How do you calculate first article inspection time?

Divide the number of characteristics by the verification rate, then apply the allowance. For 60 characteristics at 3 per minute the base is 20 minutes, and a 20 percent allowance yields 24 minutes.

What is a good verification rate for FAI?

It varies widely. Simple caliper and mic dimensions run 3 to 5 per minute, but GD&T features requiring a CMM routine or optical comparator can drop below 1 per minute, so blend the rate to your actual balloon mix.

Why is FAI measured by characteristics instead of parts?

Because FAI verifies one part exhaustively against every drawing callout. The workload scales with the number of ballooned characteristics, not the lot size, which is the opposite of routine production inspection.

What allowance should I use for first article fixturing?

Twenty to 40 percent is common because FAI often needs custom fixturing, program setup, and detailed AS9102 form entry. Our example uses 20 percent, appropriate for a moderately complex part with existing fixtures.

Does FAI time include filling out the AS9102 forms?

The allowance should absorb form population, ballooning reconciliation, and record-keeping. If your shop treats documentation as a separate task, raise the allowance or add that time explicitly.

How can I shorten first article inspection time?

Standardize fixtures, pre-write CMM programs from the CAD model, and use automated ballooning software to cut manual transcription. Reducing the allowance from documentation drag often saves more than speeding the measurement itself.

Quality & Metrology calculator

First Article Inspection Time Calculator

First article inspection (FAI) time is the minutes needed to verify every characteristic on a new or changed part against the drawing and balloon report before a production run is released. Quality engineers in aerospace and other AS9102-driven shops use it to schedule the launch gate and to price the up-front verification into a job. Unlike routine in-process inspection, FAI is characteristic-driven rather than part-driven: you measure dozens of dimensions on one piece, so the count of balloons and the fixturing burden dominate the estimate. Underestimating it stalls a production release while the part sits waiting for a full dimensional layout.

What this calculator does

Estimate first article inspection time from the number of characteristics to verify, the verification rate, and a setup allowance.
Use it when scheduling a first article inspection and you need to reserve realistic time on the CMM or bench.
It computes required first article inspection time by dividing the characteristic count by the per-feature verification rate and inflating it with a setup and fixturing allowance.

Formula used

Base first article inspection time = characteristics to verify ÷ verification rate
Required first article inspection time = base time × allowance factor

Inputs explained

Characteristics to verify:
Verification rate per feature:
Setup and fixturing allowance:

How to use the result

Use it when planning an AS9102 or PPAP launch, scheduling the metrology lab for a new part, or quoting the one-time verification cost of a program.
A single verification rate averages fast linear dimensions with slow GD&T and CMM callouts, so a part heavy in true-position or profile tolerances will run longer than the flat rate implies.

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 time? Divide the number of characteristics by the verification rate, then apply the allowance. For 60 characteristics at 3 per minute the base is 20 minutes, and a 20 percent allowance yields 24 minutes.
What is a good verification rate for FAI? It varies widely. Simple caliper and mic dimensions run 3 to 5 per minute, but GD&T features requiring a CMM routine or optical comparator can drop below 1 per minute, so blend the rate to your actual balloon mix.
Why is FAI measured by characteristics instead of parts? Because FAI verifies one part exhaustively against every drawing callout. The workload scales with the number of ballooned characteristics, not the lot size, which is the opposite of routine production inspection.
What allowance should I use for first article fixturing? Twenty to 40 percent is common because FAI often needs custom fixturing, program setup, and detailed AS9102 form entry. Our example uses 20 percent, appropriate for a moderately complex part with existing fixtures.
Does FAI time include filling out the AS9102 forms? The allowance should absorb form population, ballooning reconciliation, and record-keeping. If your shop treats documentation as a separate task, raise the allowance or add that time explicitly.

Last reviewed 2026-05-12.