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First Article Inspection

Operator awaiting first article inspection in ShopPulse

Overview​

First Article Inspection (FAI) adds a quality inspection step to the setup-to-production transition on MES-enabled machines. When an operator completes setup and is ready to begin production, they can submit the first piece for inspection before transitioning. A QA inspector reviews the piece at a dedicated inspection station and either approves it — clearing the operator to enter production — or rejects it with a reason, sending the operator back to setup to correct the issue and try again.

FAI helps catch quality problems before production begins — reducing scrap, rework, and wasted machine time.

Feature Availability​

RequirementDetails
ModuleMES Package
ERP IntegrationRequired. Active integration with a supported ERP.
MES EnabledMES must be enabled on the individual machine.
Manage Jobs InMust be set to ShopPulse (not ERP Driven).
Jobs Selected ByWorks with both Operator and Program configurations.
FAI ToggleMust be enabled per machine — either from the MES Settings page (FAI column) or the individual machine's Production & Operations tab (Optional Features section → "Enable first article inspection").
Access LevelOperators interact with FAI in ShopPulse. QA inspectors access the inspection interface via a dedicated URL or Labs link. Managers and Executives can enable/disable the feature in MES Settings.

How It Works​

When an operator transitions from setup to production, they're prompted to either submit the first piece for inspection or skip. If submitted, the request enters the inspector's queue. The inspector approves (clearing the operator to enter production) or rejects with a reason (sending the operator back to setup to correct and resubmit).

The ShopPulse header color reflects the current FAI state throughout the process:

StateHeader Color
In Setup (before submission)Yellow
Awaiting InspectionOrange
Inspection in ProgressTeal
Inspection ApprovedGreen
Inspection RejectedRed (with rejection reason)

The operator can cancel an inspection request while it is still pending (waiting for an inspector to pick it up). Once an inspector has started reviewing the piece, the cancel option is no longer available. Canceling dismisses the inspection request and returns the operator to the regular setup screen — setup time and counters are not affected.

The Inspector Interface​

QA inspectors work from a standalone interface — separate from ShopPulse — accessed via a Labs link in MachineMetrics or directly at first-article-inspection.svc.machinemetrics.com.

The interface shows a shared queue of all pending inspection requests across every machine and order — every inspector sees every pending request regardless of station.

The inspector selects a request, examines the piece, and taps Approve or Reject. Once an inspector picks up a request, they must approve or reject it — there is no option to release it back to the queue. When rejecting, the inspector selects a reason from a predefined list (Damaged Part, Incorrect Setup, Missing Documentation, Out of Tolerance, Other) and can add optional comments. These reasons are system-defined and not configurable per customer.

Current Shift Dashboard​

Supervisors and managers can monitor FAI status from the Current Shift Dashboard. Machine tiles show the same color-coded states as the ShopPulse header (orange for awaiting, teal for in progress, red for rejected with reason, green for approved), each with an elapsed timer.

How to Use It​

For Administrators: Enabling FAI​

  1. Navigate to Settings → MES → Machines tab.
  2. Locate the machine in the table and toggle the FAI column to on.

Alternatively, open the individual machine's settings, go to the Production & Operations tab, scroll to Optional Features, and toggle "Enable first article inspection" on.

FAI can be enabled on any MES-enabled machine where "Manage jobs in" is set to ShopPulse.

For Operators: Submitting for Inspection​

  1. Complete your setup and run the first piece.
  2. When transitioning from setup to production, a prompt appears asking whether to submit for inspection.
  3. Tap Send for Inspection to submit the piece to the QA queue. (Tap Skip if inspection is not needed.)
  4. Wait for the inspector to review. Your ShopPulse header shows the current status.
  5. If approved: Tap Enter Production, or submit your setup labor ticket as "Complete."
  6. If rejected: Review the rejection reason on screen. Tap Return to Setup, correct the issue, run a new first piece, and submit again.

For QA Inspectors: Performing Inspections​

  1. Open the inspection interface via the Labs link or navigate to first-article-inspection.svc.machinemetrics.com.
  2. Select a pending request from the queue to begin the inspection.
  3. After examining the piece:
    • Tap Approve if the piece meets specifications.
    • Tap Reject if it does not. Select a rejection reason, add optional comments, and save.

Tips & Best Practices​

  • Monitor the dashboard for long wait times. The Current Shift Dashboard shows how long machines have been waiting for inspection. Long "Awaiting Inspection" timers may indicate the QA team is bottlenecked.
  • Coordinate inspector staffing with shift schedules. If no inspector is available, operators will wait — or skip inspection. Plan inspector availability around shift starts when first articles are most common.

FAQs & Troubleshooting​

  • Why don't I see the inspection prompt? FAI must be enabled on your specific machine by an administrator. Check with your manager if you expect to see it and don't.

  • What happens if I cancel an inspection request? The request is removed from the inspector's queue and you return to your regular setup screen. Your setup time and counters are not affected. You can only cancel while the request is still pending — once an inspector has started reviewing, cancel is no longer available.

Need Help?​

Contact your Solutions Delivery Manager or email support@machinemetrics.com.