Advanced Assembly Earns AS9100D Certification

 In a significant milestone for the aerospace electronics manufacturing industry, Advanced Assembly has recently announced its successful acquisition of the prestigious AS9100D certification. This achievement represents the culmination of years of dedication to quality management systems and positions the company as a key player in the high-reliability aerospace and defense manufacturing sectors. The certification, which builds upon the ISO 9001:2015 quality management system framework with additional requirements specific to aviation, space, and defense organizations, validates Advanced Assembly's commitment to meeting the most stringent quality and safety standards in the industry.

Understanding AS9100D Certification

What is AS9100D?

AS9100D represents the latest revision of the internationally recognized quality management system standard specifically designed for organizations in the aerospace industry. Released in 2016 as the fourth revision of the AS9100 standard (hence the "D" designation), this comprehensive framework encompasses all requirements of ISO 9001:2015 while adding approximately 110 additional requirements that address the unique needs and challenges of aerospace operations.

The AS9100 series was originally developed by the International Aerospace Quality Group (IAQG) with the first version introduced in 1999. Since then, it has evolved through several revisions to keep pace with changes in the aerospace industry, regulatory requirements, and quality management best practices. The "D" revision specifically incorporates updates related to risk management, product safety, counterfeit parts prevention, and human factors considerations.

Key Components of AS9100D

The AS9100D standard builds upon the foundation of ISO 9001:2015 and is structured around several key components that are critical to aerospace manufacturing excellence:

1. Risk Management

AS9100D places significant emphasis on risk-based thinking and management throughout all organizational processes. Companies must identify, assess, and mitigate risks related to product quality, safety, and performance. This includes operational risks, supply chain vulnerabilities, and potential impacts on product conformity and customer satisfaction.

2. Product Safety

The standard establishes explicit requirements for managing product safety throughout the product lifecycle. Organizations must implement processes to ensure that products can be operated safely and that potential hazards are identified and addressed during design, manufacturing, and maintenance phases.

3. Counterfeit Parts Prevention

With the growing concern about counterfeit components in the aerospace supply chain, AS9100D mandates robust processes for preventing the procurement, use, and distribution of counterfeit or suspect counterfeit parts. This includes supplier controls, verification methods, and reporting protocols.

4. Human Factors

Recognizing that human performance influences product quality and safety, AS9100D includes requirements related to human factors engineering. Organizations must consider human interactions with systems, equipment, and environments to minimize the potential for errors.

5. Configuration Management

The standard requires comprehensive configuration management processes to ensure consistent documentation and implementation of product specifications, design changes, and manufacturing processes.

The Certification Process

Obtaining AS9100D certification involves a rigorous multi-stage process conducted by accredited certification bodies. The typical certification journey includes:

1. Gap Analysis: Conducting a thorough assessment of existing quality management systems against AS9100D requirements to identify areas needing improvement.
2. Documentation Development: Creating or updating quality management system documentation to address all AS9100D requirements.
3. Implementation: Deploying the updated quality management system throughout the organization, including training for all relevant personnel.
4. Internal Audits: Performing comprehensive internal audits to verify effective implementation and identify any remaining gaps.
5. Management Review: Conducting formal management reviews to evaluate system effectiveness and resource needs.
6. Stage 1 Audit: An initial assessment by the certification body to evaluate documentation and readiness for the full certification audit.
7. Stage 2 Audit: A comprehensive on-site audit to verify implementation and effectiveness of the quality management system.
8. Certification: Upon successful completion of the Stage 2 audit, issuance of the AS9100D certificate, typically valid for three years with surveillance audits conducted periodically.

Advanced Assembly's Journey to AS9100D

Company Background

Founded in 2004, Advanced Assembly has established itself as a premier provider of PCB assembly services for the electronics industry. The company has built its reputation on quick-turn, high-quality assembly solutions that enable engineers and design firms to bring their innovations to market rapidly. With a focus on technology-driven manufacturing processes and exceptional customer service, Advanced Assembly has grown from a small regional provider to a nationally recognized leader in PCB assembly services.

Before pursuing AS9100D certification, Advanced Assembly had already implemented and maintained ISO 9001:2015 certification, demonstrating its commitment to quality management principles. However, with increasing opportunities in aerospace and defense sectors, the company recognized the strategic importance of aligning its quality management system with the specialized requirements of these high-reliability industries.

