First Article Inspection Checklist [FREE PDF]

First Article Inspection (FAI) is a formal verification process confirming that a production process can produce parts that meet all engineering design and specification requirements. AS9100 Rev D clause 8.1.3 mandates FAI for new or revised part configurations, and IATF 16949 clause 8.3.4.2 requires documented evidence of design validation including dimensional and functional verification. A thorough FAI reduces downstream nonconformances, protects regulatory compliance, and provides objective

  • Industry: Aerospace QA
  • Frequency: Per Event
  • Estimated Time: 60-90 minutes
  • Role: QA Engineer
  • Total Items: 36
  • Compliance: AS9100 Rev D Clause 8.1.3 - First Article Inspection, ISO 9001:2015 Clause 8.5.1 - Control of Production and Service Provision, IATF 16949:2016 Clause 8.3.4.2 - Design and Development Validation, SAE AS9102B - Aerospace First Article Inspection Requirement, ASTM E2905 - Standard Practice for Examination and Evaluation of Documents

Documentation & Drawing Review

Verify all design documentation, drawings, and specifications are current and accessible before inspection begins.

  • Is the engineering drawing at the correct revision level matching the purchase order or contract requirements?
  • Has a complete Bill of Materials (BOM) been reviewed and confirmed against the design record?
  • Are all applicable material and process specifications listed on the drawing available and current?
  • Has the First Article Inspection Report (FAIR) form been initiated with all header information completed?
  • Are all customer-specific requirements and special notes on the drawing identified and documented?

Material & Raw Stock Certification

Confirm material traceability, certifications, and compliance with specified material standards.

  • Is a material certification (mill cert or CoC) available for all raw materials used in the part?
  • Does the material certification confirm the correct alloy, temper, or grade as specified on the drawing?
  • Has material heat or lot traceability been recorded on the FAI documentation package?
  • Are any restricted or hazardous substances (e.g., REACH, RoHS) verified and documented if applicable?
  • Is material test evidence (hardness, tensile, or chemical analysis) included in the FAI package where required?

Dimensional & Geometric Inspection

Perform and record all dimensional measurements against drawing tolerances using calibrated equipment.

  • Have all drawing dimensions been ballooned and assigned a characteristic number on the inspection report?
  • Is all measurement equipment used for dimensional inspection calibrated with current calibration labels?
  • Do all measured dimensions fall within the specified tolerances noted on the engineering drawing?
  • Have all Geometric Dimensioning and Tolerancing (GD&T) callouts (flatness, perpendicularity, true position, etc.) been verified?
  • Are actual measured values (not just pass/fail) recorded for every characteristic on the FAIR Form 3?
  • Has a photograph or CMM print been attached to document critical feature measurements?

Surface Finish & Visual Inspection

Assess surface finish requirements, cosmetic acceptance criteria, and absence of visible defects.

  • Does the surface finish meet the Ra or RMS value specified on the drawing, verified with a profilometer or comparator?
  • Is the part free from visible defects such as cracks, burrs, scratches, porosity, or incomplete machining?
  • Have all edges been deburred and broken per drawing or workmanship standard requirements?
  • Is visual inspection being performed under adequate lighting conditions per acceptance criteria?
  • Has a representative photograph of the completed part's surface and general appearance been captured?

Special Processes & Coatings Verification

Verify all special processes (heat treatment, plating, NDT, welding) were performed per specification and are properly certified.

  • Are special process certifications (heat treat, plating, anodize, weld, NDT) available for all processes applied to the part?
  • Are all special process suppliers listed on an Approved Supplier List (ASL) or Approved Processor List (APL)?
  • Does the coating thickness measurement meet the minimum and maximum values specified on the drawing?
  • Has non-destructive testing (NDT) been completed and results documented where drawing-required?
  • Are weld inspection records (visual, PT, RT, or UT) included in the FAI package where welding is performed?

Functional, Fit & Form Verification

Confirm the first article assembles correctly, meets functional requirements, and interfaces properly with mating parts.

