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Quest Training

First Article Inspection (FAI) Training Course

Covers verifying a first production article against drawings, specifications and design requirements before full-scale production goes ahead.

SQA · Supplier & Supply Chain Quality ManagementAll Levels#2895ClassroomEnglish , Arabic
Duration
5 Days
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Free substitution at any time · 30+ days' notice: full refund minus 10%. Cancellation policy

Sectors:Quality Management & Operational ExcellenceCategories:Supplier & Supply Chain Quality Management

Course Overview

The First Article Inspection (FAI) Training Course develops the knowledge and practical skills required to verify that the first production article meets all applicable engineering drawings, technical specifications, design requirements, and quality standards. It focuses on establishing objective evidence that manufacturing processes can consistently produce conforming parts before full-scale production or the release of subsequent production batches. The course covers FAI planning, engineering drawing interpretation, characteristic identification, dimensional verification, material and process certification, inspection documentation, and nonconformity management. Participants learn how to review ballooned drawings, prepare inspection plans, verify critical and key characteristics, evaluate measurement results, and compile complete First Article Inspection Reports (FAIRs). The programme also introduces the AS9102 framework used in aerospace manufacturing, while explaining how FAI principles can be adapted to other manufacturing sectors. Through practical exercises and realistic manufacturing scenarios, participants develop the ability to coordinate FAI activities across engineering, production, and quality teams, identify documentation gaps, resolve inspection discrepancies, and determine when partial or repeat inspections are required following significant changes. The course supports stronger production readiness, improved traceability, reduced manufacturing risk, and greater confidence in product conformity.

Learning Objectives

  • Explain the purpose, scope, and benefits of First Article Inspection.
  • Interpret engineering drawings, technical specifications, and applicable inspection requirements.
  • Identify product characteristics requiring verification and objective evidence.
  • Develop FAI plans and inspection documentation aligned with applicable standards.
  • Apply dimensional inspection and measurement verification techniques.
  • Review material certifications, special process records, and supplier documentation.
  • Prepare and verify First Article Inspection Reports (FAIRs).
  • Identify, document, and resolve nonconformities discovered during FAI.
  • Determine the need for partial or repeat FAI following design or manufacturing changes.
  • Establish effective coordination between engineering, manufacturing, suppliers, and quality teams.

Who Should Attend

Quality Assurance and Quality Control Engineers. First Article Inspection and Dimensional Inspection Inspectors. Manufacturing and Production Engineers. Design and Mechanical Engineers. Supplier Quality Engineers and Supplier Development Specialists. Metrology and Calibration Personnel. Production Planning and Industrial Engineering Professionals. Aerospace and precision manufacturing quality personnel. Document Control and Quality Systems Specialists. Professionals responsible for product verification, process qualification, and production release.

Learning Outcomes

  • Define FAI scope, objectives, responsibilities, and acceptance requirements.
  • Interpret engineering drawings and identify product characteristics for inspection.
  • Prepare ballooned drawings and characteristic accountability records.
  • Verify dimensions, materials, specifications, and special process requirements.
  • Assess measurement results against drawing tolerances and acceptance criteria.
  • Compile traceable evidence supporting each applicable product characteristic.
  • Complete and review FAIR documentation for accuracy and completeness.
  • Identify nonconformities and manage their resolution before production approval.
  • Determine when partial or repeat FAI is necessary after relevant changes.
  • Improve coordination and readiness for product and process release.

Course Outline

Day 1

First Article Inspection Fundamentals and Requirements

  • Purpose, principles, and role of FAI in manufacturing quality assurance.
  • Differences between First Article Inspection, routine production inspection, and process qualification.
  • FAI lifecycle, responsibilities, planning, and approval requirements.
  • Overview of AS9102 requirements and their application in aerospace manufacturing.
  • Understanding engineering drawings, revisions, technical specifications, and purchase requirements.
  • Identifying critical characteristics, key characteristics, and special requirements.
  • Practical Exercise: Review a sample engineering drawing and define the FAI scope, applicable requirements, and required inspection evidence.
Day 2

FAI Planning, Drawing Review, and Characteristic Identification

  • Reviewing drawing revisions and confirming configuration requirements.
  • Preparing ballooned drawings and assigning unique characteristic numbers.
  • Establishing characteristic accountability and traceability.
  • Developing inspection plans and linking characteristics to verification methods.
  • Identifying dimensional, material, functional, and special process requirements.
  • Selecting suitable measuring instruments and establishing measurement methods.
  • Practical Exercise: Prepare a ballooned drawing and characteristic accountability matrix for a selected manufactured component.
Day 3

Inspection Execution and Technical Verification

  • Performing dimensional inspection using suitable measurement equipment.
  • Verifying geometric dimensions and tolerances (GD&T), where applicable.
  • Reviewing material test certificates and evidence of compliance with specifications.
  • Verifying special processes, including heat treatment, coating, welding, or surface treatment where applicable.
  • Assessing inspection results against drawing requirements and acceptance criteria.
  • Managing measurement discrepancies, missing evidence, and traceability gaps.
  • Practical Exercise: Inspect a sample component using drawing requirements and measurement records, then document the results and identify discrepancies.
Day 4

FAIR Preparation, Nonconformity Management, and Review

  • Understanding the structure and purpose of a First Article Inspection Report.
  • Preparing applicable FAI forms and supporting documentation in accordance with the relevant standard.
  • Linking drawing characteristics to inspection results and objective evidence.
  • Reviewing material, process, and functional verification records.
  • Identifying incomplete documentation, nonconformities, and inconsistencies in FAIR submissions.
  • Managing corrective actions and determining whether re-inspection is required.
  • Practical Exercise: Compile and review a sample FAIR package, identify documentation and conformity gaps, and prepare a corrective action list.
Day 5

FAI Changes, Approval, and Production Readiness

  • Identifying changes that may trigger partial or repeat FAI.
  • Evaluating design changes, manufacturing process changes, tooling changes, and supplier changes.
  • Establishing change review and FAI revalidation procedures.
  • Defining responsibilities for technical review, quality approval, and production release.
  • Maintaining FAI records, configuration traceability, and document control.
  • Integrating FAI findings into process improvement and production readiness reviews.
  • Practical Exercise: Evaluate a simulated engineering or manufacturing change and determine the required FAI scope, supporting evidence, and approval actions.

Upcoming Dates

Selected date

Lisbon · 16 – 20 Nov 2026 · Classroom

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Available in: Istanbul · Dubai · London · Riyadh · Doha · Amsterdam

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