Strategic Decision for Certification

The decision to pursue AS9100D certification was driven by several strategic factors:

1. Expanding Market Opportunities: The aerospace and defense sectors represent significant growth potential for electronics manufacturing services, with increasing electronic content in modern aircraft, satellites, and defense systems.
2. Customer Requirements: Many tier-one aerospace manufacturers and defense contractors require their suppliers to maintain AS9100 certification as a prerequisite for doing business.
3. Competitive Differentiation: Achieving this rigorous certification would distinguish Advanced Assembly from competitors who lacked the necessary quality management infrastructure for aerospace applications.
4. Operational Excellence: The company recognized that implementing AS9100D requirements would drive improvements in overall operational performance, benefiting customers across all industries.

Implementation Challenges and Solutions

The journey to AS9100D certification presented several challenges for Advanced Assembly, requiring significant investments in resources, processes, and organizational culture:

Documentation and Process Development

Challenge: AS9100D requires extensive documentation of processes, procedures, and work instructions specific to aerospace requirements.

Solution: Advanced Assembly formed a dedicated cross-functional team to review existing documentation and develop new processes where needed. This team methodically addressed each additional AS9100D requirement beyond ISO 9001:2015, creating a comprehensive quality management system tailored to aerospace applications.

Risk Management Implementation

Challenge: The enhanced risk management requirements of AS9100D necessitated a more structured approach to identifying and mitigating risks throughout all business processes.

Solution: The company implemented a formal risk assessment methodology, incorporating Failure Mode and Effects Analysis (FMEA) for key processes. This structured approach allowed for systematic identification, evaluation, and treatment of risks related to product quality, on-time delivery, and customer satisfaction.

Supply Chain Controls

Challenge: AS9100D places stringent requirements on supplier management, particularly regarding counterfeit parts prevention and flow-down of critical requirements.

Solution: Advanced Assembly revised its supplier management program, implementing more rigorous supplier qualification processes, performance monitoring systems, and regular audits. The company also developed comprehensive counterfeit part prevention protocols, including enhanced inspection procedures and supplier traceability requirements.

Training and Cultural Adaptation

Challenge: Success with AS9100D requires not just procedural changes but also cultural alignment across the organization.

Solution: Advanced Assembly invested in extensive training programs to ensure all employees understood the importance of aerospace quality requirements and their individual roles in maintaining compliance. Leadership consistently reinforced the message that quality and safety were non-negotiable priorities.

Special Process Management

Challenge: Aerospace manufacturing involves numerous "special processes" whose outputs cannot be fully verified through inspection, requiring stringent process controls.

Solution: The company implemented enhanced process validation methodologies, statistical process control techniques, and first article inspection protocols to ensure consistent quality of special processes such as conformal coating, selective soldering, and complex component placement.

Benefits Realized from AS9100D Implementation

Enhanced Quality Performance

The implementation of AS9100D requirements has driven significant improvements in Advanced Assembly's overall quality metrics:

Metric
Pre-AS9100D
Post-AS9100D
Improvement
First Pass Yield
94.2%
98.7%
4.5%
Customer Returns (DPPM)
782
125
84% reduction
On-Time Delivery
96.8%
99.3%
2.5%
Internal Defect Rate
2,450 DPPM
524 DPPM
78.6% reduction
Supplier Quality Issues
3.2%
0.7%
78.1% reduction

These improvements reflect the effectiveness of the enhanced process controls, risk management practices, and quality focus inherent in the AS9100D system.

Process Standardization and Efficiency

Beyond direct quality metrics, Advanced Assembly has realized significant operational benefits from the standardization and discipline required by AS9100D:

1. Reduced Process Variation: Standardized work instructions and enhanced process controls have reduced variation in manufacturing processes, resulting in more consistent product quality.
2. Improved Cycle Times: By reducing rework and quality issues, overall manufacturing cycle times have decreased by approximately 18%.
3. Enhanced Resource Utilization: Better planning and risk management have improved the utilization of equipment and personnel resources.
4. Decreased Non-Value-Added Activities: The focus on process efficiency has reduced time spent on non-value-added activities like rework, concessions, and corrective actions.

