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First Article Inspection (FAI) Guide

Part of the Operator Dashboard / ShopPulse Feature Set

Overview​

What is First Article Inspection (FAI)?​

First Article Inspection (FAI) is a feature within the Operator Dashboard (ShopPulse) that transforms manual, paper-based first piece inspection workflows into a real-time digital process that eliminates waiting time, provides instant visibility, and creates complete traceability.

The Problem:

  • Hidden waiting time: Operators don't know if QA has been notified, is available, or has received the request
  • Manual coordination overhead: Operators walk to QA, make phone calls, leave paper forms
  • Status black holes: No visibility into queue position or estimated approval time
  • Paperwork errors: Incomplete documentation, missing signatures, lost traceability
  • Production risk decisions: Operators sometimes "run at risk" before FAI approval, creating potential scrap
  • QA bottlenecks invisible: Supervisors lack real-time visibility into inspection backlogs

Industry Context:

  • In high-mix manufacturing, FAI events occur multiple times per shift per machine
  • Manual coordination creates significant inefficiency and production delays

The Solution: Instead of walking to QA or waiting with no status updates, operators submit FAI requests with a single tap in ShopPulse. Quality inspectors immediately receive notifications with full part context, work through prioritized queues efficiently, and approve or reject parts digitally. Operators get instant alerts when inspections complete.

Who Uses FAI:

  • Machine Operators: Submit inspection requests, receive instant approval alerts
  • Quality Inspectors: Manage centralized queue, perform inspections, approve/reject digitally
  • Production Supervisors: Monitor queue depth and wait times, reallocate QA resources proactively
  • Quality Managers: Complete digital audit trail, 100% traceability for compliance
  • Plant Managers: Track FAI-specific idle time, measure cycle time improvements

Key Features​

For Operators​

One-Click Submission:

  • After completing first part, tap "Request Inspection" in ShopPulse
  • System automatically captures:
    • Part number
    • Job details
    • Machine state
    • Timestamp
  • No paperwork, no walking to QA

Real-Time Status Tracking:

  • Operator sees live updates:
    • "Submitted" → "In QA Queue" → "Inspection Started" → "Approved"
  • No checking back required
  • Transparency throughout process

Machine State Management:

  • Machine automatically enters "Awaiting Inspection" state
  • Clear visibility across dashboards that machine pending QA approval
  • Distinguishes FAI wait time from other downtime

Instant Approval Alerts:

  • When QA approves (or rejects), operator receives immediate notification via ShopPulse alert
  • Operator can resume production immediately
  • No guesswork or repeated check-ins

Documented Decision Trail:

  • Complete record of FAI request, timing, inspector notes, and approval/rejection
  • Automatically logged for audit trail
  • Available in reports and job history

For Quality Inspectors​

Centralized Inspection Queue:

  • QA dashboard displays all pending FAI requests across shop floor
  • Key details visible:
    • Part number
    • Machine
    • Operator
    • Wait time
  • No paper forms scattered across shop

Guided Inspection Workflow:

  1. Select FAI from queue
  2. System displays part and order information
  3. Perform physical inspection
  4. Enter results (measurements, notes)
  5. Approve or reject with notes
  6. Move to next inspection

Prioritization:

  • Sort by wait time (longest wait first)
  • Sort by priority (high-priority parts first)
  • Filter by machine group or department
  • Efficient workflow management

For Supervisors and Quality Managers​

Real-Time Visibility Dashboards:

  • Monitor inspection queue lengths
  • Average cycle times
  • Inspector workloads
  • Bottleneck trends across shifts

Proactive Alerting:

  • Receive notifications when FAI wait times exceed thresholds (e.g., >30 minutes)
  • Reallocate QA resources before production delays compound
  • Prevent bottlenecks proactively

Performance Metrics:

  • Track FAI cycle time by:
    • Part family
    • Machine
    • Inspector
    • Shift
  • Identify improvement opportunities

Audit Trail:

  • Complete history of all FAI events
  • Timestamps
  • Inspector notes
  • Approval decisions
  • 100% traceability for quality system compliance

For Operators​

Submitting an FAI Request​

When to Request FAI:

  • First part off a new setup
  • First part after tool change (if required)
  • First part of new work order
  • First part after process change
  • As specified by work instructions or quality plan

