Quality & Metrology worked example

First Article Inspection Cost with first article parts to inspect of 1.5 parts: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop first article parts to inspect to 1.5 parts, then walk the calculation through step by step. Estimate the cost of a first article inspection from the parts to inspect, variable inspection cost, fixed program cost, and labor and overhead.

The inputs for this scenario

  • First article parts to inspect: 1.5 parts (the input this scenario stresses; the baseline uses 3)
  • Variable inspection cost per part: 120 $ / part (held at the documented default)
  • Fixed program cost: 200 $ (held at the documented default)
  • Labor and overhead adder: 150 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total first article inspection cost = first article parts to inspect × variable inspection cost per part + fixed program cost + labor and overhead adder.
  • Total first article inspection cost works out to 530 $ at these inputs, and this is the headline figure for the scenario.
  • Cost per part works out to 353 $ / piece at these inputs.
  • Variable inspection cost works out to 180 $ at these inputs.
  • Fixed program and overhead cost works out to 350 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where first article parts to inspect sits at 3 parts and the headline result is 710 $, this scenario comes in 25.35% below the baseline at 530 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to first article parts to inspect, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. 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.

Results at a glance

  • Total first article inspection cost: 530 $ (headline result)
  • Cost per part: 353 $ / piece
  • Variable inspection cost: 180 $
  • Fixed program and overhead cost: 350 $

Run it with your numbers

  • To rerun this with your own numbers, open the live First Article Inspection Cost calculator, set first article parts to inspect to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.