  • Has the part been trial-assembled or verified with mating components or a functional gauge to confirm fit?
  • Have all functional tests or performance checks specified in the design record been completed and passed?
  • Is the part correctly identified with required markings (part number, revision, heat/lot, date code) per drawing notes?
  • Has the part been inspected for correct weight within the drawing tolerance if a weight requirement is specified?
  • Recorded weight of the first article sample (if required)?

FAI Disposition & Approval

Document the overall FAI outcome, any open nonconformances, and obtain required approval signatures for production release.

  • Have all nonconforming characteristics been documented on a formal nonconformance report (NCR) or corrective action request?
  • Has the completed FAI package been reviewed and approved by the responsible QA Engineer or Manager?
  • What is the overall FAI disposition for this part?
  • Has the approved FAI package been filed in the quality management system with controlled document retention?
  • Additional observations, open action items, or notes for the FAI package?

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Why Use This First Article Inspection Checklist [FREE PDF]?

This first article inspection checklist [free pdf] helps aerospace qa teams maintain compliance and operational excellence. Designed for qa engineer professionals, this checklist covers 36 critical inspection points across 7 sections. Recommended frequency: per event.

Ensures compliance with AS9100 Rev D Clause 8.1.3 - First Article Inspection, ISO 9001:2015 Clause 8.5.1 - Control of Production and Service Provision, IATF 16949:2016 Clause 8.3.4.2 - Design and Development Validation, SAE AS9102B - Aerospace First Article Inspection Requirement, ASTM E2905 - Standard Practice for Examination and Evaluation of Documents. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What is a First Article Inspection Checklist [FREE PDF]?

A First Article Inspection Checklist [FREE PDF] is a standardized inspection form used by qa engineer to ensure consistent aerospace qa operations. It contains 41 inspection points organized into 7 sections. FREE First Article Inspection checklist PDF. Verify dimensional, material & process compliance per AS9100 & ISO 9001:2015 before production approval.

How often should I use this aerospace qa checklist?

This checklist is designed to be completed per event. Regular use ensures compliance with AS9100 Rev D Clause 8.1.3 - First Article Inspection and ISO 9001:2015 Clause 8.5.1 - Control of Production and Service Provision and helps identify issues before they become problems.

Can I download this First Article Inspection Checklist [FREE PDF] as a PDF?

Yes, you can download this checklist as a FREE PDF for printing or offline use. The checklist includes 41 fields across 7 sections and typically takes 60-90 minutes to complete.

What compliance standards does this checklist cover?

This checklist helps ensure compliance with AS9100 Rev D Clause 8.1.3 - First Article Inspection, ISO 9001:2015 Clause 8.5.1 - Control of Production and Service Provision, IATF 16949:2016 Clause 8.3.4.2 - Design and Development Validation, SAE AS9102B - Aerospace First Article Inspection Requirement, ASTM E2905 - Standard Practice for Examination and Evaluation of Documents. Following these standards protects your organization and ensures best practices.

How do I complete this aerospace qa inspection checklist?

Begin by completing the header fields for Inspection Date & Time, Inspector Name, Inspection Location / Facility, Part Number / Revision Level, and Work Order / Lot Number. Work through each of the 7 sections, marking items Yes or No as applicable. Add notes for any issues found. The entire process takes approximately 60 to 90 minutes.

What are the key sections in this aerospace qa checklist?

This aerospace qa checklist is organized into 7 key sections: Documentation & Drawing Review, Material & Raw Stock Certification, Dimensional & Geometric Inspection, Surface Finish & Visual Inspection, Special Processes & Coatings Verification, Functional, Fit & Form Verification, FAI Disposition & Approval. Each section contains specific inspection points that qa engineer must verify. The structured layout ensures nothing is missed during aerospace qa inspections and makes the process efficient, typically taking 60-90 minutes to complete.

Who should use this First Article Inspection Checklist [FREE PDF]?

This checklist is primarily designed for qa engineer working in aerospace qa operations. However, it is also valuable for quality assurance teams, safety officers, compliance managers, and supervisors who need to verify that aerospace qa standards are being met. Organizations of all sizes can benefit from using this First Article Inspection Checklist [FREE PDF] to maintain consistency and accountability.

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