Step-by-Step:

  1. Complete First Part:

    • Run first part through full operation
    • Part is ready for inspection

  2. Open ShopPulse on operator tablet

  3. Tap "Request Inspection" button on job card

  4. System Auto-Captures:

    • Part number
    • Work order
    • Operation
    • Machine ID
    • Timestamp
    • Operator ID

  5. Add Notes (Optional):

    • Any concerns or observations
    • Tool numbers used
    • Measurement results (if self-inspecting)

  6. Tap "Submit"

  7. Confirmation:

    • "FAI Request Submitted"
    • Request ID displayed (e.g., FAI-00123)
    • Status: "Waiting for QA"

What Happens Next:

  • Machine state changes to "Awaiting Inspection"
  • FAI request appears in QA queue
  • QA inspector receives notification
  • Operator monitors status on tablet

[Recommended Image]: Screenshot of ShopPulse showing "Request Inspection" button on job card

Monitoring FAI Status​

Status Indicators:

  • 🕐 Submitted: Request sent to QA queue
  • 📋 In QA Queue: Waiting for inspector
  • 🔍 Inspection Started: Inspector reviewing part
  • ✅ Approved: Part passed, can start production
  • ❌ Rejected: Part failed, make corrections

Viewing Status:

  • Status banner appears at top of ShopPulse
  • Tap banner for full details
  • Shows:
    • Current status
    • Wait time so far
    • Inspector name (if assigned)
    • Queue position (e.g., "3rd in queue")

Estimated Time:

  • Based on average FAI cycle time
  • Updates as queue progresses
  • Example: "Est. approval in 15 minutes"

Receiving Approval​

Instant Notification:

  • Approved: Green banner: "FAI Approved - Resume Production"
  • Rejected: Red banner: "FAI Rejected - See Inspector Notes"

Approved:

  1. Notification appears on tablet
  2. Machine state returns to normal
  3. Operator can start production run
  4. FAI approval documented in job history

Rejected:

  1. Notification with rejection reason
  2. Inspector notes displayed
  3. Corrective action required
  4. Submit new FAI after corrections

Handling Rejections​

If FAI Rejected:

  1. Read Inspector Notes: Understand what failed

    • Dimension out of tolerance
    • Surface finish issue
    • Tool problem
    • Setup issue

  2. Make Corrections:

    • Adjust setup
    • Change tool
    • Modify program
    • Consult supervisor if unclear

  3. Produce New First Article

  4. Submit New FAI Request:

    • Tap "Request Inspection" again
    • Add notes: "Corrected [issue], resubmitting"

  5. Wait for Re-Inspection

Best Practices:

  • Don't start production without approval (unless authorized "run at risk")
  • Communicate with inspector if unsure about rejection
  • Document what was changed for future reference

For Quality Inspectors​

Accessing the FAI Queue​

Navigate to: Quality → FAI Queue

Dashboard Shows:

  • All pending FAI requests
  • Current inspections in progress
  • Recently completed inspections

Queue Columns:

  • Request ID: Unique identifier (FAI-00123)
  • Part Number: What needs inspection
  • Machine: Where part was produced
  • Operator: Who made the part
  • Submitted: Time request received
  • Wait Time: How long operator has been waiting
  • Priority: High/Medium/Low (configurable)

[Recommended Image]: Screenshot of QA FAI Queue showing list of pending requests

Performing an Inspection​

Step-by-Step:

  1. Select FAI from Queue:

    • Click request row
    • Or tap highest priority item

  2. Review Part Details:

    • Part number and revision
    • Work order information
    • Drawing/specification (if linked)
    • Operator notes

  3. Retrieve Physical Part:

    • Walk to machine
    • Collect first article from operator
    • Verify part matches request

  4. Perform Inspection:

    • Check dimensions per specification
    • Verify surface finish
    • Check features and tolerances
    • Use CMM, calipers, gauges as needed
    • Document measurements

  5. Enter Results in System:

    • Click "Enter Results"
    • Record measurements:
      • Dimension 1: 2.500" (spec: 2.495" - 2.505") ✅
      • Dimension 2: 1.002" (spec: 0.998" - 1.002") ✅
      • Surface Finish: 32 Ra (spec: <63 Ra) ✅
    • Add notes: Any observations, concerns, or recommendations

