How Manufacturers Can Eliminate FAI Errors, With or Without a CMM

If you’ve ever filled out a First Article Inspection (FAI) report by hand, you know how tedious the process can be. Between ballooning a drawing, taking hundreds of measurements, and manually typing those values into an AS9102 form, it’s easy to lose hours or even days just getting through one part.

And yet, despite the time investment, most quality teams still find themselves redoing reports because of simple errors: a missed decimal, a wrong tolerance, or a mismatched dimension label.

At GroundControl, we built our software to eliminate exactly those problems. Our platform automates the FAI process, from extracting features on a drawing to validating the entered data against its nominal, upper, and lower limits. Instead of juggling spreadsheets, engineers can generate error-free, AS9102-compliant reports in a fraction of the time.

What Happens After the Measurements Are Taken

For manufacturers with coordinate measuring machines (CMMs), importing data into GroundControl is seamless. The CMM exports measurement results in a structured format, and GroundControl automatically matches those values to the right features in the FAI. That means no transcription, no copy-pasting, and no risk of rounding errors.

But not every shop floor is equipped with a CMM. Many manufacturers still rely on hand tools like calipers, micrometers, or height gages for dimensional inspection. That’s where the process usually slows down. Every number must be typed in manually.

Digitizing Manual Measurement with MicroRidge

To solve that gap, GroundControl works hand-in-hand with MicroRidge Systems, a company that’s been helping manufacturers collect measurement data digitally for over four decades.

MicroRidge’s MobileCollect Wireless and GageWay Wired interfaces connect directly to the tools you already use: calipers, micrometers, indicators, bore gages, and more. Instead of writing down or typing each reading, operators simply press a button on the gage, and the measurement is instantly transmitted to a computer or tablet.

When paired with GroundControl, those values populate directly into the corresponding FAI fields. You get the benefits of automation and accuracy, even on a manual bench.

From Shop Floor to Report, Without Errors

Here’s what the workflow looks like in practice:

1. Measure — Take readings with a CMM or hand/bench tools connected via MicroRidge.
2. Capture — Data is automatically streamed or imported into GroundControl.
3. Validate — GroundControl checks every measurement against its design limits.
4. Generate — The software builds a fully compliant AS9102 report in seconds.

By closing the loop between data capture and report generation, manufacturers can eliminate nearly all the friction in the FAI process. With validation at every step, the chance of submitting an incorrect report drops close to zero.

Why It Matters

FAIs aren’t just paperwork. They’re a vital handshake between suppliers and OEMs — a proof that every dimension meets spec before production ramps up. But the time spent on rework, manual entry, and data transfer slows down that handshake and increases costs on both sides.

With GroundControl and MicroRidge, the process finally catches up to modern manufacturing. Data flows straight from the tool to the report, ensuring accuracy, consistency, and traceability. It’s a small change that unlocks big gains in efficiency and confidence.

About GroundControl

GroundControl builds cloud-based quality software for aerospace and defense manufacturers. Its platform helps suppliers complete AS9102 First Article Inspection reports digitally — faster, cleaner, and without errors. gndctl.com

About MicroRidge

MicroRidge designs measurement collection systems that let manufacturers capture and transmit gage data instantly and accurately, eliminating manual entry and transcription errors. microridge.com