# AS9100 FAI Template (AS9102 Forms 1, 2 and 3 in One Report, with ERP Data Mapping)

> Source: https://netray.co/tools/as9100-fai-template-forms-1-2-3-with-erp-mapping
> Publisher: Netray (netray.co), AI and integration engineering for ERP and manufacturing systems.
> Section: Free Tools

## Short answer

One document with the three AS9102 form structures, a filled example for a machined bracket, and a table showing where each field comes from in your ERP.

## Category

aerospace-defense

## Industry

Aerospace

## Audience

- Aerospace quality engineer
- Supplier quality engineer
- Inspector

## Tool

**Kind:** template

**Output:** document

**Fields:**

#### Part number

**Key:** pn

**Type:** text

**Default:** BRK-48213-01

#### Part name

**Key:** pname

**Type:** text

**Default:** Mounting bracket, machined

#### Serial or lot number

**Key:** sn

**Type:** text

**Default:** LOT-260915-A

#### Drawing revision

**Key:** rev

**Type:** text

**Default:** C

#### FAI report number

**Key:** fai_no

**Type:** text

**Default:** FAI-2026-0187

#### Manufacturer

**Key:** org

**Type:** text

**Default:** Acme Precision Aerospace Ltd

#### CAGE code

**Key:** cage

**Type:** text

**Default:** 1ABC2

#### Purchase order

**Key:** po

**Type:** text

**Default:** PO-100245

#### FAI type

**Key:** fai_type

**Type:** select

**Options:**

- Full FAI
- Partial FAI (delta)

**Default:** Full FAI

#### Reason for FAI

**Key:** reason

**Type:** select

**Options:**

- New part
- Revision change
- Process change
- Tooling change
- Lapse in production

**Default:** New part

#### Raw material

**Key:** material

**Type:** text

**Default:** Aluminum 7075-T651 plate, AMS 4045

#### Special process

**Key:** process

**Type:** text

**Default:** Anodize Type II, MIL-A-8625

#### Date

**Key:** date

**Type:** date

**Default:** 2026-10-20

**Blocks:**

#### Form 1. Part Number Accountability

**Body:** FAI report number: {{fai_no}}
Part number: {{pn}}  Part name: {{pname}}
Serial or lot number: {{sn}}  Drawing revision: {{rev}}
Organization: {{org}}  CAGE: {{cage}}
Purchase order: {{po}}
FAI type: {{fai_type}}  Reason: {{reason}}
Date: {{date}}

#### Form 1. Assemblies and details

**Table:**

**Columns:**

- Part number
- Part name
- Revision
- FAI report no.
- Supplier / CAGE

**Rows:**

**0:** {{pn}}

**1:** {{pname}}

**2:** {{rev}}

**3:** {{fai_no}}

**4:** {{cage}}

#### Form 2. Product Accountability: Materials, Special Processes, Functional Testing

**Table:**

**Columns:**

- Type
- Name / specification
- Process or material supplier
- Certificate no.
- Result

**Rows:**

**0:** Raw material

**1:** {{material}}

**2:** Mill: ____

**3:** Cert: ____

**4:** Accept

**0:** Special process

**1:** {{process}}

**2:** Processor: ____ (customer-approved)

**3:** Cert: ____

**4:** Accept

**0:** Functional test

**1:** Test per drawing note: ____

**2:** Lab: ____

**3:** Report: ____

**4:** Accept

#### Form 3. Characteristic Accountability, Verification and Compatibility Evaluation

**Table:**

**Columns:**

- Char no.
- Drawing zone
- Requirement
- Results
- Designed / special characteristic
- Tool or gauge
- Accept / reject