  6. Make Decision:

    • Approve: Part meets specification → Tap "Approve"
    • Reject: Part out of spec → Tap "Reject", select reason

  7. Approval Confirmation:

    • System time-stamps approval
    • Operator notified immediately
    • Machine state updates
    • Request moves to "Completed" tab

Rejection Reasons (Configurable):

  • Dimension out of tolerance
  • Surface finish issue
  • Tool marks / damage
  • Missing features
  • Incorrect material
  • Setup issue
  • Other (add notes)

Managing the Queue​

Prioritization Strategies:

By Wait Time (Default):

  • Longest-waiting requests first
  • Ensures no operator waits excessively
  • Fair first-come, first-served approach

By Priority Level:

  • High-priority parts first (customer hot orders, expedites)
  • Medium-priority next
  • Low-priority when time allows

By Machine Group:

  • Focus on one department at a time
  • Efficient if inspector specializes
  • Reduces walking between areas

Filtering:

  • Filter by part family (similar inspections)
  • Filter by machine (geographic grouping)
  • Filter by operator (if training new operators)

Batching:

  • If multiple requests for same part, inspect together
  • Reduces setup time (one drawing, one fixture setup)
  • Faster throughput

Communicating with Operators​

During Inspection:

  • System shows operator "Inspection in Progress"
  • If issue found during inspection, can message operator via system
  • Example: "Need you to show me the setup for dimension clarification"

After Inspection:

  • Approval/rejection notification automatic
  • Inspector notes visible to operator
  • Can include recommendations:
    • "Check tool wear after 50 parts"
    • "Monitor dimension X, trending towards lower limit"

For Supervisors and Quality Managers​

Monitoring the FAI Dashboard​

Access: Dashboards → Quality → FAI Performance

Real-Time Metrics:

  • Pending Requests: Current queue depth
  • Average Wait Time: How long operators wait for QA
  • In Progress: How many inspections active now
  • Completed Today: Total FAI events processed
  • Approval Rate: % approved on first submission

Trend Charts:

  • Queue depth over time (spikes indicate bottlenecks)
  • Average cycle time (improving or degrading?)
  • Approval rate by machine (which machines produce good first articles?)
  • Approval rate by operator (training opportunities?)

[Recommended Image]: Screenshot of FAI Performance Dashboard showing metrics and trends

Proactive Resource Allocation​

Scenario: Queue Depth Rising

Dashboard Alert:

  • "FAI Queue: 8 requests, Avg Wait: 45 minutes"
  • Threshold exceeded (configured at 30 min)

Actions:

  1. Check inspector availability
    • How many inspectors working?
    • Any available to help with queue?
  2. Reallocate resources
    • Pull inspector from lower-priority task
    • Assign additional inspector to FAI
  3. Communicate with production
    • "QA backlog, expect 45-min wait for FAI"
    • Prioritize setup to be ready when approval comes

Result:

  • Queue clears faster
  • Wait times return to normal
  • Production delays minimized

Analyzing Performance​

Weekly Review:

Metrics to Track:

  1. Average FAI Cycle Time: From submission to approval

    • Target: <30 minutes
    • Industry benchmark: 45 minutes
    • Best-in-class: <20 minutes

  2. First-Pass Approval Rate: % approved on first submission

    • Target: >90%
    • If <80%, investigate:
      • Operator training needs?
      • Setup issues?
      • Tool problems?

  3. Peak Queue Times: When do backlogs occur?

    • Morning shift starts (many setups)?
    • Shift changeovers?
    • Specific days of week?

  4. Inspector Throughput: Inspections per inspector per shift

    • Compare inspectors (training opportunities?)
    • Identify bottlenecks in inspection process

Monthly Trends:

  • Is cycle time improving or degrading?
  • Are approval rates improving (operators getting better at setups)?
  • Where are the biggest gains/losses?

