AS9100DShort courseFoundation

First Article Inspection to AS9102

Plan, perform and document a first article inspection that passes customer review

Duration: 3 hours
Modules: 6
Final exam: 70% to pass
Certificate: No expiry

$99

Lifetime access to the course and your certificate
Verifiable Certificate of Completion. Certificate does not expire.
3 exam attempts
Progress saved to your account on every slide

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About this course

A first article inspection proves that your production process, documentation and tooling can make the drawing, using one representative item from the first production run as the evidence. AS9100D clause 8.5.1.3 requires it, and AS9102 is the method aerospace customers write into their purchase orders. Most FAIR rejections come from a short list of avoidable mistakes: notes and specifications that were never ballooned, 'pass' where a measured value belongs, the wrong drawing revision, a special process from an unapproved source, and a missing sub-tier report.

This course takes you through the whole job in the order you do it: deciding whether a full or partial FAI is needed and what triggers one, reading the drawing package and ballooning every design characteristic including notes, title block defaults and model-based definition, selecting a representative item, and then completing Form 1 (Part Number Accountability), Form 2 (Product Accountability) and Form 3 (Characteristic Accountability) line by line. Key characteristics are covered with reference to AS9103, and measurement system basics explain what makes a recorded result credible.

The final module covers the internal review before submission, how to handle nonconformances and resubmit, delta FAIs after a change, records retention, customer submission portals and what an auditor checks. It is written for inspectors, quality engineers, planners and supplier quality staff at aerospace and defense suppliers of all sizes.

The course closes with a 20-question examination drawn from a bank of 30. On passing you receive a PlanetISO Certificate of Completion with lifetime access to the course content and your certificate. The certificate does not expire.

What you will be able to do

Explain the purpose of first article inspection, what it does not demonstrate, and the AS9100D clause 8.5.1.3 requirement behind it.
Decide whether an event triggers a full or partial FAI, including design, process, tooling, source and location changes and a lapse in production.
Balloon a drawing or model-based definition so that every design characteristic, note and specification has a unique number.
Complete AS9102 Form 1 for detail and assembly FAIs, including sub-tier FAIRs, report numbering and the completion status.
Complete Form 2 with material, special process and functional test evidence from approved sources, traceable to the first article.
Complete Form 3 with an actual result, the measuring equipment and method, tooling and nonconformance references for every characteristic.
Review a FAIR before submission, handle nonconformances and resubmission, and recognize what customers and auditors reject.

Course outline

1
What a first article inspection is and is not
The purpose of first article inspection, full versus partial FAI, the events that trigger one, who performs it and when, and the AS9100D requirement behind it.
About 30 minutes, then a module quiz
2
Planning the first article inspection
Reading the drawing package, ballooning and characteristic numbering, design characteristics including notes and specifications, digital product definition, selecting the representative item and customer-specific requirements.
About 35 minutes, then a module quiz
3
Form 1: Part Number Accountability
The fields of AS9102 Form 1, detail versus assembly FAIs, how sub-assemblies and sub-tier FAIs are indexed, report numbering, serial and lot numbers, and the completion and signature block.
About 30 minutes, then a module quiz
4
Form 2: Product Accountability
Raw material, special processes and their approved or Nadcap sources, functional testing, certificates and the traceability chain that links them to the first article.
About 30 minutes, then a module quiz
5
Form 3: Characteristic Accountability
Recording every characteristic with its requirement and an actual result, measuring equipment and method, designed tooling, nonconformance numbers, key characteristics and the measurement system basics behind a credible result.
About 35 minutes, then a module quiz
6
Review, approval and resubmission
Internal review before submission, handling nonconformances and resubmitting, delta FAIs, the common mistakes that get FAIRs rejected, records retention, customer submission portals and what an auditor checks.
About 30 minutes, then a module quiz
Final examination and certificate
20 questions drawn from the course bank. Score 70% or higher to receive your Certificate of Completion.

Who it is for

Quality inspectors and CMM programmers who perform and record first article inspections
Quality engineers who review and approve FAIRs and respond to customer rejections
Production planners and manufacturing engineers who introduce new and changed parts
Supplier quality engineers who review FAIRs from sub-tier suppliers
Buyers who flow FAI requirements down to machine shops and processors

Prerequisites

None. Familiarity with reading engineering drawings is helpful.

Questions

Do I need a copy of AS9102 to take this course?

No. The course explains the 3 forms and their fields in plain language. If you perform FAIs at work, your organization should hold the current revision of AS9102 from SAE and follow any customer-specific requirements that add to it.

Does the course cover customer-specific FAI requirements?

It explains the kinds of requirements customers add, such as submission before first delivery, shorter lapse periods, key characteristic data and electronic portals, and tells you where to look for them. It cannot cover each customer's manual; always read the supplier quality requirements called up on your purchase order.

Is this course relevant to AS9120B distributors?

Distributors do not normally perform FAIs, but those who buy manufactured parts for aerospace customers may be asked to obtain and review supplier FAIRs. Modules 3 to 6 are useful for that review.

What certificate do I receive?

You receive a PlanetISO Certificate of Completion showing the course title, your name and your exam result. It does not expire. It is evidence of training for your competence record; it is not an accreditation and does not make you a certified inspector or auditor.

How long do I have access?

Lifetime access to the course and your certificate. You can revisit any module, for example before preparing your next FAIR, and download your certificate at any time.

What happens if I fail the exam?

You have 3 attempts. Each attempt draws a different 20-question set from the bank of 30, and module quizzes can be retaken without limit to prepare.

AS9100DIntroduction
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Duration
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Level
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AS9100DInternal Auditor
AS9100D Internal Auditor
Plan, conduct and report process-based internal audits of an aviation, space and defense QMS
Duration
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Level
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AS9100DLead Auditor
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AS9100DAwareness
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What everyone in an aviation, space and defense organization needs to know about the quality system and their part in it
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AS9100DAwareness
Product Safety Awareness
How your work affects the safety of the aircraft, spacecraft or system your parts fly on
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AS9100DAwareness
FOD Prevention
Prevent, detect and remove foreign objects before they reach the product
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AS9100DAwareness
Counterfeit Parts Detection and Avoidance
Keep counterfeit, fraudulent and suspect parts and materials out of your products
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AS9100DAwareness
Human Factors in Aerospace Quality
Why capable people make errors and how to design work so errors are caught
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AS9100DAwareness
Configuration Management Awareness
Build, inspect and ship the right revision every time
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AS9100DAwareness
Supplier Flow-Down Requirements
Read the purchase order, meet every clause and pass the right requirements to your own suppliers
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Level
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AS9100DAwareness
APQP and PPAP Awareness (AS9145)
How advanced product quality planning and production part approval work in aerospace
Duration
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Level
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About this course

What you will be able to do

Course outline

What a first article inspection is and is not

Planning the first article inspection

Form 1: Part Number Accountability

Form 2: Product Accountability

Form 3: Characteristic Accountability

Review, approval and resubmission

Final examination and certificate

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