First Article Inspection (FAI) is a quality control process used to verify that a manufacturing process is capable of producing parts that meet design specifications. It involves a detailed examination of the first item produced (the “first article”) against the approved engineering drawings and specifications. The main goals are to ensure that the production process is set up correctly and that the parts meet all required dimensions, tolerances, and other specifications before mass production begins.
Process Capability Report evaluates how well a manufacturing process can produce products within specified limits. It typically uses statistical methods to assess the capability of a process, often expressed through indices like Cp, Cpk, Pp, and Ppk. These indices compare the inherent variability of the process to the specified limits.
GD&T (Geometric Dimensioning and Tolerancing) is a system for defining and communicating engineering tolerances. It specifies the allowable variation in the geometry of parts, which is crucial for ensuring proper fit and function. When performing FAI and process capability reports, GD&T is used to clarify the exact requirements for part features, helping to ensure that the inspection and analysis are based on precise criteria.
In summary, FAI ensures that the production setup is correct, while a process capability report assesses how consistently that setup can produce conforming parts, both of which can be enhanced by using GD&T for clear dimensional and geometric specifications.