Audit and Compliance​

Complete Digital Audit Trail:

  • Every FAI request recorded
  • Timestamp for each status change
  • Inspector ID for each approval/rejection
  • Measurement data captured
  • Notes and observations preserved

Regulatory Compliance:

  • Aerospace (AS9102)
  • Automotive (PPAP)
  • Medical devices (FDA 21 CFR Part 11)
  • ISO 9001 quality management

Audit Reports:

  • Access: Reports → Quality → FAI Audit Report
  • Filter by:
    • Date range
    • Part number
    • Work order
    • Inspector
  • Export to: PDF or CSV for auditors

Traceability:

  • When quality issue emerges weeks later
  • Query: "Was FAI performed for this lot?"
  • Answer: Yes, FAI-00456, approved by Inspector B on [date]
  • Proof of inspection available with measurements

FAI Workflow​

Standard FAI Process Flow​

1. OPERATOR
   ↓
   [Complete First Article]
   ↓
   [Tap "Request Inspection" in ShopPulse]
   ↓
   [System captures details, creates FAI request]
   ↓

2. SYSTEM
   ↓
   [FAI request added to QA queue]
   ↓
   [Machine state → "Awaiting Inspection"]
   ↓
   [QA notified]
   ↓

3. QA INSPECTOR
   ↓
   [View pending requests in queue]
   ↓
   [Select highest priority/longest wait]
   ↓
   [Retrieve part from operator]
   ↓
   [Perform inspection]
   ↓
   [Enter measurements and results]
   ↓
   [Approve or Reject]
   ↓

4. SYSTEM
   ↓
   [Update FAI status to "Approved" or "Rejected"]
   ↓
   [Notify operator immediately]
   ↓
   [Machine state returns to normal (if approved)]
   ↓
   [Log in audit trail]
   ↓

5. OPERATOR
   ↓
   [Receive notification]
   ↓
   IF APPROVED → [Start production run]
   IF REJECTED → [Make corrections, submit new FAI]

Time Savings Example​

Traditional FAI Process:

1. Operator completes first article: 0 minutes
2. Operator walks to QA office: 3 minutes
3. Waits for QA attention: 5 minutes
4. QA collects form, walks to machine: 3 minutes
5. Performs inspection: 10 minutes
6. QA walks back to log results: 2 minutes
7. Operator checks for approval: 2 minutes

Total: 25 minutes (15 minutes non-value-added)

Digital FAI Process:

1. Operator completes first article: 0 minutes
2. Operator taps "Request Inspection": 10 seconds
3. QA sees request immediately: 0 minutes
4. QA walks to machine: 2 minutes
5. Performs inspection: 10 minutes
6. Enters results digitally: 1 minute
7. Operator notified instantly: 0 minutes

Total: 13 minutes 10 seconds (12 minutes saved)

ROI Calculation:

Machines: 10
FAI events per machine per day: 2
Days per month: 22
Time saved per FAI: 12 minutes

Monthly time savings:
10 machines × 2 FAI/day × 22 days × 12 min = 5,280 minutes = 88 hours

At $35/hour fully-loaded operator cost:
88 hours × $35 = $3,080/month savings

Annual savings: $36,960

Configuration​

Enabling FAI​

Prerequisites:

  • ShopPulse MES module enabled
  • Job tracking active (APM, ShopPulse, or ERP-driven)
  • Quality Inspector user accounts created

Setup Steps:

  1. Navigate to: Settings → ShopPulse → Features
  2. Enable "First Article Inspection"
  3. Configure Settings:
    • Auto-Submit on First Part: Automatically prompt operator after first part? (Yes/No)
    • Require FAI Approval Before Production: Block production until approved? (Yes/No)
    • Alert Threshold: Minutes before supervisor notified of long wait (e.g., 30)
  4. Click "Save"

Configuring Rejection Reasons​

Navigate to: Settings → Quality → FAI Rejection Reasons

Default Reasons:

  • Dimension out of tolerance
  • Surface finish issue
  • Tool marks
  • Missing feature
  • Setup issue

Add Custom Reasons:

  1. Click "Add Reason"
  2. Enter reason name (e.g., "Burr not removed")
  3. Select severity (Minor, Major, Critical)
  4. Click "Save"

Setting Up Inspector Accounts​

For Each QA Inspector:

