Certifications & Quality Assurance
Understanding FAI & PPAP Requirements for Subcontractors
If your manufacturing company works regularly with subcontractors—whether producing parts or components—it's essential to understand the importance of First Article Inspection (FAI) and Production Part Approval Process (PPAP). These tools help ensure that parts meet quality standards before full-scale production begins. In this post, we'll break down what these terms mean, why they matter, and how your subcontractors should approach these requirements.
What is FAI (First Article Inspection)?
The First Article Inspection (FAI) is a detailed review of the initial parts produced by a subcontractor to verify they conform to engineering drawings, specifications, and customer requirements. Think of it as the first test drive before mass production—ensuring everything is on point before moving forward.
FAI helps catch errors early when they’re easier and cheaper to fix, preventing costly rework or scrap down the line. It typically involves checking dimensions, materials, workmanship, and verifying that production processes are capable of consistently producing parts that meet quality standards.
Key Aspects of FAI:
Documentation: The subcontractor must prepare and submit a detailed report documenting measurements, test results, and compliance with specifications.
Scope: Usually involves one or more parts, often the first run or batch, to demonstrate process stability.
Customer Approval: The OEM (original equipment manufacturer) or main contractor reviews the FAI report before approving production.
What is PPAP (Production Part Approval Process)?
PPAP is a standardized process used mainly in the automotive and aerospace industries to demonstrate that the supplier's (or subcontractor's) parts meet all customer requirements and are ready for full production.
It extends beyond FAI by encompassing various forms of evidence—including process validation, control plans, and sample parts—to prove the capability of manufacturing consistent, high-quality parts over time.
Key Elements of PPAP:
Design Records and Specs: Documentation verifying that the part design matches customer specifications.
Authorized Engineering Change Documents (if any): Ensures any changes are approved.
dimensional results from initial or sample production: Demonstrates parts meet specifications.
Process flow diagrams and control plans: Show how the process ensures quality.
Capable measurement system analysis (MSA): Confirms measurement tools and methods are reliable.
Sample parts: Physical samples submitted for approval.
Production parts and pilot runs: Evidence that ongoing production can meet standards.
Why Are FAI and PPAP Important for Subcontractors?
Quality Assurance: They confirm that parts are correct the first time, reducing defects and rework.
Customer Confidence: Showing thorough process validation builds trust with your clients.
Compliance: Many industries require these processes to meet standards (e.g., IATF 16949, AS9100).
Cost Savings: Detecting issues early avoids costly fixes at later stages.
How Should Subcontractors Prepare?
1. Understand Customer Requirements
Review the purchase order, drawings, specifications, and any specific clauses related to FAI and PPAP. Clarify any uncertainties early.
2. Develop a Robust Quality Plan
Create or update control plans, process flowcharts, and inspection procedures aligned with customer expectations and industry standards.
3. Perform Internal First Article Inspections
Before submitting to the client, run your own inspection to identify and correct issues. This demonstrates due diligence and readiness.
4. Collect and Document Evidence
Gather all measurement data, test reports, and process validation records required by PPAP. Proper documentation simplifies approval and audits.
5. Communicate Clearly with the Customer
Maintain transparency, ask for feedback, and clarify any special requirements or submission deadlines. Good communication ensures smoother approvals.
External Resources
AIAG PPAP Guidelines — Official resources for developing and understanding PPAP submissions.
IATF 16949 — Industry-specific quality management standards.
Final Thoughts
FAI and PPAP are not just bureaucratic hurdles—they're tools that help your business produce consistent, quality parts that meet your clients' expectations. For subcontractors, understanding these processes isn't about complexity; it’s about doing what’s right from the start to ensure finished products are reliable and compliant.
By thoroughly preparing, documenting accurately, and communicating openly, your company can streamline approval processes, reduce costly errors, and build stronger relationships with your customers.
Remember, excellence starts with a good process. Embrace FAI and PPAP as part of your quality culture, and the results will speak for themselves.