z zahtevami specifikacij pristojnega organa za projektiranje. Zunanji dobavitelji, ki zagotavljajo posebne procese, lahko izpolnijo zahteve iz tega dokumenta:
– z dokumentiranjem konstrukcijskih lastnosti in povezanih rezultatov pri prvem pregledu vzorcev;
– z dokumentiranjem konstrukcijskih lastnosti in povezanih rezultatov na potrdilu o skladnosti, ki ga določi stranka.
Ta dokument se uporablja za sestave, podsestave in posamezne dele, vključno z ulitki, izkovki, in spremembami izdelkov iz kataloga dokumenta ali standardnih izdelkov (COTS). Za vsakega od teh elementov je treba izvesti ločen prvi pregled vzorcev.
Če ni pogodbeno dogovorjeno drugače, se ta dokument ne uporablja za:
– razvijanje delov in prototipov, ki ne spadajo v prvo proizvodno serijo;
– izdelke, dobavljene iz standardnega kataloga, standardne izdelke ali dobavljivo programsko opremo. Te elemente je treba dokumentirati v kazalu številk delov pri pripravi poročila o prv

General Information

• Status: Published
• Publication Date: 12-Mar-2024
• ICS: 03.120.10 - Quality management and quality assurance
• ICS: 49.020 - Aircraft and space vehicles in general
• Technical Committee: ASD-STAN - Aerospace
• Drafting Committee: ASD-STAN/D 6/S 1 - EAQG European Aerospace Quality Group
• Current Stage: 6060 - Definitive text made available (DAV) - Publishing
• Start Date: 13-Mar-2024
• Completion Date: 13-Mar-2024
• Ref Project: SIST EN 9102:2024 - Aerospace series - Quality systems - First Article Inspection Requirement

Relations

• Replaces: EN 9102:2015 - Aerospace series - Quality systems - First article inspection requirements
• Effective Date: 19-Jan-2023

Overview

EN 9102:2024 - "Aerospace series - Quality systems - First article inspection requirements" (CEN) specifies requirements for planning, performing and documenting First Article Inspection (FAI). Approved March 2024 and superseding EN 9102:2015, the standard clarifies how manufacturers and suppliers demonstrate that product realization processes can produce parts that meet engineering and design requirements. EN 9102:2024 emphasizes FAI planning, evaluation, re-accomplishment and alignment with EN 9100, and it reinforces that FAI requirements are complementary to customer and statutory/regulatory requirements.

Key topics and requirements

• Purpose of FAI: Verify and validate that production processes produce characteristics conforming to engineering/digital product definition (DPD) and design requirements.
• Scope & application: Applies to assemblies, sub‑assemblies and detail parts (castings, forgings, modified COTS). Each item requires a separate FAI unless contractually excluded (e.g., certain prototypes or off‑the‑shelf items documented in an assembly index).
• FAI execution: Requires a planned, multidisciplinary approach to provide objective evidence of process capability. A FAI is a verification of processes via product assessment - not a product acceptance certificate.
• Documentation: Use of First Article Inspection Report (FAIR) forms and retained documented information, with options for external processors to use a detailed Certificate of Conformance (CoC) for special processes.
• Digital product definition (DPD): Recognizes digital drawings and 3D models as part of the design baseline; DPD characteristics must be included in the FAI.
• Nonconformance & re-accomplishment: Defines evaluation activities, nonconformance handling and when partial or full re-accomplishment of FAI is required.
• Terminology & normative references: Uses ISO 9000 vocabulary and IAQG definitions; conventions for “shall/should/may/can” are specified.

Practical applications

• Use EN 9102:2024 to establish or improve a standardized FAI process across aerospace supply chains.
• Employ FAIRs to demonstrate process readiness at production start or after design/process changes.
• Suppliers performing special processes can either submit FAIRs or detailed CoCs to satisfy requirements.
• Integrate with quality management systems (e.g., EN 9100/ISO 9001) to reduce escapes, lower rework costs, and improve product safety and delivery.

Who should use this standard

• Aerospace manufacturers, OEMs and tiered suppliers responsible for product realization.
• Quality, engineering, inspection, and procurement teams planning FAIs.
• External processors and special‑process providers needing to demonstrate conformance via FAIR or CoC.

