First Article Inspection Report Excel | FAI Form with Auto Pass Warning Fail | 30 Characteristics + FAI Log | PPAP Element 9 | iatf apqp

A first article inspection proves a new part — or a changed one — actually meets the print before you release it to production. This form runs the whole thing: type each measurement against its tolerance and the Result decides itself — Pass, Warning, Fail or Manual — then rolls all thirty characteristics up to one overall verdict.

It judges itself

Enter a measurement against the USL and LSL and the Result column returns:

PASS — inside tolerance and clear of the edges
WARNING — in spec, but within 10% of a limit (the ones that drift next)
FAIL — outside the USL or LSL; the part is rejected
MANUAL — no limits given (visual / attribute characteristics) — you make the call

The overall banner then rolls every row up to a single PASS / WARNING / FAIL / PENDING status. No manual tolerance arithmetic, no missed out-of-spec dimension.

Three sections, one controlled form
Section A — Part & Submission: part number, description, drawing rev, customer, FAI number and reason, lot/serial, quantity
Section B — Material & Process: material spec and cert, heat/lot traceability, special-process certs, equipment, calibration dates, tooling and setup approval
Section C — Dimensional & Attribute Results: 30 characteristic rows — zone, description, nominal, USL, LSL, gage, actual, auto result, notes
What's inside (6 tabs)
FAI Form — the 30-characteristic report with auto pass/warning/fail
FAI Log — a running register of every submission with live pass / warning / fail / pending tallies and pass rate
Settings — company block, automatic FAI numbering (FAI-2026-001…), dropdown lists, and the 10% warning margin
FAI Example — a completed hydraulic manifold-block FAI (seven characteristics, one warning, one fail)
Worked Example — the story behind that example, plus how FAI connects to PPAP and deviations
Instructions — how to run an FAI and the related tools in the library
Details
Microsoft Excel (.xlsx) — no macros, no plugins
Works with Excel 2016, 2019, 2021 and Microsoft 365
FAI is one of the 18 PPAP elements — pairs with the PPAP Submission Checklist (QA-F-225)
Instant digital download

Built by a quality practitioner for quality practitioners — quality engineers, APQP and launch teams, SQEs, machine shops, and IATF 16949 / PPAP suppliers.