# Delta First Article Inspection Trigger Worksheet

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

## Short answer

Score each change for design, process, supplier, tooling and location impact to decide whether a full or partial delta FAI is needed.

## Category

aerospace-defense

## Industry

Aerospace

## Audience

- Quality engineer
- Manufacturing engineer
- Configuration manager

## Tool

**Kind:** worksheet

**Mode:** editable

**Columns:**

#### Change description

**Key:** change

**Type:** text

#### ECN or reference

**Key:** ref

**Type:** text

#### Design or drawing change (1/0)

**Key:** design

**Type:** number

**Help:** 1 if the drawing, spec or revision changed

#### Manufacturing process change (1/0)

**Key:** process

**Type:** number

**Help:** 1 if routing, method, machine, program or special process changed

#### Source or location change (1/0)

**Key:** supplier

**Type:** number

**Help:** 1 if supplier, plant or sub-tier changed

#### Tooling or inspection change (1/0)

**Key:** tooling

**Type:** number

**Help:** 1 if tooling, fixtures or inspection methods changed

#### Production lapse over 2 years (1/0)

**Key:** lapse

**Type:** number

**Help:** 1 if production lapsed beyond your defined limit

#### Triggers

**Key:** triggers

**Type:** number

**Expr:** design + process + supplier + tooling + lapse

**Format:** integer

#### Decision

**Key:** decision

**Type:** select

**Options:**

- Full FAI
- Partial (delta) FAI
- No FAI, document rationale

**Rows:**

**Change:** Drawing Rev C to Rev D, bore tolerance tightened

**Ref:** ECN-4417

**Design:** 1

**Process:** 1

**Supplier:** 0

**Tooling:** 1

**Lapse:** 0

**Decision:** Partial (delta) FAI

**Change:** Moved anodize to new Nadcap supplier

**Ref:** SRC-218

**Design:** 0

**Process:** 0

**Supplier:** 1

**Tooling:** 0

**Lapse:** 0

**Decision:** Partial (delta) FAI

**Change:** New 5-axis program with different fixturing

**Ref:** MPR-9021

**Design:** 0

**Process:** 1

**Supplier:** 0

**Tooling:** 1

**Lapse:** 0

**Decision:** Partial (delta) FAI

**Change:** Part not built for 3 years, restarted at original plant

**Ref:** WO-77120

**Design:** 0

**Process:** 0

**Supplier:** 0

**Tooling:** 0

**Lapse:** 1

**Decision:** Full FAI

**Change:** Corrected typo on routing description

**Ref:** MPR-9030

**Design:** 0

**Process:** 0

**Supplier:** 0

**Tooling:** 0

**Lapse:** 0

**Decision:** No FAI, document rationale

**Totals:**

#### Total triggers logged

**Key:** triggers

**Agg:** sum

**Format:** integer

#### Highest triggers on one change

**Key:** triggers

**Agg:** max

**Format:** integer

**Summary:**

#### Average triggers per change

**Key:** avg_triggers

**Expr:** sum_triggers / count

**Format:** decimal

**Primary:** true

**Notes:** The standard defines when a new or partial first article is required. Use this sheet as a log of your evaluation, and always follow your customer's requirements and your own procedure for the final decision.

## Content

**Intro:** AS9102 expects a new full or partial first article when something that affects form, fit or function changes. This worksheet gives you a consistent way to log each change, count the triggers, record the decision and keep the evidence for auditors.

**Sections:**

#### How to use the worksheet

**Body:** Add a row for each design, process, supplier or tooling change. Mark each trigger as 1 if it applies and 0 if not. The triggers column adds them up so you can see how much changed at once. Choose a decision, then export to Excel and attach the sheet to the change record. If you decide no FAI is needed, write the rationale beside the row.

**Bullets:**

- One row per change, not per part
- Link every row to an ECN or work order
- Decide with engineering and quality together
- Re-run the sheet when changes stack up

#### Typical triggers

**Body:** Common reasons for a new or partial first article include a change in design record, a change to the manufacturing process or special process source, a move of production to a different location, a change in tooling that affects characteristics, and a lapse in production beyond the period your procedure sets. Natural events such as a customer request also apply.

#### Partial versus full

**Body:** A partial FAI covers only the characteristics, materials or processes affected by the change, while a full FAI repeats the entire report. When many triggers hit at once, or when the change affects the whole part such as a new supplier for the full part, a full FAI is often the safer and simpler choice. Document which characteristics you reviewed and why.

#### Common mistakes

**Body:** Teams often forget that a change of special process supplier or a new program on the same machine can be a trigger. Others rely on revision letters only and miss process changes that never touched the drawing. Review routing and tooling changes in the same meeting as engineering changes.

**Cta:** We can help automate this check by watching ECNs and routing changes in your ERP and flagging parts that may need a delta FAI.

**Faq:**

#### Does every drawing revision need a new FAI?

**Answer:** No. A revision that does not affect form, fit or function, such as a title block update, may not require one. Document the evaluation either way so you can show why you decided as you did.

#### What is a lapse in production?

**Answer:** A period in which the part has not been manufactured. AS9102 expects a procedure that defines the limit, often two years, after which a new first article is required. Use the limit in your procedure or contract.

#### Who decides between partial and full FAI?

**Answer:** Quality and engineering together, informed by the customer's requirements. If the customer has a stricter rule, it wins.

#### Can I attach this to the change order?

**Answer:** Yes. Export to Excel and attach it to the ECN or work order so the decision trail stays with the record.

## Search terms

delta FAI, when is a new first article required, AS9102 partial FAI change, FAI trigger change log, first article after process change, AS9102 delta first article

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