Related standards

• EN 9100 (aerospace quality management) - alignment noted in EN 9102:2024
• ISO 9000 - normative reference for quality vocabulary
• IAQG Internal Dictionary - terminology used by the industry

Keywords: EN 9102:2024, First Article Inspection (FAI), FAIR, DPD, aerospace quality, certificate of conformance, EN 9100, product realization.

Standards Content (Sample)

SLOVENSKI STANDARD
01-maj-2024
Aeronavtika - Sistem vodenja kakovosti - Zahteve za prvi pregled vzorcev
Aerospace series - Quality systems - First Article Inspection Requirement
Luft- und Raumfahrt - Qualitätsmanagementsysteme - Anforderungen an die
Erstmusterprüfung
Série aérospatiale - Systèmes qualité - Exigences pour la revue premier article
Ta slovenski standard je istoveten z: EN 9102:2024
ICS:
03.120.10 Vodenje in zagotavljanje Quality management and
kakovosti quality assurance
49.020 Letala in vesoljska vozila na Aircraft and space vehicles in
splošno general
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

EN 9102
EUROPEAN STANDARD
NORME EUROPÉENNE
March 2024
EUROPÄISCHE NORM
ICS 03.120.10; 49.020 Supersedes EN 9102:2015
English Version
Aerospace series - Quality systems - First article inspection
requirements
Série aérospatiale - Systèmes qualité - Exigences pour Luft- und Raumfahrt - Qualitätsmanagementsysteme -
la revue premier article Anforderungen an die Erstmusterprüfung
This European Standard was approved by CEN on 29 January 2024.

CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this
European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references
concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN
member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by
translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management
Centre has the same status as the official versions.

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway,
Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Türkiye and
United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION

EUROPÄISCHES KOMITEE FÜR NORMUNG

CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2024 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 9102:2024 E
worldwide for CEN national Members.

Contents Page
European foreword . 3
Introduction . 4
1 Scope . 5
1.1 General. 5
1.2 Purpose . 5
1.3 Application . 6
1.4 Convention . 6
2 Normative references . 7
3 Terms and definitions . 7
4 Requirements . 10
4.1 First article inspection planning . 10
4.2 Part requirements . 11
4.3 Digital product definition requirements . 11
4.4 Evaluation activities . 12
4.5 Nonconformance handling . 12
4.6 Partial or re-accomplishment of first article inspection . 13
4.7 Documentation . 14
4.8 Retained documented information . 15
Annex A (informative) Acronym log . 16
Annex B (normative) EN 9102 forms and supporting form instructions . 17
B.1 General. 17
B.2 Form 1: Part number accountability . 18
B.3 Form 2: Product accountability — materials, special processes and functional testing . 22
B.4 Form 3: Characteristic accountability, verification and compatibility evaluation . 25
Bibliography . 28

European foreword
This document (EN 9102:2024) has been prepared by ASD-STAN.
After enquiries and votes carried out in accordance with the rules of this Association, this document has
received the approval of the National Associations and the Official Services of the member countries of
ASD-STAN, prior to its presentation to CEN.
This document shall be given the status of a national standard, either by publication of an identical text
or by endorsement, at the latest by September 2024, and conflicting national standards shall be
withdrawn at the latest by September 2024.
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. CEN shall not be held responsible for identifying any or all such patent rights.
This document supersedes EN 9102:2015.
According to the CEN-CENELEC Internal Regulations, the national standards organizations of the
following countries are bound to implement this document: Austria, Belgium, Bulgaria, Croatia, Cyprus,
Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy,
Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Republic of North
Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Türkiye and the United
Kingdom.
Introduction
This document was revised to emphasize and enhance the first article inspection (FAI) planning,
evaluation, and re-accomplishment activities; aligning requirements to EN 9100. Additional changes to
the document requirements, definitions, and associated notes were incorporated in response to
stakeholder needs.
To ensure customer satisfaction, the aviation, space, and defence industry organizations must produce
and continually improve safe, reliable products that meet or exceed customer and regulatory
requirements. The globalization of the industry and the resulting diversity of regional/national
requirements and expectations have complicated this objective. End product organizations face the
challenge of assuring the quality and integration of products purchased from suppliers throughout the
world and at all levels of the supply chain. Industry suppliers face the challenge of delivering products
to multiple customers having varying quality requirements and expectations.
The aviation, space, and defence industry established the International Aerospace Quality Group (IAQG)
for the purpose of achieving significant improvements in quality, delivery, safety, and reductions in cost
throughout the value stream. This organization includes representation from companies in the
Americas, Asia/Pacific, and Europe.
This document standardizes FAI process requirements to the greatest extent possible. While primarily
developed for the aviation, space, and defence industry, this document can also be used in other
industry sectors where a standardized FAI process is needed.
1 Scope
1.1 General
This document establishes the requirements for performing and documenting FAI. It is emphasized the
requirements specified in this document are complementary (not alternative) to customer and
applicable statutory and regulatory requirements.
1.2 Purpose
The primary purpose of FAI is to verify and validate product realization processes are capable of
producing characteristics that meet engineering and design requirements. A well-planned and executed
FAI by a multi-disciplinary team (e.g. members from responsible functions) provides objective evidence
the manufacturer’s processes can produce compliant product; having effectively understood and
incorporated the associated requirements.
NOTE A FAI is not a product acceptance document. While interrelated, FAI and product acceptance are separate
activities. The focus of FAI is verification of production processes via assessment of product. FAI and supporting
documentation do not provide assurance regarding conformance for product acceptance purposes; neither does
the lack of a FAI necessarily imply product is nonconforming to engineering and design requirements.
FAI will:
— provide confidence, through objective evidence, the product realization processes are capable of
producing conforming product;
— demonstrate the manufacturers and processors of the product have an understanding of the
associated requirements;
— provide assurance of product conformance at the start of production and after changes, as outlined
in this document.
A FAI is intended to:
— mitigate risks associated with production startup and process changes;
— reduce future escapes;
— help ensure product safety;
— improve quality, delivery, and customer satisfaction;
— reduce costs and production delays associated with product nonconformances;
— identify product realization processes not capable of producing conforming characteristics and
initiate and/or validate associated corrective actions.

