First Article Inspection (FAI) China: Pre-Production Sample Approval Guide for Importers | $169
First Article Inspection (FAI) is a pre-production quality check performed on the initial samples from a new production run — before your supplier starts full-scale manufacturing.
First Article Inspection (FAI) is a pre-production quality check performed on the initial samples from a new production run — before your supplier starts full-scale manufacturing. Unlike pre-shipment inspection (which catches defects before the container leaves), FAI verifies that the factory's tooling, setup, and materials produce parts matching your specifications. One FAI caught a 0.4mm dimensional deviation on an electronics enclosure that would have rendered 10,000 units unsellable. CloudSpects offers FAI across electronics, hardware, plastics, and packaging from $169/man-day in all major China manufacturing hubs.
What exactly is First Article Inspection (FAI)?
FAI (also called First Piece Inspection, Initial Sample Inspection Report, or PPAP Level 1) is a systematic verification of the first production run against your design specifications. It originated in aerospace (AS9102 standard) but is now widely used in automotive, electronics, medical devices, and consumer goods.
A standard FAI checks:
- Dimensional accuracy — critical-to-function measurements against your approved drawing
- Material composition — verify alloy grade, plastic resin type, coating thickness
- Color and finish — Pantone match, surface texture, gloss level
- Assembly fit — how multiple components mate together in a multi-part product
- Functional test — switch actuation, lid closure, seal compression, weight check
FAI vs PSI: FAI happens at the start of production (samples are checked before the full run). PSI happens at the end (finished goods are inspected before shipment). They complement each other — FAI prevents a bad batch from starting; PSI prevents bad units from shipping.
When do you need FAI vs regular PSI?
| Situation | Recommended | Why |
|---|---|---|
| New product, first factory run | FAI + PSI | Verify tooling is correct, then verify final output |
| Existing product, same factory | PSI only (skip FAI) | Tooling is already validated; spot-check final output |
| New mold or die change | FAI required | New tooling dimensionally unknown — must verify |
| Material substitution | FAI recommended | Different resin/rubber may shrink differently in mold |
| Factory transferred to new location | FAI required | New machines, new operator training — verify setup |
Step 1: Prepare your specification package
For CloudSpects to perform FAI, send these documents before the inspector visits the factory:
- Approved drawing (PDF or CAD) with critical dimensions clearly marked with tolerances
- Material specification sheet — resin grade, alloy standard, hardness range, coating thickness
- Color reference — Pantone code, RAL number, or physical color chip standard
- Assembly instruction — how parts fit together, torque spec for threaded components
- Functional test criteria — pass/fail conditions for any moving or electronic function
Step 2: On-site dimensional measurement
The inspector takes 3-5 units from the first production output and measures all critical dimensions using calibrated tools:
- Digital calipers (plus/minus 0.01mm) for length, width, height
- Micrometer for thickness, wall thickness, clearance gaps
- Go/No-go gauges for holes, slots, and mating surfaces
- CMM (Coordinate Measuring Machine) for complex 3D contours — available at third-party labs in Shenzhen, Shanghai, and Guangzhou
- Tension gauge for snap-fit and latch closure force
Each measurement is recorded on a FAI report against the specified tolerance. Any dimension outside tolerance is flagged RED with a photo and deviation measurement.
Step 3: Batch consistency verification
After the First Article is measured, 25 additional units from the first production hour are checked for consistency:
- Cavity-to-cavity variation — multi-cavity molds may produce different dimensions from each cavity
- Start-to-end drift — machine warm-up can shift dimensions after the first few cycles
- Visual surface check — sink marks, flash, short shots, flow lines
- Weight check — consistent weight across units confirms consistent material fill
If standard deviation on any critical dimension exceeds the tolerance band, the production run is halted until the root cause (tool wear, machine temperature, material batch variation) is identified and corrected.
Frequently asked questions about FAI in China
How long does a First Article Inspection take?
A standard FAI takes 2-4 hours on-site for a simple product. Complex assemblies with 20+ critical dimensions may take a full day. CloudSpects charges $169/man-day regardless of complexity — no surcharge for detailed FAI reports.
Do you provide a FAI report template?
Yes. Our inspectors use a standardized FAI report that lists every checked dimension with measured value, tolerance, pass/fail status, and deviation. You receive the report as a PDF with photos within 24 hours of inspection.
Can FAI be done remotely with factory video?
FAI requires calibrated measurement tools that a factory QC team may have but may not calibrate regularly. CloudSpects brings their own calibrated instruments. Remote guided FAI is possible for simple pass/fail checks but not for critical dimensional measurements.
Is FAI included in standard PSI pricing?
FAI is a separate service from PSI because it requires different preparation (spec package, measurement criteria, test fixtures) and happens at a different production stage. However, if your FAI and PSI are scheduled on the same factory visit, you pay for only one man-day. Each additional day is $169.
How many units do you test for FAI?
Standard FAI: 3-5 units for full dimensional measurement, plus 25 units for batch consistency checks. Critical components (medical, automotive safety) get 8 units measured plus 50 for consistency.
Frequently asked questions
What exactly is First Article Inspection (FAI)?
FAI (also called First Piece Inspection, Initial Sample Inspection Report, or PPAP Level 1) is a systematic verification of the first production run against your design specifications. It originated in aerospace (AS9102 standard) but is now widely used in automotive, electronics, medical devices, and consumer goods.