Verify before scale. Document fully. AS9102 / PPAP.

AS9102 Rev C content: (1) Form 1 — part identification (number, name, revision, supplier). (2) Form 2 — product accountability (drawing notes, special characteristics, materials). (3) Form 3 — characteristic accountability (every feature with nominal, tolerance, actual). Plus attached: material certifications, special process certs, dimensional inspection records, photos. Typical AS9102 package: 10-40 pages depending on part complexity.

PPAP Level 1: warrant only. Rare for new programs. Level 2: warrant + samples + limited docs. Level 3: most common — warrant + samples + complete documentation package. Level 4: as Level 3 plus customer-specific requirements. Level 5: as Level 4 plus parts and complete supporting data retained at supplier. Customer specifies — typically Level 3 for production launch.

For typical FAI, CMM repeatability ±0.002 mm adequate. Calibration traceable to NIST. Specific high-precision applications (aerospace, semiconductor) may require ±0.001 mm — partner with calibration labs for ultra-precision measurements. Most production CMM work meets standard accuracy requirements with documented calibration.

Simple part FAI (10-20 features): 1-2 days for measurement + 2-3 days documentation. Complex part FAI (50+ features with extensive GD&T): 5-10 days total. Aerospace AS9102 with full documentation: 7-14 days typical. Plan FAI timing into project schedule — production gate typically requires customer FAI approval.

Drawing revision triggers re-inspection — features changed by revision require new measurement. Some customers require complete FAI on every revision; others only on significant changes. Specify customer policy upfront. We track revision changes and re-inspect appropriately.

AS9102 records retained 10+ years per FAR. Aerospace customers often require 25+ year retention. Medical: full product life + 2 years per FDA. Automotive: 15 years per IATF 16949. Our standard archive policy: 10+ years for all quality-controlled orders, longer per customer requirement.