  1. Navigate to: Settings → Users
  2. Create User or Edit Existing
  3. Assign Role: Quality Inspector
  4. Permissions:
    • View FAI Queue ✅
    • Approve/Reject FAI ✅
    • View all machines ✅
  5. Assign Departments (if multi-site):
    • Which areas/machine groups can this inspector handle?
  6. Click "Save"

Measuring ROI​

Key Metrics to Track​

Before FAI Implementation:

  • Baseline FAI cycle time (submission to approval)
  • Number of FAI events per day/week
  • Operator idle time during FAI wait

After FAI Implementation:

  • New FAI cycle time (compare to baseline)
  • Time savings per FAI event
  • Total time savings per month
  • Operator satisfaction (survey)

Calculating Time Savings​

Example:

Baseline (Manual FAI):

  • Average cycle time: 45 minutes
  • FAI events per month: 440 (10 machines × 2/day × 22 days)
  • Total time spent: 440 × 45 min = 19,800 minutes = 330 hours

After Digital FAI:

  • Average cycle time: 18 minutes (60% reduction)
  • FAI events per month: 440 (same)
  • Total time spent: 440 × 18 min = 7,920 minutes = 132 hours

Time Savings:

  • 330 - 132 = 198 hours per month saved
  • At $35/hour: 198 × $35 = $6,930/month
  • Annual savings: $83,160

Productivity Gains​

Reduced Idle Time:

  • Operators wait less for QA approval
  • Machines resume production faster
  • Throughput increases

QA Efficiency:

  • Centralized queue = better prioritization
  • No hunting for paper forms
  • More inspections per shift (25% improvement typical)

Quality Improvements:

  • Complete documentation = better traceability
  • Trend analysis = proactive problem solving
  • First-pass approval rate improves (operators learn from rejection patterns)

Best Practices​

For Operators​

  1. Submit FAI immediately after first part complete
  2. Add helpful notes: Any concerns, tool numbers, observations
  3. Don't run at risk: Wait for approval (unless authorized)
  4. If rejected, ask why: Learn from rejections to improve setups
  5. Stage first article: Keep accessible for inspector

For Quality Inspectors​

  1. Prioritize longest wait first: Fairness and prevents excessive delays
  2. Enter detailed notes: Help operators improve, create better records
  3. Use rejection reasons consistently: Enables trend analysis
  4. Communicate proactively: If backlog building, notify supervisor
  5. Close loop with operators: When rejecting, explain why and how to fix

For Supervisors​

  1. Monitor dashboard hourly: Catch backlogs early
  2. Set realistic alert thresholds: 30 minutes is typical starting point
  3. Review daily: End-of-shift check for patterns
  4. Provide feedback: Share approval rate data with operators
  5. Adjust resources: Flex QA staffing based on FAI demand

For Quality Managers​

  1. Track trends monthly: Are cycle times improving?
  2. Benchmark inspectors: Identify top performers, replicate best practices
  3. Analyze rejections: Common reasons = training or process improvement opportunities
  4. Celebrate wins: Recognize operators with high first-pass approval rates
  5. Audit quarterly: Ensure documentation meets regulatory requirements

Troubleshooting​

FAI Request Not Appearing in QA Queue​

Possible Causes:

  • ShopPulse FAI feature not enabled
  • Inspector doesn't have permissions
  • Network connectivity issue

Solutions:

  1. Verify FAI enabled (Settings → ShopPulse → Features)
  2. Check inspector permissions (Settings → Users → [Inspector] → Role)
  3. Refresh QA dashboard (F5)
  4. Check network connectivity

Operator Not Receiving Approval Notification​

Possible Causes:

  • Tablet screen off or locked
  • Notification settings disabled
  • Browser issue

Solutions:

  1. Wake tablet screen
  2. Check notification settings (Settings → ShopPulse → Notifications)
  3. Refresh browser on tablet
  4. Manually check FAI status (status banner at top of ShopPulse)

FAI Cycle Time Longer Than Expected​

Possible Causes:

  • QA understaffed for FAI demand
  • Inspectors not prioritizing FAI queue
  • Complex parts requiring long inspections

Solutions:

  1. Review QA staffing levels
  2. Set expectation: FAI is priority task
  3. Analyze: Which parts take longest? Can inspection be simplified?
  4. Consider adding inspector during peak FAI times (shift starts)

Questions? Contact support@machinemetrics.com