First Article Inspection (FAI)
The Safe Way to Switch Suppliers
Moving production from China to Vietnam? FAI is the documented proof your new factory can hit your specs before mass production begins. Here's everything you need to know — and how Dewin manages it on the ground.
What Is First Article Inspection?
First Article Inspection (FAI) is a formal verification step where the first production part — or a small sample from the first production run — is fully measured and documented against your engineering drawing. It's your proof of concept before you commit to full production volume.
Dimensional Inspection
Every critical and major dimension on your drawing is measured. CMM or 2D VMM equipment captures actual vs. nominal values and GD&T callouts. Typical tolerance verification: ±0.01mm and tighter.
Material Certification
Mill certificates or material test reports (MTRs) verify the alloy, grade, and mechanical properties match your BOM spec. Chemical composition + hardness confirmed before shipment.
Visual & Surface Finish
Surface roughness (Ra), coating thickness, color/gloss, burrs, and cosmetic requirements documented and verified. Comparison against your approved appearance standard or boundary sample.
What's in a Complete FAI Report?
FAI vs PPAP — What's the Difference?
Both verify a new supplier can hit your specs. Here's how they compare:
| Aspect | FAI | PPAP |
|---|---|---|
| Standard | AS9100 / customer-defined | AIAG PPAP (Automotive / broader industry) |
| Scope | Dimensional + material + surface of first parts | 18 elements incl. process capability (Cpk), FMEA, Control Plan |
| Documentation Level | Part-focused inspection report | Full process qualification package |
| Submission | Report sent to customer or retained on file | Levels 1–5 define what is submitted vs. retained |
| When required | New supplier, tooling change, process change, location change | Same triggers; also production volume changes |
| Timeline | 3–10 days after first parts produced | 2–6 weeks for full package |
| Who manages at Dewin | Dewin on-ground team with CMM/VMM inspection | Dewin manages all 18 elements + factory coordination |
In practice: FAI is often the dimensional portion of a PPAP Level 3 package. Many customers require both — PPAP for the process documentation, FAI samples as physical evidence.
🔗 For PPAP specifics including all 18 elements and AIAG Level definitions, see our full PPAP Guide →
When Is FAI Required?
FAI is not optional for these changes — skipping it risks discovering defects after production:
New Supplier or Factory Location
Moving from China to Vietnam = new factory = new FAI required. The new factory has different machines, operators, tooling, and process settings. You must verify it can hit your spec independently.
New Tooling or Major Tooling Repair
New injection mold, new die casting die, new stamping tool, or major repair (> 30% material replacement) requires new FAI to verify the tool produces conforming geometry.
Engineering Change to Drawing
Any drawing revision that changes a dimension, tolerance, material call-out, or surface finish requirement triggers FAI on the affected features — or full re-inspection if changes are major.
Process Change
New machine, new cutting tool strategy, new plating line, new heat treatment supplier, or new raw material source all require FAI verification that the change didn't affect conformance.
Production Gap > 12 Months
Many customers require FAI re-run if production has been inactive for 12+ months — tooling may have degraded, personnel changed, process memory lost.
Customer-Triggered Requalification
Customer audit finding, field quality issue, or periodic requalification requirement can mandate new FAI regardless of whether the process has changed.
How Dewin Manages FAI In Vietnam
Most US companies sourcing from Vietnam manage FAI via email and hope. We manage it in person, with calibrated instruments, before anything ships.
Factory Selection from 179+ Audited Network
We match your part to a factory that has passed our 50-point Dolphin Audit AND has the inspection equipment (CMM, 2D VMM, or 3rd-party calibrated instruments) to support FAI documentation. Not every factory is FAI-ready — we pre-screen for this.
Drawing Review & Inspection Plan
Our engineers review your drawing and create a balloon/bubble drawing identifying every critical (CC) and significant characteristic (SC) to be measured. Inspection method assigned to each dimension — CMM, caliper, gauge, optical comparator.
First Article Production & On-Site Inspection
Our on-ground team is physically present during first article production and inspection. We witness the measurement, verify calibration records on instruments, and photograph the process. No remote rubber-stamp inspections.
Material Certification Collection
We collect MTRs / mill certs from the raw material supplier, verify the alloy and grade match your spec, and include hardness test results if required. For coated parts, plating thickness and adhesion test results included.
FAI Report Compilation & Review
Full dimensional report with actual values against nominal + tolerance. Material cert. Surface finish data. Process flow. Photographs. Packaged as a single PDF and reviewed with you before production release.
