AS9100 FAI Template (AS9102 Forms 1, 2 and 3 in One Report, with ERP Data Mapping)
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.
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AS9100 FAI Template (AS9102 Forms 1, 2 and 3) with ERP Data Mapping
Form 1. Part Number Accountability
FAI report number: FAI-2026-0187 Part number: BRK-48213-01 Part name: Mounting bracket, machined Serial or lot number: LOT-260915-A Drawing revision: C Organization: Acme Precision Aerospace Ltd CAGE: 1ABC2 Purchase order: PO-100245 FAI type: Full FAI Reason: New part Date: 2026-10-20
Form 1. Assemblies and details
| Part number | Part name | Revision | FAI report no. | Supplier / CAGE |
|---|---|---|---|---|
| BRK-48213-01 | Mounting bracket, machined | C | FAI-2026-0187 | 1ABC2 |
Form 2. Product Accountability: Materials, Special Processes, Functional Testing
| Type | Name / specification | Process or material supplier | Certificate no. | Result |
|---|---|---|---|---|
| Raw material | Aluminum 7075-T651 plate, AMS 4045 | Mill: ____ | Cert: ____ | Accept |
| Special process | Anodize Type II, MIL-A-8625 | Processor: ____ (customer-approved) | Cert: ____ | Accept |
| Functional test | Test per drawing note: ____ | Lab: ____ | Report: ____ | Accept |
Form 3. Characteristic Accountability, Verification and Compatibility Evaluation
| Char no. | Drawing zone | Requirement | Results | Designed / special characteristic | Tool or gauge | Accept / reject |
|---|---|---|---|---|---|---|
| 1 | B3 | Overall length 80.00 +/- 0.10 mm | 80.04 | CMM, ID ____ | Accept | |
| 2 | C4 | Bore diameter 12.000 +0.018 / 0 mm | 12.009 | Key | Bore gauge, ID ____ | Accept |
| 3 | C2 | Surface roughness Ra 1.6 um max | 1.2 | Profilometer, ID ____ | Accept | |
| 4 | Note 5 | Anodize per specification, color clear | Conforms | Visual, cert review | Accept | |
| 5 | Note 2 | Break all sharp edges 0.2 mm max | Conforms | Visual 10x | Accept |
ERP data mapping (where each field comes from)
| FAI field | Typical ERP source | Example |
|---|---|---|
| Part number and revision | Item master and engineering change status | BRK-48213-01 rev C |
| Serial or lot | Lot or serial record, work order | LOT-260915-A |
| Purchase order | Purchase order header (for supplier FAI) or sales order | PO-100245 |
| Material and certificate | Receiving record, lot traceability, attached cert | Aluminum 7075-T651 plate, AMS 4045 |
| Special process supplier | Approved supplier list, operation on the routing | Anodize Type II, MIL-A-8625 |
| Drawing zone and requirements | Not in ERP. Comes from the ballooned drawing in PLM or document control |
Approvals
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.
Pull FAI header data from your ERP
Optional: scope an on-prem AI layer that fills Forms 1 and 2 from your ERP records.
Optional. The tool and every export work without this. No spam.
How to fill the three FAI forms
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.
- 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
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
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
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.
Frequently Asked Questions
What is the difference between AS9100 FAI and AS9102?
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?
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?
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?
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.
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.
Related Tools
AS9102 Form 1 Part Number Accountability Template
Generate the Form 1 header page of an AS9102 first article inspection report with part, drawing, FAI type and approval blocks.
Aerospace & DefenseAS9102 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 & DefenseAS9102 Form 3 Characteristic Accountability Worksheet
Record each ballooned characteristic with nominal, tolerance, actual and automatic pass or fail, then export to Excel.
Aerospace & DefenseAerospace Delta FAI Trigger Worksheet
Score each change for design, process, supplier, tooling and location impact to decide whether a full or partial delta FAI is needed.
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Free tools
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- AS9102 Form 1 Part Number Accountability TemplateGenerate the Form 1 header page of an AS9102 first article inspection report with part, drawing, FAI type and approval blocks.
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- 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.
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AI on your ERP
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Manufacturing hubs
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Software
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