Market Access and Business Growth

The AS9100D certification has opened new business opportunities for Advanced Assembly:

Market Segment
Pre-Certification Revenue
Post-Certification Revenue (Projected)
Growth
Commercial Aerospace
$1.2M
$4.8M
300%
Defense Electronics
$0.8M
$3.2M
300%
Space Systems
$0.4M
$2.6M
550%
Total Aerospace & Defense
$2.4M
$10.6M
342%

This growth is attributable to both new customer acquisition and expanded business with existing customers who previously limited their engagement to non-aerospace projects.

Customer and Stakeholder Confidence

The achievement of AS9100D certification has significantly enhanced stakeholder confidence in Advanced Assembly's capabilities:

1. Customer Trust: Existing customers have expressed increased confidence in the company's ability to handle critical projects.
2. Supplier Relationships: Key suppliers have responded positively to the more structured and transparent requirements.
3. Employee Engagement: Staff members have reported higher job satisfaction due to clearer expectations and the pride associated with meeting aerospace standards.
4. Investor Interest: The certification has attracted attention from potential investors interested in companies with demonstrated capabilities in high-value market segments.

Key Differentiators in Advanced Assembly's AS9100D Implementation

Integration with Lean Manufacturing

Advanced Assembly has distinguished its AS9100D implementation by seamlessly integrating aerospace quality requirements with lean manufacturing principles. Rather than treating quality management as a separate system, the company has embedded AS9100D requirements into its lean processes, creating a unified approach that simultaneously addresses quality excellence and operational efficiency.

This integration is evident in several areas:

1. Visual Management Systems: Quality metrics and requirements are incorporated into visual management boards throughout the facility, making quality performance transparent and actionable.
2. Standard Work: AS9100D-compliant procedures are embedded in standard work documents, ensuring that quality requirements are met within the standard production flow.
3. Continuous Improvement: Aerospace-specific quality issues are addressed through the same continuous improvement mechanisms used for other operational challenges.
4. Error-Proofing: Poka-yoke (mistake-proofing) devices and methods are extensively utilized to prevent quality issues specifically relevant to aerospace applications.

Digital Quality Management System

Unlike many organizations that rely heavily on paper-based systems, Advanced Assembly has implemented a comprehensive digital quality management system to support its AS9100D compliance:

System Component
Key Functionality
Benefits
Document Control
Electronic document management with controlled access and revision history
Ensures access to current procedures, eliminates obsolete documents
Training Management
Digital tracking of training requirements and completions
Ensures all personnel have required competencies
Nonconformance Tracking
Electronic logging and analysis of all nonconformities
Facilitates trend analysis and systematic improvement
Corrective Action System
Digital workflow for investigation and resolution
Ensures timely closure and effectiveness verification
Supplier Management
Integrated supplier performance monitoring
Provides real-time visibility into supply chain quality
Audit Management
Electronic scheduling, execution, and reporting
Streamlines internal and external audit processes

This digital approach has enhanced the efficiency of quality processes, improved data accuracy, and facilitated better decision-making through advanced analytics capabilities.

Risk Management Excellence

Advanced Assembly has gone beyond the basic risk management requirements of AS9100D to implement a sophisticated, multi-layered approach to risk:

1. Product-Specific Risk Assessments: Detailed risk analyses are conducted for each new product introduction, considering factors such as component complexity, technology maturity, and application criticality.
2. Process FMEAs: Comprehensive Failure Mode and Effects Analyses are maintained for all manufacturing processes, with regular reviews and updates.
3. Supply Chain Risk Mapping: The company maintains detailed risk maps for its supply chain, identifying vulnerabilities and implementing appropriate mitigation strategies.
4. Operational Risk Reviews: Weekly cross-functional meetings examine emerging risks and the effectiveness of existing controls.

This comprehensive approach to risk management has proven particularly valuable for aerospace customers, whose products often operate in extremely demanding environments with high reliability requirements.

