How do you calculate first article inspection cost?

Multiply parts by the variable cost per part, add fixed program cost and the labor and overhead adder. For 3 parts at $120 each plus $200 fixed and $150 overhead, the total is $360 + $200 + $150 = $710.

What is the cost per part for a first article inspection?

Divide the total by the number of first article parts. In our example, $710 across 3 parts is about $236.67 per part, which is high per-part precisely because fixed and overhead costs are spread over only a few pieces.

Why is first article inspection so expensive per part?

Because fixed program cost and loaded labor are amortized over a tiny quantity, often one to three parts. The $200 fixed and $150 overhead alone add $350, which dwarfs the $360 of variable measurement across the three parts.

Should I run more than one first article part?

Only if the customer or spec requires it. Each added part adds variable cost but spreads the fixed and overhead over more pieces, lowering cost per part; the total, however, still rises.

What goes into the fixed program cost?

One-time setup that does not scale with part count: fixture build, CMM programming, ballooning, and AS9102 form preparation. It is incurred once whether you inspect one part or five.

In-house vs outsourced FAI: how does this help?

Compute your loaded total here, then compare it to an outside inspection lab's quote. If your fixed and overhead adders are high because of one-off programming, an outside service with existing fixtures for that part family may win on the first article.

Quality & Metrology calculator

First Article Inspection Cost Calculator

First article inspection cost is the one-time dollar total to fully verify a new or changed part before production release, blending per-part measurement cost with fixed program setup and loaded labor and overhead. Quality engineers and estimators use it to price the launch gate into a quote and to decide how many first articles a customer's requirement really justifies. Because FAI is a front-loaded, non-recurring cost, misjudging it either erodes margin on a new program or prices you out of the bid. Breaking it into variable and fixed buckets shows exactly where the money goes and which lever moves the total.

What this calculator does

Estimate the cost of a first article inspection from the parts to inspect, variable inspection cost, fixed program cost, and labor and overhead.
Use it when quoting a first article inspection or deciding whether to run it in-house or at an outside lab.
It sums variable cost (parts times per-part cost) with fixed program cost and a labor and overhead adder, then divides by parts to give cost per part.

Formula used

Total first article inspection cost = first article parts to inspect × variable inspection cost per part + fixed program cost + labor and overhead adder
Cost per part = total first article inspection cost ÷ first article parts to inspect

Inputs explained

First article parts to inspect:
Variable inspection cost per part:
Fixed program cost:
Labor and overhead adder:

How to use the result

Use it when quoting a new AS9102 or PPAP program, deciding how many first articles to run, or comparing in-house FAI against an outside inspection service.
The per-part variable cost assumes uniform characteristic complexity across parts, so a first article with far more balloons than the rest will distort the average.

Current U.S. benchmarks

U.S. manufacturing runs at 75.6% of capacity (Federal Reserve, May 2026). New factory orders are up 2.3% year over year (Census).

Common questions

How do you calculate first article inspection cost? Multiply parts by the variable cost per part, add fixed program cost and the labor and overhead adder. For 3 parts at $120 each plus $200 fixed and $150 overhead, the total is $360 + $200 + $150 = $710.
What is the cost per part for a first article inspection? Divide the total by the number of first article parts. In our example, $710 across 3 parts is about $236.67 per part, which is high per-part precisely because fixed and overhead costs are spread over only a few pieces.
Why is first article inspection so expensive per part? Because fixed program cost and loaded labor are amortized over a tiny quantity, often one to three parts. The $200 fixed and $150 overhead alone add $350, which dwarfs the $360 of variable measurement across the three parts.
Should I run more than one first article part? Only if the customer or spec requires it. Each added part adds variable cost but spreads the fixed and overhead over more pieces, lowering cost per part; the total, however, still rises.
What goes into the fixed program cost? One-time setup that does not scale with part count: fixture build, CMM programming, ballooning, and AS9102 form preparation. It is incurred once whether you inspect one part or five.

Last reviewed 2026-05-12.