COO Documentation for $0 Section 301 Tariff
Vietnam-origin parts are $0 Section 301 tariff. We prepare Form B Certificate of Origin and all supporting documentation for US Customs. Your finance team will notice the difference on the first import duty payment.
Inspection Equipment Available in Our Network
Our 179+ audited factories include facilities with a range of metrology equipment. Dewin's Dolphin Audit scores each factory's inspection capability as a dedicated pillar — we know exactly who has what.
3D CMM (Coordinate Measuring Machine)
Full GD&T inspection, FAI/PPAP dimensional reports, Cpk studies
2D Video Measuring Machine (VMM)
Non-contact optical measurement, ±0.001mm accuracy, fast feature measurement
Color Comparison Machine
L*a*b* colorimetry, delta-E measurement for color-critical plastic and coated parts
Hardness Tester (Rockwell/Brinell)
Material grade verification, heat treatment confirmation, hardness FAI records
Surface Roughness Tester (Profilometer)
Ra/Rz measurement per ISO 1302, machined and ground surface verification
Coating Thickness Gauge
Plating, anodize, powder coat, and paint thickness measurement per spec
Third-Party Lab Option: For parts requiring NIST-traceable calibration, chemical analysis (OES spectrometer), or specialized testing (salt spray, tensile, impact), our team coordinates with accredited third-party inspection labs in Vietnam's industrial zones. Results included in the FAI package.
Dewin-Managed FAI vs DIY Vietnam Sourcing
What happens when you skip on-the-ground FAI management:
| FAI Factor | Dewin-Managed | Unmanaged / Alibaba |
|---|---|---|
| Inspection method verification | Witness calibrated equipment on-site | Factory emails you a table they filled in |
| Material certification | Original MTR with chemistry + hardness | Photo of a certificate (potentially fabricated) |
| Dimensional report | Bubble drawing + actual measurements, all features | Selective 'key dimensions' table |
| COO documentation | Prepared and legally compliant for US Customs | Factory-provided with unknown origin rules compliance |
| Problem response | On-ground team re-inspects same day | Email exchange across 12+ time zones |
| PPAP capability | Full 18-element package if required | Factory has never heard of PPAP |
| Tariff savings documentation | $0 Section 301 — Vietnam origin confirmed | Tariff classification risk if origin disputed |
The Real Cost of Skipping FAI
FAI is not an overhead cost — it's a risk elimination cost. Here's what the math looks like when you skip it:
Typical cost of discovering a dimensional defect after receiving a full production batch. Includes reshipping, rework labor, and customer delay penalties.
Re-tooling or supplier change caused by an undetected FAI failure. The delay compounds: you're waiting for new parts while your line or customers are idle.
Dewin includes FAI management as part of our standard sourcing service. You get documented proof of conformance before production ships — at no separate line-item charge.
FAI Requirements by Manufacturing Process
CNC Machining
Tight dimensional tolerances (±0.01mm typical). Full bubble drawing inspection required. CMM preferred for complex geometries. GD&T verification per ASME Y14.5.
Die Casting (Aluminum / Zinc)
Flash, sink marks, porosity checks. Wall thickness uniformity. CMM for critical features. X-ray for internal porosity if structurally critical.
Injection Molding
2D VMM or CMM for dimensional. Color comparison machine (L*a*b*) for color-critical parts. Mold flow verification. Gate/runner defect inspection.
Sheet Metal Fabrication
Bend angles (±0.5°), formed dimensions, weld quality (if applicable), plating thickness. Flat pattern verification before forming. Hole location and size.
Forging
Hardness testing required (verifies forging temp and heat treat). Material MTR critical. CMM for machined features post-forge. Grain flow inspection for critical structural parts.
Stamping / Punching
Progressive die: first-off sample from every stage. Burr height, hole diameter, form dimensions. Plating and surface finish. Tool wear baseline established at FAI.
FAI Frequently Asked Questions
What is First Article Inspection (FAI)?
What is the difference between FAI and PPAP?
When does a new FAI need to be performed?
Does Dewin perform FAI for parts sourced from Vietnam?
How does FAI protect me during a China-to-Vietnam supply chain move?
Ready to Source from Vietnam with Full FAI Documentation?
Our team manages every step — factory selection, on-site inspection, dimensional reports, material certs, and COO documentation for $0 Section 301 tariffs. Switch suppliers the right way.