How to Quote Inspection and FAI Jobs

Quality requirements show up on RFQs in many forms: a simple dimensional check, a full First Article Inspection (FAI) to AS9102, or an in-process CMM schedule for a production run. Most shops treat these as afterthoughts — adding a flat $200 line item and hoping it covers the actual work. That approach leaves money on the table and, worse, creates friction when the customer expects a 20-page ballooned drawing report you never budgeted for.

Break Inspection Into Billable Steps

Inspection isn’t a single task. It’s a sequence of setup, measurement, analysis, and documentation. Each step consumes machine time, software licenses, and skilled labor. Quote them separately:

• Programming time: Offline CMM programming (PC-DMIS, Calypso, Modus) or on-machine teach time. Count hours, not a lump sum.
• Fixture and staging: Custom holding, alignment pins, or magnetic bases. Include design and 3D print or machine time.
• Machine run time: Probe changes, pallet swaps, and actual touch time. Use your CMM hourly rate (machine depreciation + maintenance + operator).
• Data analysis and reporting: GD&T evaluation, statistical process control charts, ballooned drawings, AS9102 forms, PPAP packages.
• Review and sign-off: Internal quality engineer review plus customer portal upload or email coordination.

Clarify the Sampling Plan Up Front

FAI doesn’t always mean 100% inspection. AS9102 allows sampling per AS9145 or customer-specific requirements. Ask the customer (or their quality clause) for:

• Number of parts to measure (1, 3, 5, or a statistical sample)
• Which characteristics are key characteristics (KC) vs. non-key
• Whether in-process checks count toward FAI or if a separate final FAI is required
• Attribute vs. variable data requirements

Each answer changes your quote. A single-part FAI on a 50-dimension bracket is a different job than a 5-part sample with 200 dimensions each.

Account for Software and Traceability Overhead

Modern inspection workflows rely on software that isn’t free. If you use:

• Model-based definition (MBD) viewers or GD&T evaluation add-ons
• Automated reporting tools (e.g., InspectionXpert, Quality Window, or homegrown macros)
• Traceability systems linking serial numbers to CMM results

Include a per-report or per-project software surcharge. It’s legitimate — you’re paying for licenses, maintenance, and the operator’s expertise in using them.

Build In Revision Risk

FAI failures happen. When the first article shows a GD&T violation, you’ll rework, re-measure, and rewrite the report. Quote a re-measure allowance — typically 15–25% of the initial inspection cost — as a separate line item with a note: “Additional measurement cycles if disposition requires rework.” This protects margin and sets expectations.

Separate Inspection From Production in Your Quote

Don’t bury inspection inside the part price. Show it as a distinct line:

• Part production: $X
• FAI / Inspection per AS9102 Rev C: $Y (details attached)
• Re-measure allowance (if needed): $Z

Customers who understand quality will appreciate the transparency. Those who push back give you a chance to explain value — or to walk away from a job that would erode margin.

Use a Template Library for Common Standards

If you regularly quote to AS9102, PPAP (AIAG), ISO 9001, or customer-specific forms (Boeing D6-51991, Lockheed Martin QCS-001), build a template library in your quoting system. Each template captures:

• Required form sections and page counts
• Typical programming hours per feature type (hole pattern, profile, true position)
• Standard fixture assumptions
• Default re-measure percentage

When an RFQ arrives, you select the template, adjust part-specific variables, and produce a consistent, defensible quote in minutes.

Conclusion

Inspection and FAI work is high-value, high-skill labor — not a courtesy add-on. Quoting it piece by piece protects your margin, reduces surprises, and signals professionalism to quality-focused customers. Solvi lets you build inspection templates, apply CMM rates, and attach sampling-plan assumptions directly in your quote engine — so every quality line item is documented, traceable, and profitable.