What Is First Article Inspection in SAP, and How to Run It in QM
what is first article inspection in sap
Also searched as
- first article inspection sap
- sap first article inspection production order
- sap qm first article inspection setup
Short answer
First article inspection (FAI) in SAP is not a single button. You model it in SAP QM with an inspection type that creates an inspection lot when the production order is released, an inspection plan with the characteristics to verify on the first piece, and results recorded then closed by a usage decision. Aerospace AS9102-style FAI forms normally need extra reporting on top.
Applies to: SAP ECC 6.0 and S/4HANA with QM and PP active; inspection type numbers and screens vary slightly by release
Setting up and running FAI
- 1Decide the FAI trigger: new part, new revision, new tooling or process change. SAP does not decide this for you, so define the rule as a business process.
- 2Define or reuse an inspection type for in-process inspection of production orders in customizing (Quality Management, Quality Inspection, Inspection Lot Creation, Maintain Inspection Type).
- 3In the material master QM view (MM02), add that inspection type to the material, activate it, and set the inspection lot to be created at order release.
- 4Create an inspection plan (QP01) with the FAI characteristics: dimensions, tolerances, drawing balloon references, tests and certifications, and assign the plan to the material and inspection type.
- 5Release the production order (CO02). SAP creates the inspection lot automatically. Check it in QA03 or the order object list.
- 6Record results (QE51N) against the lot, using the sample of one or the sample size your sampling procedure defines for the first piece.
- 7Make the usage decision (QA11). Accept to continue the run, reject to stop and raise a notification (QM01) or rework.
What FAI means and why SAP has no single FAI function
First article inspection is the documented verification that the first part from a new or changed process meets every drawing and specification requirement before full production continues. Aerospace and defense customers often require it in a defined format, commonly AS9102.
SAP standard supports the mechanics through QM: inspection planning, lot creation, results recording and decisions. It does not ship a ready AS9102 form, so most plants configure QM for the inspection and use a custom form or a QMS tool for the formal report.
Inspection type and lot creation at order release
Inspection lot creation is controlled by the inspection type in the material master QM view. For production, a type tied to the production order creates a lot when the order is released, so the lot exists before anyone cuts metal and can hold the shop floor responsible for the first piece.
To make the lot FAI only, use a dedicated inspection type or a rule in the inspection plan so routine lots do not carry the full characteristic list. Many plants add a status or material field to say FAI required, and a user exit or enhancement to create the lot only when it is true.
Plan, results and decision
The inspection plan lists operations and master inspection characteristics. For FAI, use characteristics that mirror the drawing, quantitative where a measured value is recorded and qualitative where it is pass or fail. Link them to a sampling procedure of one piece, or 100 percent for the first article.
Results go in through QE51N. The usage decision in QA11 closes the lot and drives stock posting. A rejected FAI should block the order from proceeding through a quality notification, a follow-up action, or an operation control key requiring a confirmation of inspection.
Try it here, free
SAP QM Inspection Results Recording Worksheet
Record measured values per characteristic, see deviation from target and in-tolerance status, and keep a paper copy to key into SAP QE51N.
Common pitfalls
- !Expecting an out-of-the-box AS9102 form. Plan for a report or an external QMS document.
- !Letting the inspection type apply to every order, creating FAI lots for repeat runs.
- !Setting a sample of the whole lot instead of the first piece.
- !Not tying the usage decision to production, so a failed FAI does not stop the run.
- !Forgetting to re-trigger FAI after a revision change in the BOM or routing.
How an ERP-grounded AI assistant handles this
A private AI layer such as ERPray can read your inspection lots, plans and decisions to list which orders are missing an FAI, or which part revisions have no accepted first article. It reads and explains, while the lot, results and decision are still made in SAP QM by authorised users.
Frequently asked questions
Does SAP have a standard FAI module?
No single FAI module. You build it from QM inspection types, inspection plans, inspection lots and usage decisions. Formal AS9102 reports usually need a custom form or an external quality system fed by SAP data.
When is the inspection lot created for FAI?
Typically at production order release when the in-process inspection type is active in the material master QM view. The lot appears before work starts, so the first piece can be inspected and decided on.
How do I limit FAI to the first piece?
Use a sampling procedure with a fixed sample of one, or a dedicated inspection type for FAI only. Combine it with a rule that creates the lot only for new parts, new revisions or changed processes.
What happens if the first article fails?
Record the results, reject in the usage decision and raise a quality notification. Depending on setup, the production order can be blocked until the issue is corrected and a new inspection lot passes.
Related
SAP QM: Inspection Lot Not Created at Goods Receipt
An inspection lot is created only when QM is active for the plant, the material has an active inspection type for the goods movement, and the material carries a QM control key. Check the Quality Management view in MM02, confirm inspection type 01 (purchase order) or 04 (production order) is active, then check QM activation in the plant and the goods movement used.
How-toSAP QA11 Usage Decision: Make It and Post Stock Correctly
The usage decision (UD) in QA11 closes an inspection lot, assigns a quality score and a UD code such as accepted or rejected, and posts the lot quantity from quality inspection stock to unrestricted use, blocked stock, scrap or return to vendor. The UD is blocked until required inspection characteristics are closed and results are recorded.
How-toHow to Create a MIC (Master Inspection Characteristic) in SAP QM
A MIC is a reusable inspection characteristic in SAP QM, created in QS21 with a plant, a name and a version, then defined as quantitative (measured values with limits) or qualitative (codes from a catalog). Inspection plans (QP01) pick MICs so tolerances are maintained once. MIC data is in table QPMK, with text in QPMT.
How-toHow to Create a Sampling Procedure in SAP QM
In SAP QM, a sampling procedure decides how many units to inspect and how to accept or reject the lot. Maintain it in QDV3, choose a sample type (fixed, percentage, sampling scheme or 100 percent) and a valuation mode, and where needed build the scheme in QDP1. Then assign the procedure to a master inspection characteristic or inspection plan.
Error fixSAP M7 021: Deficit of SL Stock Quantity
M7 021 fires during a goods issue, delivery, or confirmation when SAP checks the unrestricted-use (SL) stock for the exact plant, storage location and batch combination and finds less than what you are trying to post out. Fix the entry (batch, storage location, quantity) first; only enable negative stock or downgrade the message to a warning if the business genuinely needs to post ahead of a receipt.
Error fixSAP IDoc Status 51: Application Document Not Posted
Status 51 tells you the IDoc reached the application layer and failed to post, but the status text itself is not the error - the real cause sits in the status record's long text or the linked application log. Fix the underlying data or configuration, then reprocess the IDoc through BD87 rather than editing the status.
AI for ERPAI for SAP Quality Management: Notifications, 8D, and CAPA Without the Manual Drafting
AI grounded on SAP QM data that triages notifications, drafts 8D and CAPA reports, and summarizes inspection trends, deployed on-prem for full traceability.
AI for ERPAI for NCR, CAPA, and 8D Drafting in AS9100 and ISO 9001 Quality Systems
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