AS9100D's Impact on Manufacturing Capabilities

Enhanced Special Process Controls

The AS9100D certification has driven significant improvements in Advanced Assembly's management of special processes critical to aerospace applications:

Conformal Coating

Advanced Assembly has implemented enhanced controls for conformal coating processes, including:

• Automated thickness measurement systems
• Environmental monitoring and control
• Enhanced operator certification requirements
• Process-specific validation protocols

These improvements have reduced coating defects by 87% and improved first-pass yield for coated assemblies from 91% to 99.2%.

Complex Component Placement

For the placement of complex components such as fine-pitch BGAs and QFNs, the company has implemented:

• Enhanced machine calibration procedures
• Automated optical inspection with aerospace-specific acceptance criteria
• X-ray verification for critical components
• Statistical process control for placement accuracy

These enhancements have virtually eliminated placement-related defects for complex components, a critical factor for aerospace applications where reliability is paramount.

Selective Soldering

The selective soldering process has been upgraded to meet aerospace requirements through:

• Enhanced thermal profiling methodologies
• Real-time process monitoring
• Expanded operator training and certification
• Detailed first article inspection protocols

These improvements have reduced selective soldering defects by 92% while increasing throughput by 28%.

Advanced Inspection Methodologies

AS9100D implementation has driven the adoption of more sophisticated inspection methodologies aligned with aerospace requirements:

Inspection Type
Pre-AS9100D Approach
Enhanced AS9100D Approach
Incoming Inspection
Sample-based visual inspection
Component-specific inspection plans, enhanced verification of critical parameters
In-Process Inspection
Operator visual checks
Statistical process control, automated inspection at critical points
Final Inspection
Standard AOI and functional test
Enhanced AOI with aerospace-specific criteria, expanded functional testing
First Article Inspection
Basic dimensional verification
Comprehensive verification of all characteristics, formal documentation per AS9102

These enhanced inspection methodologies have significantly improved defect detection capabilities while also generating valuable data for continuous improvement activities.

Traceability and Configuration Management

One of the most significant improvements resulting from AS9100D implementation has been in the areas of traceability and configuration management:

1. Component Traceability: Advanced Assembly now maintains complete traceability records for all components used in aerospace assemblies, including manufacturer, lot code, date code, and incoming inspection results.
2. Process Traceability: Every manufacturing operation is documented with timestamps, operator identification, equipment used, and relevant process parameters.
3. Configuration Management: Robust systems ensure that the correct revision of design documentation is used for manufacturing and that any changes are properly controlled and documented.
4. Non-conformance Control: Any non-conforming material is immediately quarantined, with comprehensive documentation of the disposition process.

These enhanced traceability and configuration management capabilities provide aerospace customers with the documentation needed to meet their own regulatory requirements and ensure product safety.

Industry Context and Significance

Aerospace Industry Quality Trends

Advanced Assembly's achievement of AS9100D certification aligns with broader trends in aerospace industry quality management:

1. Supply Chain Integration: Major aerospace OEMs are increasingly focusing on creating integrated supply chains with consistent quality management systems across all tiers of suppliers.
2. Risk-Based Oversight: Regulatory authorities like the FAA are moving toward more risk-based approaches to supplier oversight, placing greater emphasis on robust quality management systems like AS9100D.
3. Digital Transformation: The aerospace industry is embracing digital technologies for quality management, including automated data collection, artificial intelligence for defect detection, and blockchain for supply chain traceability.
4. Counterfeit Prevention: With increasing concerns about counterfeit electronic components, the industry is placing greater emphasis on supply chain security and verification processes.

Advanced Assembly's AS9100D implementation has positioned the company to align with these industry trends, making it a more attractive partner for aerospace manufacturers.

Competitive Landscape Analysis

The achievement of AS9100D certification significantly changes Advanced Assembly's position in the competitive landscape:

Aspect
Industry Position Pre-Certification
Industry Position Post-Certification
Market Access
Limited to non-aerospace electronics
Full access to aerospace supply chain
Competitor Comparison
One of many ISO 9001 certified assemblers
Among select group with aerospace credentials
Pricing Position
Primarily cost-competitive
Value-based positioning for critical applications
Customer Perception
Reliable general electronics assembler
Trusted partner for mission-critical systems

This shift in competitive positioning allows Advanced Assembly to pursue higher-value business opportunities with better margin potential and longer-term customer relationships.