**Rows:**

**0:** 1

**1:** B3

**2:** Overall length 80.00 +/- 0.10 mm

**3:** 80.04

**5:** CMM, ID ____

**6:** Accept

**0:** 2

**1:** C4

**2:** Bore diameter 12.000 +0.018 / 0 mm

**3:** 12.009

**4:** Key

**5:** Bore gauge, ID ____

**6:** Accept

**0:** 3

**1:** C2

**2:** Surface roughness Ra 1.6 um max

**3:** 1.2

**5:** Profilometer, ID ____

**6:** Accept

**0:** 4

**1:** Note 5

**2:** Anodize per specification, color clear

**3:** Conforms

**5:** Visual, cert review

**6:** Accept

**0:** 5

**1:** Note 2

**2:** Break all sharp edges 0.2 mm max

**3:** Conforms

**5:** Visual 10x

**6:** Accept

#### ERP data mapping (where each field comes from)

**Table:**

**Columns:**

- FAI field
- Typical ERP source
- Example

**Rows:**

**0:** Part number and revision

**1:** Item master and engineering change status

**2:** {{pn}} rev {{rev}}

**0:** Serial or lot

**1:** Lot or serial record, work order

**2:** {{sn}}

**0:** Purchase order

**1:** Purchase order header (for supplier FAI) or sales order

**2:** {{po}}

**0:** Material and certificate

**1:** Receiving record, lot traceability, attached cert

**2:** {{material}}

**0:** Special process supplier

**1:** Approved supplier list, operation on the routing

**2:** {{process}}

**0:** Drawing zone and requirements

**1:** Not in ERP. Comes from the ballooned drawing in PLM or document control

#### Approvals

**Signatures:**

- FAI performed by
- Quality approval
- Customer representative (if required)

**Notes:** This reproduces the structure of the AS9102 forms and common fields, not the official form. Check that your customer accepts a custom layout. Every drawing characteristic needs a balloon and a row in Form 3. A partial FAI must still cover all impacted characteristics, and the reason must match AS9102 triggers such as a design change, a manufacturing process change, a change in location, or a production lapse.

## Content

**Intro:** This AS9100 FAI template puts AS9102 Forms 1, 2 and 3 in one editable report, with a filled example for a machined bracket and a table that shows which fields can be pulled automatically from your ERP. Change the defaults, export to Word or PDF, and attach your ballooned drawing.

**Sections:**

#### How to fill the three FAI forms

**Body:** Form 1 proves you know which part you built: the part number, drawing revision, serial or lot, and the FAI type. Form 2 proves the material, special processes and functional tests are right, with certificates and approved suppliers. Form 3 is the heart of the report: every characteristic on the ballooned drawing listed with its requirement, measured result, gauge and accept or reject. Fill the form fields here, replace the example rows with your own characteristics, and attach certificates and measurement data. Sign off only when every row is dispositioned.

**Bullets:**

- Balloon every dimension, note and specification on the drawing
- Measure characteristics on the actual FAI sample, not on a similar part
- Record the actual value, not just pass or fail
- Document nonconformances before approval, never after

#### When AS9102 requires an FAI

**Body:** AS9100 clause 8.5.1.3 (production process verification) requires a first article inspection for a new part, and again after changes that invalidate the previous result. AS9102 lists the triggers: a change in design affecting form, fit or function; a change in the manufacturing source, process, location, tooling or the method of manufacture; a lapse in production; or a change in numerical control program. A delta or partial FAI covers just the impacted characteristics, while a full FAI covers everything. Your customer may add flow-down requirements, so read the purchase order.

#### Mapping FAI data from your ERP

**Body:** Much of Form 1 and Form 2 already exists in your ERP: part number and revision, lot or serial, purchase order, raw material receiving record with certificate, and the special process step on the routing. The drawing characteristics and measurement results usually do not. They live in the ballooned drawing, a CMM program or a spreadsheet. The mapping table in this template shows the source for each field so you can automate the header data and avoid transcription errors. Keep the item master revision aligned to the drawing revision, or the FAI will cite the wrong revision.

#### Common mistakes

**Body:** The most frequent rejections are a missing balloon, a Form 3 row without an actual result, an FAI on a drawing revision that is not current, special process certificates from a supplier that is not on the customer's approved list, and a signed FAI with open nonconformances. Also check that raw material test reports match the specification revision called out, and that inspection equipment calibration was current on the measurement date.

**Cta:** If you want FAI header data pulled from SyteLine, SAP or another ERP without sending drawings or data to a public cloud, Netray can build a private AI layer on your own servers.

**Faq:**

#### What is the difference between AS9100 FAI and AS9102?

**Answer:** AS9100 is the quality management standard that requires first article inspection under clause 8.5.1.3. AS9102 is the aerospace standard that defines how to do it and what the report forms must contain.

#### Do I have to use the official AS9102 forms?

**Answer:** Not always. AS9102 requires the content of Forms 1, 2 and 3 but allows other formats if the information is complete and the customer agrees. Many suppliers use electronic or ERP-generated layouts.

#### How many characteristics need to be on Form 3?

**Answer:** All of them: every dimension, tolerance, note and specification on the drawing, including those that flow down from referenced specifications. Each gets a balloon number and a row. Assemblies also need characteristics of the assembly itself.

#### Can I do a partial FAI instead of a full FAI?

**Answer:** Yes, when a change affects only some characteristics, provided you assess the impact and cover every affected one. If the change is wide or you are unsure, a full FAI is safer. Record the rationale in the report.

## Search terms

as9100 fai template, as9100 fair template, as9100 fai report, as9102 fai forms 1 2 3, first article inspection report template, fai report example, as9102 form 3 example, fai erp data mapping

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