First Article Inspection AS9102
First Article Inspection AS9102 template for documenting part accountability, material traceability, dimensional results, and characteristic-level verification before production release.
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Built for: Aerospace Manufacturing · Defense Supply Chain · Precision Machining · Contract Manufacturing
Overview
This First Article Inspection AS9102 template is built to document the full approval package for a new or changed aerospace part. It captures inspection setup and traceability, Form 1 part number accountability, Form 2 product accountability, Form 3 characteristic accountability, dimensional verification, and final review and approval in one controlled record.
Use it when you need to prove the first production part matches the released drawing, material specification, special process requirements, and customer purchase order or contract. It is especially useful after a new part launch, revision change, tooling change, process transfer, or supplier change. The template helps you organize the evidence a reviewer expects to see: current documents, calibrated equipment, material certifications, heat or lot traceability, measured dimensions with units and tolerances, and characteristic-by-characteristic results.
Do not use this as a substitute for routine in-process inspection or a simple receiving check. It is not meant for cosmetic review or general quality auditing. If the part is already in steady production and no first article trigger exists, a lighter inspection record may be more appropriate. The main value of this template is that it forces the first build to be traceable, measurable, and reviewable before release, which reduces rework, missing evidence, and approval delays.
Standards & compliance context
- The template supports AS9102 first article expectations by organizing part accountability, product accountability, and characteristic accountability into a single reviewable record.
- It aligns with aerospace quality management practices commonly used under AS9100-style programs, where traceability, objective evidence, and controlled revisions are required.
- Material and special process review fields help support supplier documentation expectations that often accompany aerospace purchase orders and customer flow-downs.
- If the part includes safety-related or airworthiness-critical features, the record should be reviewed against customer requirements and any applicable authority or certification flow-downs before release.
General regulatory context for orientation only — verify current requirements with counsel or the relevant agency before relying on this template for compliance.
What's inside this template
Inspection Setup and Traceability
This section matters because it confirms the inspection is being performed against the correct controlled documents and traceable part identity before any measurements are taken.
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Inspection package includes current drawing, specification, PO, and revision-controlled work instructions
Verify the inspection package is complete and matches the current released configuration.
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Part number and revision match the traveler and drawing
Confirm the part number, dash number, and revision status are consistent across all records.
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Serial number or lot/batch identification recorded
Record the unique identifier used to trace the inspected part or lot.
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Inspection equipment calibrated and within due date
Verify all measurement tools used for the inspection are in calibration and suitable for the tolerance range.
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Environmental conditions suitable for measurement
Confirm temperature, lighting, and cleanliness are adequate to support accurate inspection results.
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Inspection status of part
Select the disposition of the part being inspected.
AS9102 Form 1 - Part Number Accountability
This section matters because it ties the first article record to the exact released part definition, source, and contract reference.
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Part number recorded exactly as released
Enter the released part number exactly as shown on the controlled drawing or purchase order.
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Part name / nomenclature recorded
Record the formal part name or nomenclature associated with the drawing.
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Part revision level recorded
Capture the current revision level for the part and drawing.
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Reason for first article inspection identified
Select the reason the first article inspection is being performed.
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Manufacturing source and location recorded
Record the manufacturing site, work center, or supplier source used to produce the part.
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Customer purchase order or contract number recorded
Capture the customer PO, contract, or release number associated with the first article.
AS9102 Form 2 - Product Accountability
This section matters because it proves the material, special processes, and supporting certifications are traceable to the specific part being approved.
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Raw material certification matches drawing specification
Verify the material certification matches the specified alloy, grade, temper, form, and applicable specification.
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Material heat/lot number traceable to received certification
Confirm the heat, lot, or batch number on the part traces to the certification package.
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Special process certifications reviewed
Select all special processes applicable to the part and verify supporting certifications are present.
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Certificate of Conformance present for purchased or processed items
Confirm certificates of conformance are available for all applicable purchased or outsourced items.
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Functional test or product verification evidence reviewed
Verify any required functional, fit, or product-level test evidence is complete and acceptable.
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Nonconforming material or concessions identified
Identify any open nonconformance, deviation, waiver, or concession affecting the first article.
Dimensional Verification
This section matters because it captures the actual measured results against the drawing tolerances and exposes any out-of-tolerance characteristics early.
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All drawing dimensions measured and recorded
Confirm every applicable dimension, note, and characteristic on the drawing has been measured or otherwise accounted for.
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Critical-to-quality characteristics within tolerance
Verify all critical or key characteristics meet the specified tolerance limits.
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Measured dimensions recorded with units
Enter measured values and units for the inspected characteristic or attach the detailed measurement report.
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Tolerance limits recorded
Record the nominal dimension and tolerance limits used to evaluate the measured result.
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Measurement method identified
Select the primary method used to verify the characteristic.
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Out-of-tolerance characteristics documented
Document any characteristic that is out of tolerance and reference the associated nonconformance record.
AS9102 Form 3 - Characteristic Accountability
This section matters because it links each drawing requirement to a unique characteristic number and a specific inspection result for auditability.
