Delta First Article Inspection Trigger Worksheet
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.
| Change description | ECN or reference | Design or drawing change (1/0) | Manufacturing process change (1/0) | Source or location change (1/0) | Tooling or inspection change (1/0) | Production lapse over 2 years (1/0) | Triggers | Decision | |
|---|---|---|---|---|---|---|---|---|---|
3 | |||||||||
1 | |||||||||
2 | |||||||||
1 | |||||||||
0 |
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.
Flag FAI triggers from your ERP
Optional: discuss detecting ECN and routing changes that need a delta FAI.
Optional. The tool and every export work without this. No spam.
How to use the worksheet
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.
- 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
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
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
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.
Frequently Asked Questions
Does every drawing revision need a new FAI?
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?
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?
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?
Yes. Export to Excel and attach it to the ECN or work order so the decision trail stays with the record.
We can help automate this check by watching ECNs and routing changes in your ERP and flagging parts that may need a delta FAI.
Related Tools
AS9102 Form 2 Product Accountability Template
Fill in AS9102 Form 2 style product accountability records for raw materials, special processes and functional tests, then export a PDF or Word file.
Aerospace & DefenseAerospace Material Review Board Disposition Template
Document an MRB decision with nonconformance details, engineering rationale, customer approval status and disposition, then export a PDF.
Aerospace & DefenseNadcap Special Process Supplier Approval Tracker
Editable worksheet for tracking special process suppliers, their Nadcap or customer approvals, scope and days to expiry.
Aerospace & DefenseFirst Article Inspection (AS9102) Checklist
A 30-point checklist for complete, first-pass-acceptable AS9102 FAIs - planning, Form 1/2/3 completeness, characteristic accountability, and the delta FAI triggers teams miss.
More Aerospace & Defense tools
See all- AS9102 Form 1 Part Number Accountability Template
- AS9102 Form 3 Characteristic Accountability Worksheet
- FOD Prevention Program Checklist
- Aerospace Key Characteristics Worksheet
- Aerospace Supplier OTD and Quality Rating Calculator
- Aerospace Delta FAI Cost Savings Calculator
- Aerospace Internal Audit Programme Planner Worksheet
- Aerospace MRB Nonconformance Disposition Record Template
- AS9100D Clause Structure Reference
Keep exploring
Free tools
- Aerospace Delta FAI Cost Savings CalculatorCompares the cost of a full first article inspection with a delta FAI that re-inspects only affected characteristics.
- AS9100 FAI Template (AS9102 Forms 1, 2 and 3) with ERP Data MappingOne 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.
- Aerospace Supplier ScorecardRate a supplier across 10 criteria - OTD, quality escapes, AS9100 status, FAI performance, CAPA responsiveness, compliance flowdown, and financial health - for an instant risk rating.
Guides
- How to Price First Article Inspection (AS9102) in an Aerospace QuoteHow to price AS9102 first article inspection in aerospace quotes: ballooning, CMM programming, outside lab, process certs and delta FAI, without losing margin.
- SyteLine First Article Inspection (FAI) Process ConfigurationConfigure SyteLine first article inspection for new part qualification. Set up FAI plans, measurement recording, and AS9102 compliance reporting in CloudSuite Industrial.
- How to Set Up AS9100 Compliance in SyteLineComprehensive guide to configuring Infor SyteLine for AS9100 aerospace quality management compliance. Set up first article inspection, special processes, key characteristics, and traceability requirements.
AI on your ERP
- AI for 1factory: First Article and Inspection Data Joined to Your ERPPrivate AI for 1factory: first article inspection (AS9102), ballooned drawings and inspection data joined to ERP work orders, lots and suppliers.
- AI for AS9100 Quality Management on Your ERPAI on top of your ERP quality module for AS9100D suppliers: NCR/CAPA drafting, FAI support, counterfeit parts screening, with a full audit trail.