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.
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