9102 Understanding FAI

Course Description

AS9102-compliant FAI is the structured, disciplined verification that the product realization process is capable of producing conforming aerospace hardware—before risk becomes escape, delay, or cost. For organizations operating in the aerospace industry, FAI is one of the clearest demonstrations of operational integrity, customer confidence, and technical competence.

This 8-hour AS9102 Fundamentals course is designed for early-career quality professionals, manufacturing engineers, inspectors, and program team members who have working exposure to aerospace requirements but need clarity on what FAI truly is, how it is structured, and what it is intended to accomplish.

Through the Plexus Learning Model— which is interactive, workshop-based, and application-driven; participants do not simply review the standard but explore the intent.

They work through the structure of Forms 1, 2, and 3, trace requirements from drawing to verification, identify common breakdowns in ballooning and characteristic accountability, and understand how FAI connects to risk reduction, configuration control, and process validation. The focus goes beyond compliance language to intent.

• Why does AS9102 exist?
• What problem is it trying to prevent?
• How does a well-executed FAI protect schedule, margin, and reputation?

Participants leave with the ability to confidently contribute to or lead an FAI effort that is accurate, complete, and value-driven—not reactive. This course reflects Plexus International’s mission to move beyond the letter of the standard and emphasize improved performance through practical application . The result is not just understanding the forms—but developing competency in executing FAI correctly within the aerospace supply chain

Course Details

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Learning Objectives

By the end of this course, participants will be able to:

• Explain the intent and purpose of AS9102 and its role within the AS9100 quality management system
• Define when a full, partial, or re-accomplishment FAI is required
• Describe the structure and function of AS9102 Forms 1, 2, and 3
• Accurately interpret drawing requirements and flow them into accountable characteristics
• Apply proper ballooning techniques aligned with aerospace expectations
• Identify objective evidence required for design characteristics, material, special processes, and functional testing
• Recognize common FAI failures and implement best practices to prevent escapes
• Connect FAI to risk mitigation, process validation, configuration control, and customer satisfaction
• Confidently participate in or support an FAI review process within their organization

Who Should Attend

This course is ideal for:

• Entry-level to early-career Quality Engineers
• Manufacturing Engineers supporting aerospace programs
• Inspectors and Quality Technicians performing FAI documentation
• Program Managers needing a structured understanding of FAI risk
• Supplier Quality Representatives
• Individuals transitioning into aerospace quality roles

It is particularly valuable for organizations onboarding new aerospace team members who must quickly understand how compliance, risk reduction, and customer confidence interact within the FAI process.

Agenda

AM

• The Intent of AS9102 – Why FAI Exists
• When is an FAI Required?
• Understanding the Structure of AS9102 Forms
• Drawing Review and Characteristic Accountability

PM

• Verification Evidence and Objective Proof
• Common FAI Pitfalls and Best Practices
• FAI as a Value-Added Process
• Competency Demonstration