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Methods

First Article Inspection

Definition

verification of a new product before series release

Synonyms:
FAIInitial Sample InspectionErstmusterprüfung

What is First Article Inspection?

First article inspection (FAI) refers to the verification of a new product before series release. The method delivers actionable quality data for product release, process optimisation and root-cause analysis.

Scientific background

Methodologically, the procedure relies on standardised workflows covering data acquisition, segmentation, feature extraction and evaluation. Core elements include feature inspection against drawing, specification and process window. Meaningful results only emerge from traceable criteria and defined acceptance limits.

Relevant key metrics

  • Detection limit and misclassification risk for the relevant failure modes.
  • Repeatability of the evaluation for identical input data.
  • Relationship between indicators and functional load zones / specifications.

Standards and thresholds

  • Standards: VDA Volume 2 (6th revised edition, 04/2020) and AIAG PPAP (PPAP-4, 4th Edition, 2nd Printing, Nov 2009).
  • Typical thresholds (in practice): 100 % verification of defined sampling characteristics; special characteristics must stay within specification.
  • Validity: Inspection scope, sampling and evidence format are contractually / customer-specifically defined.

Application in industrial practice

  • Data-based release decisions during ramp-up and series production.
  • Early detection of deviations with cause-oriented prioritisation.
  • Improved customer and supplier communication through objective CT reports.

Sources and reference date

  • VDA Volume 2, 6th revised edition, release date 04/2020.
  • AIAG PPAP, product code PPAP-4, 4th Edition, 2nd Printing (Nov 2009).
  • Reference date: February 2026.