First Article Inspection (FAI) is the mandatory full verification of the first production unit of a new or changed part — every dimension, material property, and special process on the engineering drawing is checked before volume production is authorized. This program's FAI was performed against AS9102 (Aerospace First Article Inspection Requirement).
Why it exists: a production run of hundreds of wing panels is only as good as the tooling and process that made the first one. FAI catches a systemic tooling or process error before it is baked into every downstream part, instead of after — this is the core of the Program CBA's cost-avoidance case.
The three AS9102 forms
An AS9102 First Article Inspection Report (FAIR) is not a single document — it is a package of three standardized forms that, together, prove the part matches the engineering definition and every requirement behind it is traceable. All three carry the same part number, drawing revision, and FAIR reference number in their header fields so they can be tied back together.
| Form | Name | What It Captures | CWP-700 Content |
|---|---|---|---|
| Form 1 | Part Number Accountability | Identifies exactly what was inspected — part number, drawing revision, serial number, supplier, and whether this is a full or partial FAI | CWP-700 panel, drawing rev per Meridian ECN log, S/N 0001, full FAI (new part introduction) |
| Form 2 | Product Accountability | Confirms every supporting requirement is documented and traceable — material certifications, special process certifications, and any customer-required functional test | Prepreg batch cert, autoclave cure cycle record, NDT ultrasonic scan record |
| Form 3 | Characteristic Accountability | Every ballooned characteristic from the engineering drawing, listed individually with nominal, tolerance, and actual measured value | 100% of drawing characteristics measured (CMM + hand tools) — see FAI Checklist item 2 |
This program follows AS9102 Rev C conventions: the person completing Form 1 ("FAIR Reviewed By") and the person giving final approval ("FAIR Approved") are two different qualified individuals — R. Kessler performs the review, and Meridian's source inspection representative provides the customer approval signature on-site.
Composite-specific FAI evidence
Composite structures carry FAI evidence requirements beyond a typical machined-metal part, since the material properties are created during the manufacturing process itself rather than inherent to raw stock. The CWP-700 FAIR package includes:
- Material traceability — composite prepreg batch/roll IDs, adhesive film lot numbers, and freezer log records (prepreg has a limited out-of-freezer working life and must be tracked from receipt through layup).
- Process records — the layup traveler documenting ply count and orientation, debulk steps, and the autoclave cure cycle chart (time/temperature/pressure profile) tied to the specific tool ID the panel was cured on.
- Dimensional verification — CMM and hand-tool measurement results for every ballooned feature on the engineering drawing, plus NDT ultrasonic scan results confirming no internal voids or delamination.
FAI Checklist — CWP-700, Panel S/N 0001
| # | Verification Item | Owner | Result |
|---|---|---|---|
| 1 | Part number / revision matches released engineering drawing | M. Osei | Pass |
| 2 | Full dimensional layout — 100% of drawing characteristics measured (CMM + hand tools) | M. Osei | Pass |
| 3 | Material certification traceable to raw material lot (composite prepreg batch) | S. Pham | Pass |
| 4 | Special process records — autoclave cure cycle, NDT ultrasonic scan | L. Vance | Pass |
| 5 | Functional test results (where applicable) | M. Osei | N/A — no functional test required this part |
| 6 | Nonconformance disposition records, if any characteristics were out of tolerance | R. Kessler | 1 nonconformance — see MRB-001 |
| 7 | AS9102 Form 1/2/3 package complete and signed | R. Kessler | Pass |
| 8 | Customer (Meridian) source inspection witness / delegation | C. Tyrrell | Witnessed on-site |
What happened on this program
The initial tooling run (S/N 0001) found an edge-trim dimension out of tolerance on 2 of 8 panel positions (RAIDD I-01). Rather than fail the FAI outright, the nonconformance was dispositioned through the Material Review Board as rework-and-reinspect. The reworked panel passed full FAI re-verification and Meridian's source inspection representative witnessed and accepted the result on site, releasing Phase 2 production.
When a new FAI is required
AS9102 requires a new First Article Inspection — full or partial, depending on what changed — any time the conditions that produced the original FAI no longer hold. On this program, that means:
| Trigger | FAI Type Required |
|---|---|
| New part introduction (this program's original FAI, Panel S/N 0001) | Full FAI |
| Engineering change affecting form, fit, or function | Partial FAI — limited to the changed characteristics |
| Change of manufacturing process, tooling, or material source | Partial or full FAI, depending on scope of the change |
| Change of manufacturing location | Full FAI |
| Production lapse of more than 2 years, or per Meridian's specific contract terms | Full FAI |
Gate to production
Production volume (Phase 2) does not start until the FAI package is complete, all nonconformances are dispositioned, and the customer source inspection sign-off is on file. A re-triggered FAI (partial or full) is required if the part design, process, tooling, or material source changes after the original FAI — the same discipline AS9102 requires industry-wide.