1.3 Application
This document applies to organizations and their suppliers responsible for product realization
processes that produce the design characteristics of the product. The organization shall flow down the
requirements of this document to suppliers who produce design characteristics.
This document also applies to suppliers performing special process(es). A certificate of conformance
(CoC) provided by processors attests to satisfying the requirements. External suppliers providing
special process(es) can satisfy this document's requirements by either:
— documenting the design characteristics and associated results on a first article inspection report
(FAIR); or
— documenting the design characteristics and associated results on a detailed CoC.
This document applies to assemblies, sub-assemblies, and detail parts including castings, forgings, and
modifications to standard catalogue or commercial-off-the-shelf (COTS) items. Each of these items have
a separate FAI.
Unless contractually required, this document does not apply to:
— development and prototype parts that are not considered as part of the first production run;
— procured standard catalogue item, COTS, or deliverable software. When these items are included in
an assembly, they shall be documented in the index of part numbers in an assembly FAIR.
1.4 Convention
If there is a conflict between the requirements of this document, and customer or applicable
statutory/regulatory requirements, the latter takes precedence.
In this document, the following verbal forms are used:
— “shall” indicates a requirement;
— “should” indicates a recommendation;
— “may” indicates a permission;
— “can” indicates a possibility or a capability.
Information marked as “NOTE” is for guidance in understanding or clarifying the associated
requirement .
Notes to entry used in definitions, however, are considered normative and will provide additional information
that supplements the terminological data such as statements, instructions, recommendations, or requirements
relating to the use of a term.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies. For
undated references, the latest edition of the referenced document (including any amendments) applies.
ISO 9000, Quality management systems — Fundamentals and vocabulary
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 9000, the IAQG Internal
Dictionary and the following apply.
An acronym log for this document is presented in Annex A.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https://www.iso.org/obp
— IEC Electropedia: available at https://www.electropedia.org/
3.1
assembly
product that is produced by joining two or more detail parts, COTS, standard catalogue items, or sub-
assemblies into one item
3.2
attribute data
result from a characteristic or property that is appraised only as to whether it does or does not conform
to a given requirement
3.3
ballooned design characteristic
clear and uniquely identified design characteristic indicated on a ballooned document
Note 1 to entry: the unique identifier may be circled or highlighted for easy visual identification.
3.4
ballooned document
aid used in FAI to identify all the design characteristics, including all documents [e.g., drawings,
purchase order, digital product definition (DPD)]; typically sequentially numbering the design
characteristics and putting a circle around or highlighting the numbered design characteristics
3.5
baseline part number
part number from the previous FAI or approved configuration, including revision level, to which a
partial FAI is performed
Note 1 to entry: an example of an approved configuration is a part produced and verified as conforming product
prior to the requirements of this document.

