Supplier and process readiness directly determine the success of First Article Inspection (FAI). If suppliers lack preparation or processes are unstable, FAI results will likely include non-conformities, delays, or costly rework. To help manufacturers and SMEs achieve first-time FAI success, here are the top seven tips for ensuring strong supplier and process readiness.
1. Verify Supplier Technical Understanding Early
Before production begins, confirm that the supplier thoroughly understands:
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Drawing specifications
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GD&T requirements
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Critical dimensions
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Special processes
Misunderstandings at this stage are the leading cause of FAI failures. A technical review meeting can eliminate ambiguity and set the foundation for success.
2. Confirm Availability of Qualified Equipment
Suppliers must have machines, tools, and inspection equipment capable of meeting required tolerances. Ensure:
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Calibration is up to date
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Equipment capability matches design requirements
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Measuring tools can accurately verify critical features
This avoids measurement errors and production inaccuracies.
3. Evaluate Supplier Workforce Competence
A well-trained team is essential. Validate that:
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Operators know the process steps
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Inspectors understand measurement methods
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Engineers can interpret design changes
Providing training or documentation support can significantly improve first-pass yield.
4. Validate the Entire Manufacturing Process Flow
A ready process is not just about machines—it’s about consistency. Review the full process flow, including:
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Setup parameters
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Fixtures and tooling
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Work instructions
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Inspection points
A validated process prevents variation and ensures the FAI part is produced using the same conditions as mass production.
5. Ensure Process Capability and Stability
Conduct capability studies (Cp, Cpk) where needed, especially for critical-to-quality dimensions. A stable, capable process gives confidence that production can meet tolerances repeatedly—not just once for FAI.
6. Complete All Documentation Before FAI Submission
Missing documents are one of the most common causes of FAI rejection. Ensure you have:
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Material certificates
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Process FMEA
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Control plans
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MSA results
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Drawings and revisions
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First article measurement reports
Proper documentation shows readiness and demonstrates robust process control.
7. Perform a Pre-Production Trial Run
A trial run simulates the real manufacturing environment. It helps identify:
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Setup issues
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Measurement inconsistencies
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Process variation
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Tool wear problems
By solving these issues before FAI, suppliers can significantly increase the chances of a successful first submission.
Final Thoughts
Supplier and process readiness are critical to passing FAI smoothly. By applying these seven tips—technical alignment, equipment readiness, trained workforce, validated processes, capability checks, complete documentation, and trial runs—manufacturers can reduce risk, improve quality, and prevent expensive delays.
