Context
FAI and sampling are not competing methods. They are different tools for different risk phases.
FAI versus sampling is a risk decision. Run full FAI at launch, then move to sampling once process stability is proven.
The Trap
The trap is skipping FAI on a new process or overusing FAI once the process is stable. Both increase risk or cost unnecessarily.
The Geppetto Take
We run FAI when the process is new or critical. Once stability is proven, we shift to sampling with defined control limits.
Evidence / Data
- FAI validates process capability at launch.
- Sampling maintains control with lower inspection load.
Control Actions
- Use FAI for new part, new supplier, or major revision.
- Define sampling rate based on risk tier.
- Escalate back to FAI if drift appears.
Checklist
- FAI scope defined for launch.
- Sampling plan tied to tolerance tiers.
- Drift triggers documented.
- Records stored for audit.
What to Send
Send inspection requirements, revision history, and risk tiering.
FAQ
When is FAI mandatory?
On new parts, new processes, or major revisions.
How do we choose sampling rates?
Based on risk, criticality, and process capability.
Can sampling replace FAI?
Not at launch. It only replaces FAI after stability is proven.
CTA
Send a screenshot for a chaos-check.