Published by: ISO International Organization for Standardization http://www.iso.ch/.
Located on the IAQG website: https://iaqg.org/tools/dictionary/.
3.6
commercial-off-the-shelf (COTS) item
commercially available item intended by design to be procured and utilized without modification (e.g.,
common electronic components)
Note 1 to entry: any item or assembly meeting all of the following requirements:
a) defined by industry, manufacturer, military, or recognized specifications or standards;
b) without design modification, specifically for a customer;
c) customarily used by the public or industries; and
d) offered for sale to the public, though catalogues, price list, brochures, stores, or websites.
3.7
deliverable software
embedded or loadable airborne, spaceborne, or ground support software or firmware components
which are part of an aircraft type design, weapon system, missile, or spacecraft
3.8
design characteristic
dimensional, visual, functional, mechanical, and material features or properties, which describe and
constitute the design of the product
Note 1 to entry: these characteristics can be measured, inspected, tested, or verified to determine conformance to
the design requirements as specified on the parts list, purchasing document, drawing, or DPD, to which the
product is to be produced:
— dimensional design characteristics include in-process locating features (e.g. additive manufacturing, target-
machined or forged/cast dimensions on forgings and castings, weld/braze joint preparation necessary for
acceptance of finished joint);
— material design characteristics include processing output variable (e.g. plating or coating thickness/runout,
material hardness/conductivity). These provide assurance of intended characteristics that could not be
otherwise defined.
3.9
designed tooling
product specific tooling [e.g. check fixtures, coordinate measurement machine (CMM) program]
specifically made to validate the design characteristics of a product
3.10
detail part
article/part produced to engineering definition that does not include assembly processes (i.e. processes
that join two or more parts together)
Note 1 to entry: detail parts may include processing, finishes, and/or special processes.

