AS9102: Aerospace First Article Inspection (FAI)

AS9102 sets out how aviation, space and defence suppliers plan, perform and document a First Article Inspection: a documented check that a production process can make a part or assembly that meets every design requirement. The current edition is AS9102 Revision C, issued 28 June 2023, which replaced Revision B.

Why FAI matters

A well-planned FAI gives objective evidence, at the start of production and after relevant changes, that your processes are capable and that the requirements were understood. That means fewer escapes, less rework and fewer production delays. Revision C adds that an FAI is not a product acceptance document: it does not replace product acceptance.

What changed in Revision C

  • Planning comes first (clause 4.1, First Article Planning): you need a documented process to plan the FAI, the planning activities must be verified, and the revision of any embedded or deliverable software must be checked.

  • Application (1.3): each item needs its own FAI, the old exemption for unique single-run production orders was removed, and there is more detail on when a certificate of conformance can be accepted for special processes.

  • Partial FAI and re-accomplishment (4.6): you need a documented process to evaluate changes. The trigger is no longer the "potential to affect fit, form or function"; it is whether characteristics have been invalidated or are not represented.

  • Nonconformances (4.5 and Form 1, field 19): instead of "FAI complete / not complete", the form now asks whether the FAIR contains a documented nonconformance.

  • Forms: the FAIR identifier is now required on Forms 1, 2 and 3; Form 1 gains separate fields for who verified and who reviewed/approved the FAIR, customer approval, and comments; the signature and date fields were removed from Forms 2 and 3; Form 3 can record software as a requirement.

  • Definitions (section 3): new or changed terms include assembly, detail part, ballooned design characteristic, ballooned document, COTS item and modified COTS / standard catalogue item.

Moving from Revision B

Review your FAI procedure, templates and training against Revision C, paying particular attention to FAI planning, the new partial-FAI trigger, the nonconformance question on Form 1 and the new required fields. Confirm with your customers when they expect Revision C to apply to their parts.

How Paradygm can help

We help aerospace suppliers set up FAI planning, update FAI procedures and forms for Revision C, train inspectors and planners, and audit the FAI process as part of AS9100. Call 1-855-702-9001 or request a quote.

AS9102 is published by SAE International and IAQG member bodies; buy the standard from SAE. This page is a summary in Paradygm's own words and does not reproduce the standard.