Achieving AS9100 Rev D Certification: A Step-by-Step Guide

AS9100 Rev D certification is a valuable credential for aerospace organizations, signifying their commitment to quality, safety, and compliance with industry standards. The certification process can seem complex, but by following a structured approach, organizations can navigate the requirements efficiently. This article provides a step-by-step guide to achieving AS9100 Rev D certification, from initial assessment to the final certification audit.

Table of Contents

• Step 1: Preparation and Initial Assessment
• Step 2: Develop or Update the Quality Management System (QMS)
• Step 3: Conduct an Internal Audit
• Step 4: Conduct a Management Review
• Step 5: Certification Audit by an Accredited Body
• FAQs on AS9100 Rev D Certification

Step 1: Preparation and Initial Assessment

The first step in achieving AS9100 Rev D certification is a comprehensive initial assessment. This involves evaluating the organization’s current practices, processes, and documentation against AS9100 requirements. Essential preparation activities include:

• Conducting a Gap Analysis: A gap analysis identifies areas where the organization’s existing practices do not meet AS9100 Rev D standards, providing a roadmap for necessary improvements.
• Assigning a Project Team: Designate a team responsible for the certification process, including representatives from quality, operations, and management, to coordinate activities and ensure accountability.
• Setting a Timeline: Develop a realistic timeline for each phase of the certification process, including milestones for implementation, audits, and final certification.

This initial assessment allows organizations to understand the scope of work required to achieve certification and establish a clear action plan.

Step 2: Develop or Update the Quality Management System (QMS)

AS9100 Rev D certification requires a documented Quality Management System (QMS) that aligns with the standard’s requirements. Key elements of this step include:

• Documentation: Develop comprehensive documentation, including quality manuals, procedures, and work instructions, that address AS9100’s requirements.
• Risk Management Processes: Implement risk management procedures to identify, assess, and mitigate risks related to quality, product safety, and regulatory compliance.
• Training and Competency: Ensure that all employees are trained on AS9100 requirements, quality standards, and their roles within the QMS.
• Configuration Management: Establish configuration management practices to control and track changes to product specifications, processes, and documentation.

A well-documented QMS is essential for compliance with AS9100 Rev D and provides a foundation for quality assurance across all operational activities.

Step 3: Conduct an Internal Audit

An internal audit is a required step before the certification audit. Internal audits allow organizations to evaluate the effectiveness of their QMS and address any non-conformities. Key actions during the internal audit include:

• Reviewing Processes and Documentation: Assess each process, document, and procedure to verify they meet AS9100 standards and the organization’s quality objectives.
• Identifying Non-Conformities: Document any instances where the QMS does not meet AS9100 requirements, categorizing non-conformities by severity to prioritize corrective actions.
• Implementing Corrective Actions: Address non-conformities through corrective actions, documenting the solutions and ensuring processes are updated accordingly.

This internal audit prepares the organization for the certification audit by identifying and addressing potential issues in advance.

Step 4: Conduct a Management Review

A management review is an essential part of AS9100 Rev D certification, involving top management in evaluating the QMS’s performance and effectiveness. During the management review, organizations should:

• Review Audit Findings: Present the results of the internal audit to management, including non-conformities and corrective actions taken.
• Evaluate Quality Objectives: Assess whether quality objectives are being met and discuss any necessary adjustments to improve performance.
• Discuss Resource Allocation: Ensure the organization has sufficient resources to maintain and improve the QMS, including personnel, technology, and training.
• Plan for Continuous Improvement: Identify opportunities for further improvement within the QMS, setting new goals to enhance quality and compliance.

The management review ensures top management is actively involved in the QMS, aligning organizational goals with AS9100 requirements and driving continuous improvement.

Step 5: Certification Audit by an Accredited Body

The final step is the certification audit, conducted by an accredited certification body. This audit verifies compliance with AS9100 Rev D requirements and confirms the effectiveness of the QMS. The certification audit typically involves:

• Stage 1 Audit: The auditor reviews documentation and conducts preliminary assessments to ensure the organization is ready for the full audit.
• Stage 2 Audit: The main audit involves detailed evaluations of processes, interviews with personnel, and examination of records to verify compliance with AS9100 Rev D.
• Issuance of Certification: If the organization meets all requirements, the certification body issues an AS9100 Rev D certificate, valid for three years with annual surveillance audits.

Successfully passing the certification audit demonstrates that the organization meets AS9100 Rev D standards, establishing its commitment to quality and compliance.

FAQs on AS9100 Rev D Certification

• How long does it take to achieve AS9100 certification? - The timeline varies, but most organizations complete the process in 6–12 months, depending on the complexity of their operations.
• What is the difference between Stage 1 and Stage 2 audits? - Stage 1 reviews documentation and readiness, while Stage 2 is a comprehensive assessment of QMS implementation and compliance.
• Is recertification required for AS9100? - Yes, AS9100 certification is valid for three years, with annual surveillance audits and a full recertification audit at the end of the period.
• What should be included in the management review? - The management review should include audit results, quality objectives, resource needs, and plans for continuous improvement.

Conclusion

Achieving AS9100 Rev D certification requires a systematic approach, from initial assessment and QMS development to internal audits and certification audits. By following these steps and involving all levels of the organization, aerospace companies can demonstrate their commitment to quality, safety, and regulatory compliance. AS9100 Rev D certification strengthens customer confidence, improves operational efficiency, and provides a competitive edge in the aerospace industry.

For more guidance on AS9100 Rev D certification or to explore our training programs, visit QMII’s AS9100 Training page or contact us here for personalized support and resources.