3.11
digital product definition
DPD
digital data file(s) that disclose, directly or by reference, the physical or functional requirements,
including data files that disclose the design or acceptance criteria of a product
Note 1 to entry: examples of DPD include the following:
— digital data file(s) and fully dimensioned two-dimensional (2D) drawing sheets;
— three-dimensional (3D) data model, and simplified or reduced content 2D drawing sheets;
— 3D data model with design characteristics displayed as text;
— any other data files containing design characteristics that define a product in its entirety.
3.12
first article inspection
FAI
planned, complete, independent, and documented inspection and verification process to ensure that
prescribed production processes have produced an item conforming to engineering drawings, DPD,
planning, purchase order, engineering specifications, and/or other applicable design documents
Note 1 to entry: the intent of independent as referenced above is to mitigate the effect of measurement error.
This includes ensuring the person that verifies the characteristic for the first article not be the same person that
generated the characteristic. Self-inspection (i.e. operator self-verification) is not considered independent. The
equipment used to verify the characteristic should be different from the equipment used to produce the
characteristic.
3.13
first article inspection report
FAIR
comprised of the forms identified in Annex B, all ballooned design characteristics, and the supporting
documentation determined by FAI planning for a part number (e.g., detail, sub-assembly, or assembly)
3.14
first production run
initial group of one or more parts that are the result of a planned process designed to be used for
production of these same parts
3.15
modified commercial-off-the-shelf (COTS)/standard catalogue item
COTS or standard catalogue item that has a change made to it from its original designed configuration
Note 1 to entry: Once modified, these items are categorized as detail parts for the purpose of assembly.
3.16
multiple characteristics
identical characteristics that occur at more than one location (e.g. “4 places”), but are identified by a
single set of drawing or DPD requirements (e.g. rivet hole size, dovetail slots, corner radii, chemical
milling pocket thickness)
3.17
product
any intended output resulting from the product realization process, which in the context of this
document includes finished detail parts, sub-assemblies, assemblies, forgings, and castings
3.18
qualified tooling
universal (not part specific) calibrated monitoring and measuring equipment (e.g. go/no go gauges,
thread gauges, radius gauges) used to validate product design characteristics using attribute data
3.19
reference characteristic
characteristic (including reference and basic dimensions) that are used for “information only” or to
show relationship; these are dimensions without tolerances and refer to other dimensions on the
drawing or in the DPD
3.20
special process
any process for production and service provision where the resulting output cannot be verified by
subsequent monitoring or measurement and, as a consequence, deficiencies become apparent only after
the product is in use or the service has been delivered
3.21
standard catalogue item
part or material that conforms to an established industry or national authority published specification,
having all characteristics identified by written description or an industry/national/military standard
drawing
3.22
variable data
quantitative measurements taken on a continuous scale (e.g. the diameter of a cylinder, the gap
between mating parts)
4 Requirements
4.1 First article inspection planning
a. The organization shall have a documented process to plan for FAI. This process shall identify the
responsible functions and address the activities to be performed, prior to the first production run.
b. The organization shall verify the revision for embedded or deliverable software as defined by the
bill of materials (BOM), drawing/DPD, specification, or purchase order requirements.
c. The organization shall consider the following activities during FAI planning and, if required by
contract, coordinate planning with the customer:
1. determine design characteristic inspection and sequencing for inspection of characteristics not
measurable in the final product and provisions to carry out those activities at the appropriate
stage of the manufacturing process;
2. evaluate DPD design characteristics required for product realization which are not fully
defined on 2D drawings, including tolerances for nominal dimensions;
3. determine the required objective evidence to be included in the FAIR for each design
characteristic, including supporting documentation;
NOTE This includes bubbled or ballooned document(s), and can also include certifications, inspection
reports, test reports, manufacturing plans, purchase orders, etc.
4. identify the approved special process, laboratory, material, and customer required sources, as
applicable, and confirm the manufacturing planning, routing, and purchase document identify
the correct specification and relevant sources;
5. identify key characteristic and critical item requirements, as applicable (see IAQG standards
EN 9100 and EN 9103 for supporting guidance/direction);
6. determine suitable monitoring and measuring equipment of appropriate resolution and
accuracy. Ensure part specific gauges and tooling are identified, qualified, and traceable.
Metrology principles (e.g. accuracy ratio, measurement uncertainty) should be taken into
consideration when selecting a measurement method;
7. coordinate customer FAI review(s) at any stage;
8. identify events requiring an updated FAI (see subclause 4.6).
d. The organization shall verify FAI planning activities have been completed.
4.2 Part requirements
a. The organization shall perform a FAI on new product representative of the first production run.
The first production product delivery requires a FAI.
b. The organization shall use one or more representative items from the first production run of a new
product to verify that the production processes, production documentation, and tooling have the
ability to produce products that meet established requirements.
c. For assemblies, the assembly level FAI shall be performed on those characteristics specified on the
assembly drawing or DPD.
d. Detail part characteristics created or modified during assembly may be accounted for at the
assembly level FAI, all other detail part characteristics shall be accounted for on the detail part FAI.
4.3 Digital product definition requirements
a. When design requirements are in a DPD format and traditional 2D drawing information is not
available for all applicable design requirements, DPD design characteristics required for product
realization shall be extracted, verified, and included in the FAIR.
b. The organization shall:
1. establish a process to extract the applicable DPD design characteristics;
2. extract the DPD design characteristics required for product realization;
3. ensure the production, inspection, and operations requiring verification have been completed
as planned to achieve DPD design characteristics.
NOTE For additional information on DPD, refer to ASME Y14.41 and/or ISO 16792.

4.4 Evaluation activities
The organization shall conduct the following activities during product realization in support of FAI to
ensure conformance with design characteristics:
a. review the manufacturing process documentation (e.g. routing sheets, risk analysis, manufacturing
or quality plans, manufacturing work instructions) to ensure all operations are complete as
planned and call out the correct specification, material types, conditions, and approvals;
b. review supporting documentation for completeness;
c. verify the raw material and special process certifications (e.g. CoC, special process completion
certification, raw material test report number, modified standard catalogue item compliance report
number, traceability number) call out the correct specification, material types, conditions, and
approvals;
d. verify that required customer approved sources are utilized (e.g. directed source, approved
suppliers list);
e. review nonconformance documentation for completeness;
f. verify that required designed tooling (e.g. part specific gauges) is used;
g. verify that every design characteristic requirement, including DPD characteristics as required per
4.3b, is accounted for, uniquely identified, and has inspection results traceable to each unique
identifier (e.g. ballooned design characteristic);
h. verify the design characteristics resulting from the output of the manufacturing process are
measured, inspected, tested, or verified to determine conformance, including DPD characteristics as
required per 4.3b.;
i. verify part marking has met defined requirements, such as legibility (i.e. human/machine
readable), method, material, content, size, and location.
4.5 Nonconformance handling
a. When processing a FAIR with documented nonconformances, the organization shall:
1. record the nonconfor
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