# Delta FAI vs Full First Article Cost Calculator (AS9102)

> Source: https://netray.co/tools/aerospace-delta-fai-cost-savings-calculator
> Publisher: Netray (netray.co), AI and integration engineering for ERP and manufacturing systems.
> Section: Free Tools

## Short answer

Compares the cost of a full first article inspection with a delta FAI that re-inspects only affected characteristics.

## Category

aerospace-defense

## Industry

Aerospace

## Audience

- Quality engineer
- Inspection supervisor
- Program manager

## Tool

**Kind:** calculator

**Inputs:**

#### Characteristics on the drawing

**Key:** chars

**Type:** number

**Default:** 140

**Min:** 1

**Step:** 5

**Unit:** chars

#### Measurement time per characteristic

**Key:** min_per_char

**Type:** number

**Default:** 6

**Min:** 0

**Step:** 0.5

**Unit:** min

#### CMM programming and fixture time

**Key:** prog_hours

**Type:** number

**Default:** 10

**Min:** 0

**Step:** 1

**Unit:** hours

**Help:** Needed for a full FAI only; assumed reused on a delta.

#### Ballooning and report preparation

**Key:** report_hours

**Type:** number

**Default:** 8

**Min:** 0

**Step:** 1

**Unit:** hours

#### Loaded inspection rate

**Key:** rate

**Type:** number

**Default:** 75

**Min:** 0

**Step:** 5

**Unit:** per hour

#### Cost of parts and tests consumed

**Key:** material

**Type:** number

**Default:** 650

**Min:** 0

**Step:** 50

#### Share of characteristics affected by the change

**Key:** delta_pct

**Type:** slider

**Default:** 25

**Min:** 5

**Max:** 100

**Step:** 5

**Unit:** %

#### Delta FAIs per year

**Key:** delta_count

**Type:** number

**Default:** 20

**Min:** 0

**Step:** 1

**Outputs:**

#### Measurement hours (full)

**Key:** measure_h

**Expr:** chars * min_per_char / 60

**Format:** decimal

#### Cost of one full FAI

**Key:** full_cost

**Expr:** (measure_h + prog_hours + report_hours) * rate + material

**Format:** currency

**Primary:** true

#### Cost of one delta FAI

**Key:** delta_cost

**Expr:** (measure_h * delta_pct / 100 + report_hours * delta_pct / 100) * rate + material * delta_pct / 100

**Format:** currency

#### Saving per delta FAI

**Key:** save_each

**Expr:** full_cost - delta_cost

**Format:** currency

#### Annual saving

**Key:** annual_save

**Expr:** save_each * delta_count

**Format:** currency

**Primary:** true

**Chart:**

#### Delta FAI cost vs share of characteristics affected

**Type:** line

**X:** delta_pct

**From:** 5

**To:** 100

**Steps:** 20

**Series:**

- delta_cost
- full_cost

**Currency:** $

**Disclaimer:** AS9102 sets when a full or partial FAI is required, and your customer may add rules. This tool only estimates cost. A delta FAI must still cover every characteristic affected by the change.

## Content

**Intro:** When a design, process or location change affects only part of a part, AS9102 allows a partial (delta) first article instead of a full one. This calculator estimates what each costs and how much you save per year if a share of your first articles qualify as delta.

**Sections:**

#### How to use it

**Body:** Enter the characteristic count, measurement time, programming and reporting hours, and your loaded inspection rate. Set the share of characteristics the change touches and the number of delta FAIs per year. The tool shows a full FAI cost, the delta cost, the saving per event, and the annual total. The chart plots both costs as the affected share rises to 100%.

**Bullets:**

- Count characteristics from the ballooned drawing.
- Use real inspection times from the CMM report.
- Include consumed or destructive test cost.

#### When delta is allowed

**Body:** AS9102 calls for a full FAI for a new part, and a partial FAI when a change in design, manufacturing source, location, process, tooling, numerical control program or lapse in production may affect form, fit or function. The partial FAI covers the affected characteristics plus any that are impacted by them. Record why it is partial, and when in doubt, treat the change as affecting more.

#### Common mistakes

**Body:** Underestimating knock-on characteristics, for example a datum change that moves every feature referenced to it. Treating a delta as a shortcut for evidence you no longer have. And ignoring reporting time, which is often as large as measurement time. Check the model against two or three real events before you rely on it.

**Cta:** If first article records and revision history sit across several systems, we can help connect them to your ERP so affected characteristics are easier to trace.

**Faq:**

#### What is a delta FAI?

**Answer:** A delta, or partial, first article inspection is an AS9102 FAI limited to the characteristics affected by a change, plus those that depend on them. It is used instead of a full FAI when the rest of the part is unchanged.

#### Who decides if a delta FAI is acceptable?

**Answer:** The supplier's process determines it using AS9102 criteria, but the customer can add requirements or require full FAI. Always check the contract flow-down before choosing partial.

#### Does the programming time repeat on a delta?

**Answer:** This model assumes the existing CMM program is reused for a delta. If the program must change, add that time to the measurement or report inputs.

#### How is annual saving calculated?

**Answer:** Saving per event is the full FAI cost minus the delta cost. It is multiplied by the number of delta FAIs you expect per year, so enter only events that truly qualify.

## Search terms

delta FAI cost, full FAI vs partial FAI, AS9102 first article cost, first article inspection cost calculator, FAI hours estimate, AS9102 delta first article, FAI cost per characteristic, first article savings

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