How is the share of tolerance used calculated?

For a characteristic with two limits it is the distance from the middle of the tolerance band divided by half the band. A 0.250 in dimension with plus or minus 0.005 measured at 0.2542 uses 84 percent of its tolerance; at 0.250 it uses 0 percent, and at a limit 100 percent. For an upper-limit-only characteristic such as position 0.05 mm or Ra 0.8 um, it is the reading divided by the limit.

Can I mix inch and metric drawings?

Yes. Every characteristic row has its own unit, and its nominal, tolerances and reading are compared in that unit; nothing is converted, so inch and millimetre parts sit in the same log. If you need a conversion, 1 in is exactly 25.4 mm, but convert the drawing requirement and the reading together.

How do I record a partial FAI after a failure?

Add a new FAI row with type Partial and reason Corrective action, and list only the characteristics you re-inspect. The original FAI keeps its FAIL as the record. In the example, F26-032 failed on bore position and the partial FAI F26-036 re-inspected three characteristics and passed.

How is the inspection time estimated?

Characteristics x minutes per characteristic + setup and fixturing + planning and reporting, all set on Setup: the same formula as the First Article Inspection Time calculator. A 16-characteristic FAI at 3 minutes each with 36 minutes of setup and 45 of reporting needs 129 minutes; with the calculator's example of 60 characteristics it is 261 minutes.

Does this replace the AS9102 form?

No. The workbook is your characteristic accountability and results record. AS9102 and many customers require their own forms, which are not reproduced here; transfer the balloon numbers, requirements, results and gauge IDs onto the form your customer specifies.

Quality Systems and Compliance

First Article Inspection Tracker Excel Template

Record every first article and each ballooned characteristic with its nominal, tolerances and reading, and see which FAIs are open or overdue, which failed, and which characteristics sit close to a limit.

Overview

This first article inspection tracker is a working Excel workbook for quality engineers and inspectors at machine shops, aerospace and medical device suppliers. It ships with example data for a fictional machine shop with eleven first articles for three customers, 93 ballooned characteristics in inches and millimetres, two failed FAIs and their partial re-inspections, so the register, results and dashboard are populated the moment you open it.

Each characteristic carries its own unit, nominal and signed tolerances, so a 0.3125 in bore with +0.0010/-0.0000 and a 20 mm H7 bore sit side by side without any conversion. The workbook works out the limits, the deviation and the share of the tolerance used (0 percent in the middle of the band, 100 percent at a limit), and calls each reading PASS or FAIL; attributes such as threads, notes and certificates are recorded as Conforms or Does not conform. Each FAI counts its own characteristics: it fails if any characteristic fails, is in progress while any is unmeasured, and passes when all are measured and conform. AS9102 and customer FAI forms are not reproduced; the workbook is the record you transfer onto them.

In practice, add the FAI to the register when the job is released, balloon the drawing into the results sheet, and record readings as you measure. The Dashboard shows which FAIs are overdue, how much measuring is left and the inspection hours it needs; the near-limit count tells the process engineer which features pass today but leave little margin for production.

What this template includes

FAI Register table: FAI number, part number, revision, part name, customer, reason, full or partial FAI, inspector, planned and completed dates
Characteristic Results table with one row per ballooned characteristic: number, description, category, its own unit (mm, in, deg, Ra), nominal, signed tolerances, measured value or attribute result, and gauge
Per characteristic: lower and upper limits, deviation, share of tolerance used, PASS/FAIL and a near-limit flag for conforming readings past a share you set
Per FAI: characteristic count, measured, nonconforming, measured share, overall result (PASS, FAIL, In progress), due status in words and an estimate of inspection time
Check columns that name problems in words: duplicate balloon numbers, a reading without a nominal, a missing upper tolerance or gauge, an FAI completed with unmeasured characteristics
Dashboard with KPI tiles for open and overdue FAIs, measured share, completed FAIs that passed against your target, nonconforming and near-limit characteristics and the inspection hours open FAIs need
Two native charts: characteristic results by FAI and findings by characteristic category, plus by-FAI and by-category summary tables
Method sheet with every formula, and a Verify sheet that re-checks the formulas against an independent reference (Self-check: PASS)

Suggested use case

Use it to run first article inspections for new parts, design changes, process or source changes and production lapses; to keep characteristic accountability before you fill in your customer's FAI form; and to see which features run close to their limits before production starts.

How to use it

On Setup, set the status date, the due-soon window, the near-limit share, your pass target and your time standards, then replace the example customers, reasons, categories and inspectors.
On FAI Register, add one row per first article with the part, revision, customer, reason, full or partial, inspector and planned date.
On Characteristic Results, add one row per balloon on the drawing with its unit, nominal and signed tolerances; type each reading (or the attribute result) and the gauge as you measure.
Type the completed date on the register when the FAI is signed, and fix anything the Check columns flag.
Move the status date forward and review the Dashboard; transfer the results onto your customer's FAI form.

Frequently Asked Questions

How is the share of tolerance used calculated?: For a characteristic with two limits it is the distance from the middle of the tolerance band divided by half the band. A 0.250 in dimension with plus or minus 0.005 measured at 0.2542 uses 84 percent of its tolerance; at 0.250 it uses 0 percent, and at a limit 100 percent. For an upper-limit-only characteristic such as position 0.05 mm or Ra 0.8 um, it is the reading divided by the limit.
Can I mix inch and metric drawings?: Yes. Every characteristic row has its own unit, and its nominal, tolerances and reading are compared in that unit; nothing is converted, so inch and millimetre parts sit in the same log. If you need a conversion, 1 in is exactly 25.4 mm, but convert the drawing requirement and the reading together.
How do I record a partial FAI after a failure?: Add a new FAI row with type Partial and reason Corrective action, and list only the characteristics you re-inspect. The original FAI keeps its FAIL as the record. In the example, F26-032 failed on bore position and the partial FAI F26-036 re-inspected three characteristics and passed.
How is the inspection time estimated?: Characteristics x minutes per characteristic + setup and fixturing + planning and reporting, all set on Setup: the same formula as the First Article Inspection Time calculator. A 16-characteristic FAI at 3 minutes each with 36 minutes of setup and 45 of reporting needs 129 minutes; with the calculator's example of 60 characteristics it is 261 minutes.
Does this replace the AS9102 form?: No. The workbook is your characteristic accountability and results record. AS9102 and many customers require their own forms, which are not reproduced here; transfer the balloon numbers, requirements, results and gauge IDs onto the form your customer specifies.