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Each drawing characteristic assigned a unique characteristic number
Confirm each requirement is uniquely numbered or otherwise cross-referenced for traceability.
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Characteristic description matches drawing requirement
Verify the characteristic description matches the drawing note, dimension, or specification requirement.
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Inspection result recorded for each characteristic
Confirm pass/fail or measured result is recorded for every characteristic.
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Evidence of inspection method or report attached
Attach or reference the inspection report, CMM output, or other supporting evidence.
Final Review and Approval
This section matters because it confirms the package is complete, any exceptions are documented, and the record is ready for quality sign-off.
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All required AS9102 forms complete
Confirm Forms 1, 2, and 3 are complete and internally consistent.
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Open nonconformances or corrective actions documented
Record any open issues requiring containment, corrective action, or customer disposition.
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Inspector signature
Inspector signs to confirm the first article inspection was completed accurately.
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Quality approval signature
Quality representative approves the completed first article package.
How to use this template
- 1. Gather the current drawing, specification, purchase order, traveler, work instructions, and all supporting certifications before you start the inspection.
- 2. Record the part identity, revision, serial or lot number, manufacturing source, and first article reason in Form 1 so the package matches the released definition.
- 3. Review raw material, special process, certificate of conformance, and test evidence in Form 2, and flag any missing traceability or concessions before continuing.
- 4. Measure every drawing characteristic, enter the result with units and tolerance limits, and attach the method or report used for each characteristic in Forms 3 and dimensional verification.
- 5. Document any out-of-tolerance condition or nonconformance, then route the record for corrective action, quality review, and final approval only after all required evidence is complete.
Best practices
- Use the exact released drawing revision and specification set, and stop the inspection if the traveler or package shows a mismatch.
- Balloon the drawing or otherwise assign each characteristic a unique number before measurement so the Form 3 record stays traceable.
- Record units, tolerance limits, and actual measured values for every dimension instead of marking features as pass or fail only.
- Attach material certifications, special process certificates, and test reports to the record at the time of review, not after approval.
- Photograph or otherwise capture evidence for any defect, concession, or out-of-tolerance condition before the part leaves the inspection area.
- Verify calibration status on all measurement equipment used for the inspection and do not rely on expired or unverified tools.
- Separate critical-to-quality characteristics from general dimensions so reviewers can quickly identify the features that drive acceptance.
What this template typically catches
Issues teams running this template most often surface in practice:
Common use cases
Frequently asked questions
What does this First Article Inspection AS9102 template cover?
This template covers the core AS9102 first article package: Form 1 part number accountability, Form 2 product accountability, Form 3 characteristic accountability, dimensional verification, and final approval. It is designed to capture the evidence needed to show the part matches the released drawing, material, and process requirements. Use it as the record for a first build, a new revision, a process change, or a moved manufacturing source.
When should a first article inspection be run?
Run it when a new part is introduced, when a drawing or specification revision changes the requirement, after a tooling or process change, when production moves to a new site, or when the customer contract requires revalidation. It is not a routine in-process inspection form. The goal is to prove the first conforming build matches the controlled definition before repeating production.
Who should complete this template?
A trained quality inspector, CMM operator, or manufacturing quality engineer usually completes the dimensional and documentation review, with production or engineering supplying traceability records and special process evidence. Final approval should come from the quality function or another authorized reviewer. The person completing it should understand the drawing, the measurement method, and the acceptance criteria.
How does this template align with AS9102 expectations?
It is structured around the three AS9102 forms and the supporting evidence typically expected in aerospace first article packages. The template helps organize part accountability, product accountability, and characteristic accountability so the record is traceable and reviewable. It does not replace customer-specific requirements, but it gives you a clean starting point that can be customized to match them.
What are the most common mistakes this template helps catch?
Common misses include using the wrong drawing revision, failing to trace material heat or lot numbers to the certification, leaving special process evidence unattached, and recording dimensions without units or tolerance limits. Another frequent issue is incomplete characteristic numbering, which makes the Form 3 package hard to audit. The template also helps surface out-of-tolerance features before the part is released.
Can this template be customized for customer-specific AS9102 requirements?
Yes. Many aerospace customers add required fields for source inspection, digital signatures, ballooned drawing references, or specific test reports. You can add those fields to the template while keeping the Form 1, Form 2, Form 3 structure intact. That makes it easier to standardize the workflow without losing customer-specific evidence.
What documents should be attached to the inspection record?
Attach the current drawing, specification list, work instructions, material certifications, special process certificates, certificates of conformity, test reports, and any ballooned drawing or characteristic map used during inspection. If a characteristic is measured with a CMM or other report-based method, include the report or file reference. The record should let a reviewer trace each requirement back to objective evidence.
How is this different from a normal receiving or in-process inspection?
A normal inspection checks a limited set of features at a point in the process, while a first article inspection verifies the full part definition and supporting documentation before production is released. This template is broader because it includes traceability, accountability, and characteristic-level evidence. It is meant to prove the manufacturing process can produce a conforming part, not just that one feature passed.
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