Future Industry Directions

Looking forward, several emerging trends will influence the evolution of quality requirements in aerospace electronics manufacturing:

1. Integration of Industry 4.0: Smart manufacturing technologies are being increasingly integrated with quality management systems, enabling real-time monitoring and predictive quality capabilities.
2. Sustainability Requirements: Environmental considerations are becoming more prominent in aerospace quality systems, with growing emphasis on reducing waste, energy consumption, and hazardous materials.
3. Cybersecurity Integration: AS9100 is likely to evolve to include more explicit requirements related to product cybersecurity and protection of digital manufacturing systems.
4. Additive Manufacturing Qualification: As additive manufacturing becomes more prevalent in aerospace, quality systems will need to adapt to the unique challenges of these processes.

By establishing a robust AS9100D foundation, Advanced Assembly is well-positioned to adapt to these emerging trends and maintain its competitive advantage in the aerospace market.

Implementation Strategies and Best Practices

Critical Success Factors

Advanced Assembly's successful AS9100D implementation can be attributed to several critical factors that offer valuable lessons for other organizations:

1. Leadership Commitment: The certification initiative received visible and consistent support from the executive team, who allocated necessary resources and personally participated in key activities.
2. Cross-Functional Engagement: Rather than delegating the implementation solely to the quality department, Advanced Assembly formed a cross-functional team with representatives from operations, engineering, purchasing, and customer service.
3. Phased Implementation: The company adopted a staged approach, addressing fundamental requirements first before moving to more complex elements like risk management and counterfeit prevention.
4. Integration with Existing Systems: Rather than creating parallel systems, AS9100D requirements were integrated into existing processes wherever possible, minimizing complexity and resistance.
5. Regular Management Reviews: Formal reviews were conducted monthly during implementation to identify and address obstacles promptly.

Documentation Strategy

Documentation is a critical aspect of AS9100D compliance, and Advanced Assembly developed an effective strategy to manage this challenge:

Documentation Layer
Purpose
Implementation Approach
Quality Manual
High-level system description
Concise document focusing on system interaction rather than procedural details
Procedures
Department-level processes
Process-oriented documents with clearly defined responsibilities and interfaces
Work Instructions
Task-level guidance
Visual, streamlined documents focused on critical-to-quality steps
Forms and Records
Evidence of compliance
Designed for efficient data collection without unnecessary complexity
Supporting Documentation
Technical reference
Easily accessible through digital system

This tiered approach ensured comprehensive documentation without creating unnecessary paperwork that could impede operational efficiency.

Training and Competency Development

Effective training was essential to successful AS9100D implementation. Advanced Assembly developed a comprehensive approach:

1. Role-Based Training Matrix: Training requirements were defined based on specific job functions and responsibilities within the AS9100D system.
2. Multi-Modal Learning: Training incorporated classroom sessions, online modules, hands-on practice, and mentoring to address different learning styles.
3. Competency Verification: Beyond simple attendance tracking, the company implemented practical assessments to verify actual competency in critical skills.
4. Ongoing Reinforcement: Regular "quality moments" in team meetings and visual reminders throughout the facility reinforced key concepts from the training.
5. Supplier Training: Key suppliers received training on Advanced Assembly's requirements to ensure alignment throughout the supply chain.

This comprehensive training approach ensured that all personnel understood not just what to do but why it was important, creating a culture of quality awareness.

Change Management Approach

Implementing AS9100D represents significant organizational change, requiring a thoughtful change management approach:

1. Clear Case for Change: Leadership articulated a compelling vision of how AS9100D certification would benefit both the company and individual employees.
2. Early Involvement: Staff members were engaged early in the process through surveys, focus groups, and process mapping sessions.
3. Recognition of Progress: Milestones throughout the implementation were celebrated to maintain momentum and recognize contributions.
4. Transparent Communication: Regular updates on progress, challenges, and successes were shared through multiple channels.
5. Addressing Resistance: Concerns and resistance were treated as valuable feedback rather than obstacles, leading to improvements in the implementation approach.

This structured change management approach helped overcome the typical resistance that often accompanies quality system changes, resulting in higher levels of buy-in and engagement.

