Template
AS9100 Audit Packet Template
AS9100D is the aerospace QMS standard built on ISO 9001:2015 with roughly 100 aerospace-specific additions, harmonized internationally as EN 9100:2018 and JISQ 9100:2016. Audits run through the IAQG's ICOP scheme (9101F audit process); auditors expect a pack that proves configuration control, traceability, risk, and special-process conformity for every delivered article.
Configuration Management (Clause 8.1.2)
Baseline definitions, change-control records, and effectivity tracking. Auditors sample recent ECOs and ECNs and trace them from requirement to drawing revision to work order to as-built record. Gaps between ERP BOM, drawing revision, and work-order effectivity are the single most common CB finding.
First Article Inspection per AS9102 Rev B
FAI reports using Forms 1 (part accountability), 2 (product accountability — materials, processes, functional tests), and 3 (characteristic accountability). A new or updated FAI is required for first production run, design change, two-year production lapse, process change, or source change. Partial FAIs are permitted with delta justification.
Counterfeit Parts Prevention (AS5553 / AS6174)
Required by AS9100D 8.1.4. The pack should include your approved supplier list with counterfeit-risk scoring, incoming inspection criteria, GIDEP participation records where applicable, and disposition records for any suspect or counterfeit parts.
Product Safety (8.1.3) and Foreign Object Prevention (8.1.4)
Documented product-safety process, hazard identification linked to design risk, FOD and FOE program with training records, work-area inspections, and tool accountability. Rev D added these and they are still common weak areas.
Operational Risk Management (Clause 8.1.1)
Distinct from the strategic risk in Clause 6.1 — this is project and operation-level. Evidence: a per-program risk register, mitigation actions, and explicit links to configuration changes and special-process qualifications.
Special Processes and NADCAP
AS9100D 8.5.1.2 requires qualification of processes where the output cannot be verified by subsequent inspection — heat treat, NDT, chem processing, welding, composites, coatings. Evidence: NADCAP accreditation certificates (AC7004 QMS plus commodity-specific ACs like AC7102 heat treat and AC7114 NDT), operator certifications, and process-parameter records per job.
Recommended pack structure
- QMS context — quality manual, scope, interested parties, org chart.
- Risk register (strategic and operational) and opportunities log.
- Configuration management plan plus sample ECO/ECN trace.
- Design and development records (if applicable under Clause 8.3).
- Approved Supplier List, counterfeit-prevention procedure, and AS9120 flowdown.
- FAI library (AS9102 Forms 1–3) indexed by part number.
- Special-process certifications (NADCAP) and operator qualifications.
- Product safety and FOD program artifacts.
- Nonconformance, CAPA, and escape records with root-cause analysis.
- Internal audit reports, management-review minutes, and KPI dashboards.
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