FAI report Level 1, 2, 3 – effort and benefit compared.

First article inspection to VDA 2 has been the de facto standard in the German automotive and mechanical engineering supply chain for years. It has also become established in medical technology and special machine building. This article walks you through the three levels and provides practical guidance on when each level makes sense.

The purpose of first article inspection is clear: before the start of series production, a documented procedure demonstrates that the component meets the specified requirements. The first article inspection report (FAI report, German: EMPB) is the official documentation – it is prepared by the supplier and approved by the customer.

VDA 2 distinguishes three levels, depending on the criticality of the component. Level 1 is the simplest variant: a visual sample with confirmation of the essential dimensions. It is used for simple standard components where the technical risk is low. Effort: minimal, often integrated into the ongoing series ramp-up.

Level 2 is the standard variant for functional components. Here, all dimensioned features on the drawing are inspected and documented, geometric tolerances are verified, and a material certificate (3.1 material certificate) is included. Effort: roughly 4–8 hours of inspection time, depending on part complexity. Standard for most industrial applications.

Level 3 is the comprehensive variant for critical components. In addition to Level 2, it integrates destructive testing (hardness testing on a cross-section, tensile testing where applicable), functional testing (e.g. leak test, pressure test), and confirmation by external experts. Effort: 8–20 hours, sometimes several weeks of lead time. Standard for safety-relevant components, implant components and high-performance applications.

The choice of level is a matter of negotiation between supplier and customer – and it has a direct cost dimension. Level 2 is usually included in the unit price of the first article (no separate line item). Level 3, on the other hand, is often quoted as a separate item because the effort is significant.

From 77 years of practice: the most common source of error in first article processes is not part quality but the specification. If design and purchasing do not agree on which dimension is functionally critical, we end up inspecting dimensions nobody cares about – and may fail to emphasize what is functionally critical. A good first article review between customer and supplier before the start clarifies: Which dimensions are functional? Which tolerances are critical? Which tests need to be documented? That saves effort and reduces the risk of complaints.

A first article inspection is not a one-time event – it is triggered again by clearly defined circumstances. Requalification becomes due, among other things, after a material change (e.g. switching from 1.4305 to 1.4404), after a tooling or process change, with a new material batch showing a deviating mill certificate, when production is relocated to a different machine or site, and after an extended production interruption. In all of these cases, it is no longer assured that the originally approved result can still be achieved reproducibly.

A first article inspection report is only as reliable as the measuring equipment used. Before every sampling, measurement capability must therefore be demonstrated: calibrated measuring equipment with a valid calibration certificate and a documented measurement system analysis (MSA). Especially with tight tolerances such as IT6 or reproducible surface finishes of Ra 0.4, the variation of the measurement process determines whether a dimension can be assessed with confidence. Without capable measuring equipment, an FAI report delivers seemingly precise figures whose validity is not assured and will not hold up in a complaint case.

You should coordinate the scope of sampling cleanly before production starts. The basis is a complete characteristics list in which all characteristic features from the drawing and specification are recorded and numbered. Special characteristics such as safety and functional characteristics are flagged separately because they require greater inspection and documentation effort, such as an extended sample size or a capability study. This way, inspection effort flows specifically to where it is genuinely needed, instead of documenting non-critical dimensions to the same extent as function-critical ones.

Transmission and archiving are also part of the first article process. Structured reports to VDA 2, ideally transmitted digitally, can be reviewed and approved by the customer faster than unsorted individual records. The first article documents must be archived traceably for the agreed retention period, together with material certificates to DIN EN 10204 and batch traceability records. A clean FAI history considerably defuses later complaints: in the event of a claim, it can be demonstrated which revision was approved when and on what data basis, instead of having to make assumptions after the fact.

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