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Delta FAI vs Full First Article Cost Calculator (AS9102)

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.

Your numbers

Characteristics on the drawing

chars

Measurement time per characteristic

min

CMM programming and fixture time

hours

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

Ballooning and report preparation

hours

Loaded inspection rate

per hour

Cost of parts and tests consumed

Share of characteristics affected by the change

25 %

Delta FAIs per year

Your results

Cost of one full FAI

$3,050

Annual saving

$49,500

Measurement hours (full)

Cost of one delta FAI

$575

Saving per delta FAI

$2,475

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.

Save results:

Delta FAI cost vs share of characteristics affected

Sweeps Share of characteristics affected by the change from 5 to 100, holding your other inputs fixed.

First article data from your ERP

Optional: we can review how revisions, routings and FAI status could be linked in your ERP.

Optional. The tool and every export work without this. No spam.

How to use it

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%.

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

When delta is allowed

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

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.

Frequently Asked Questions

What is a delta FAI?

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?

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?

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?

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.

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.

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