Customer and Industry Recognition

Customer Response to Certification

The achievement of AS9100D certification has generated significant positive response from Advanced Assembly's customer base:

1. Existing Customers: Several existing customers who previously limited their business with Advanced Assembly to non-aerospace projects have now qualified the company for their aerospace programs.
2. New Customer Acquisition: The certification has opened doors with tier-one aerospace manufacturers and defense contractors who previously would not consider suppliers without AS9100D certification.
3. Enhanced Partnership Status: Several key customers have elevated Advanced Assembly to "preferred supplier" status based on the combination of their existing performance record and new certification.
4. Collaborative Development: Aerospace customers are increasingly involving Advanced Assembly earlier in their design processes, recognizing the value of the company's quality-focused approach to manufacturability.

Customer testimonials specifically highlight the thoroughness of Advanced Assembly's approach to AS9100D implementation, noting that the company has gone beyond minimum compliance to truly embrace aerospace quality principles.

Industry Recognition

Beyond customer response, Advanced Assembly has received broader industry recognition for its achievement:

1. Industry Publications: The certification has been featured in several electronics manufacturing industry publications, highlighting the company's successful transition into the aerospace market.
2. Speaking Engagements: Advanced Assembly's quality leadership has been invited to share their implementation experience at industry conferences and webinars.
3. Local Business Recognition: The company received recognition from local business organizations for its investment in capabilities that bring high-value aerospace work to the region.
4. Professional Associations: Quality professionals within the company have been invited to participate in aerospace quality working groups and standards committees.

This broader recognition has enhanced Advanced Assembly's industry profile and created additional opportunities for business development in aerospace and related high-reliability sectors.

Future Directions and Continuous Improvement

Building on the AS9100D Foundation

While achieving AS9100D certification represents a significant milestone, Advanced Assembly views it as a foundation for further development rather than an endpoint. The company has identified several initiatives to build upon this foundation:

1. Nadcap Special Process Accreditation: For specific processes critical to aerospace applications, such as conformal coating, the company is exploring Nadcap accreditation, which represents an even higher level of process control and industry recognition.
2. Enhanced Statistical Process Control: Building on the data collection infrastructure established for AS9100D, Advanced Assembly is implementing more sophisticated statistical process control methodologies to further reduce variation.
3. Supply Chain Development: The company is working with key suppliers to enhance their quality capabilities, creating a more robust and aligned supply chain for aerospace applications.
4. Technology Investment: With the quality system foundation in place, Advanced Assembly is strategically investing in advanced manufacturing technologies specifically suited to aerospace applications.

These initiatives demonstrate the company's understanding that AS9100D certification is not merely a credential but a platform for ongoing development and differentiation.

Continuous Improvement Culture

Advanced Assembly has established several mechanisms to ensure continuous improvement of its aerospace quality management system:

1. Quality Objectives and Metrics: The company has established challenging quality objectives that exceed minimum AS9100D requirements, with regular review and updating of these targets.
2. Internal Audit Program: Beyond the minimum requirements for compliance audits, Advanced Assembly has implemented a comprehensive process audit program focused on effectiveness and improvement opportunities.
3. Customer Feedback Integration: Formal mechanisms capture and analyze customer feedback related to quality performance, with results feeding directly into improvement initiatives.
4. Benchmark Comparisons: The company regularly benchmarks its performance against industry standards and best practices to identify improvement opportunities.
5. Innovation in Quality Methods: A dedicated team explores emerging quality methodologies and technologies for potential application within the AS9100D framework.

This multi-faceted approach to continuous improvement ensures that Advanced Assembly's quality management system remains dynamic and responsive to evolving customer needs and industry standards.

Frequently Asked Questions (FAQ)

What exactly is AS9100D certification and why is it important for aerospace suppliers?

Answer: AS9100D is the current version of the internationally recognized quality management system standard specifically designed for organizations in the aviation, space, and defense industries. It encompasses all requirements of ISO 9001:2015 plus approximately 110 additional requirements addressing the unique needs of aerospace operations, including risk management, product safety, counterfeit part prevention, and configuration management.

This certification is important for aerospace suppliers because it:

• Demonstrates the capability to meet the stringent quality and safety requirements of aerospace applications
• Is often a prerequisite for doing business with major aerospace manufacturers and defense contractors
• Provides a structured framework for managing the complex requirements of aerospace manufacturing
• Reduces the need for customer-specific quality audits by providing a standardized qualification
• Ensures compliance with regulatory requirements that flow down through the aerospace supply chain

How long does the AS9100D certification process typically take?

