First Article Inspection Re-validation

Remote Outsourced FAI Solution Resolved Backlog of Supplier Revalidations

First Article Inspection Re-validation

The Challenge

Our aircraft engine OEM customer was faced with a backlog of more than 1,800 supplier First Article Inspection Report (FAIR) re-validations, with no capacity to support the process within their current organizational structure. As well as recovering this backlog, regular production throughput needed to be maintained.

The customer was further challenged with the lack of suitable interim facilities to perform this activity. The facilities has to be secured and network infrastructure and information assurance protocols complied with all national security and ITAR data flow-down requirements.

The Solution

  • A Verify FAI expert assessed current state and prepared a recovery plan including rapid set-up facilities.
  • Verify established an outsourced FAI validation facility within 30-days, staffed with dedicated Verify FAI engineers.
  • A secure UK based network infrastructure was utilized to store FAl packages and communicate with suppliers.
  • Real-time access to FAI validation status and results via secure custom built solution was provided.
  • A standardized work flow, including a managed supplier re-work loop, was developed and implemented.
  • Verify FAI experts visited problematic suppliers for assessment, consulting and training.

The Results

  • Outperformed recovery target by 25% whilst maintaining allocated budget
  • The Verify FAI validation process was twice as efficient as prior customer team – resulting in long term agreement on solution
  • Improved supplier RTF from 10% to 40%, with ongoing supplier visits to continue this trend

We were delighted with the outsourced facility and FAI team that Verify established. The responsiveness and accuracy of FAI validation process has been impressive ~ Aircraft Engine OEM Customer