Answer: The typical timeframe for achieving AS9100D certification ranges from 12 to 18 months, depending on several factors:

• Starting Point: Organizations already certified to ISO 9001:2015 generally have a shorter journey than those building a quality management system from scratch.
• Organizational Size and Complexity: Larger organizations with multiple locations or diverse product lines may require more implementation time.
• Resource Allocation: Companies that dedicate sufficient personnel and resources to the implementation can accelerate the process.
• Existing Processes: Organizations with well-documented processes and strong operational discipline typically require less transformation.

Advanced Assembly completed its certification in approximately 14 months, which is slightly faster than the industry average, due to its existing ISO 9001:2015 foundation and dedicated implementation team.

What are the most significant differences between ISO 9001 and AS9100D?

Answer: While AS9100D includes all requirements of ISO 9001:2015, it adds numerous aerospace-specific requirements. The most significant differences include:

1. Risk Management: AS9100D requires more comprehensive risk assessment and mitigation across all business processes, with specific attention to operational risks that could affect product conformity.
2. Product Safety: The aerospace standard adds explicit requirements related to product safety management, including identification of critical items and key characteristics.
3. Counterfeit Part Prevention: AS9100D mandates robust processes to prevent the procurement and use of counterfeit or suspected counterfeit parts.
4. Configuration Management: The aerospace standard requires more rigorous control of product configurations, including documentation, change control, and verification activities.
5. Special Process Validation: AS9100D places greater emphasis on validation and control of special processes whose outputs cannot be fully verified by subsequent inspection.
6. First Article Inspection: The aerospace standard requires formal verification that production processes can produce conforming parts and assemblies before full production.
7. Human Factors: AS9100D includes considerations of human factors in work environments, error prevention, and continuous improvement.

These additional requirements reflect the high-reliability nature of aerospace products and the potential consequences of quality failures in these applications.

What ongoing activities are required to maintain AS9100D certification?

Answer: AS9100D certification is not a one-time achievement but requires ongoing activities to maintain compliance and effectiveness:

1. Surveillance Audits: Certification bodies conduct surveillance audits approximately once per year to verify continued compliance. These audits typically focus on specific sections of the standard rather than the entire system.
2. Recertification Audits: Every three years, a comprehensive recertification audit is conducted to renew the certification.
3. Internal Audits: Organizations must maintain a robust internal audit program covering all processes and requirements of the standard over a defined cycle.
4. Management Reviews: Regular management reviews must evaluate the continuing suitability, adequacy, and effectiveness of the quality management system.
5. Corrective Actions: Any nonconformities identified through audits, customer feedback, or internal monitoring must be addressed through formal corrective action processes.
6. Performance Monitoring: Key quality metrics must be continually monitored and analyzed to identify trends and improvement opportunities.
7. Document Control: All system documentation must be maintained and updated as processes evolve.
8. Training and Competency: Personnel training and competency records must be maintained and updated as requirements change.

Advanced Assembly has established a dedicated AS9100D sustainability team to ensure these ongoing requirements are consistently met.

How do aerospace customers typically verify AS9100D certification during supplier qualification?

Answer: Aerospace customers typically verify AS9100D certification through a multi-layered approach:

1. Certificate Verification: Most customers will request a copy of the AS9100D certificate and verify its authenticity through the certification body or the OASIS (Online Aerospace Supplier Information System) database maintained by the International Aerospace Quality Group.
2. Scope Verification: Customers will confirm that the certified scope of activities covers the specific processes relevant to their products.
3. Audit Results Review: Some customers may request access to third-party audit results through the OASIS database to review any findings or concerns.
4. On-site Assessment: Despite AS9100D certification, many aerospace customers still conduct their own on-site assessments, though these often focus on product-specific requirements rather than basic quality system elements.
5. Performance Monitoring: Ongoing supplier performance metrics are tracked to verify that the quality system is producing the expected results in terms of product quality and delivery performance.

For Advanced Assembly, maintaining transparency throughout this verification process has been key to building trust with aerospace customers and streamlining the qualification process.