Understanding AS9100 Transition and Changes in Aerospace Quality Management

The AS9100 transition marks a critical shift for the aerospace industry as companies move from older versions of the standard to the more comprehensive AS9100D. PERRY JOHNSON Consulting INC. study has revealed that:

“AS9100D registered organizations almost universally realize major increases in customer acceptance, as well as reductions in costs.”

The study highlights that the transition is not just about meeting compliance requirements—it’s also about improving operational processes, minimizing risks, and ensuring long-term success.

This transition isn’t just about compliance—it’s about enhancing your company’s processes, reducing risks, and ensuring long-term success. In this blog, we’ll discuss the key changes in the AS9100 transition and explore how these updates help aerospace companies optimize their operations and meet the industry's ever-growing demands.

What Does AS9100 Transition Mean to the Aerospace Industry?

The AS9100 transition refers to the shift from the previous versions of the AS9100 standard to a more comprehensive and updated version, focusing on quality management systems in the aerospace sector. 

Developed in 1999 by the International Aerospace Quality Group (IAQG), AS9100 is based on the ISO 9001 standard but tailored to the aerospace industry's specific needs and regulatory demands. The standard provides guidelines to ensure quality, consistency, and safety in aerospace manufacturing and services.

The updated AS9100 emphasizes more on features like:

• Latest regulatory changes
• Industry trends
• Technological advancements
• Risk management
• Stakeholder engagement 
• Continuous improvement. 

The most recent revision, AS9100D, was released in 2016. This update aligned the standard with ISO 9001:2015, ensuring that the aerospace industry complies with global quality management practices.

This transition is necessary to ensure aerospace companies maintain the following criteria:

• Remain competitive
• Meet evolving customer expectations 
• Comply with international standards

 For businesses, the AS9100 transition provides an opportunity to optimize processes, reduce risks, and improve overall efficiency, ensuring long-term success in a highly regulated and competitive industry.

Now, let’s understand the key changes in the AS9100 Transition.

What Are the Key Changes in AS9100 Transition and Revision

AS9100D introduces key changes to enhance aerospace quality management. These include a stronger focus on risk-based thinking, life cycle management, and supply chain management. Let’s understand them in detail.

1. Greater Emphasis on Risk-Based Thinking

One of the most notable changes in AS9100D is the introduction of risk-based thinking. The standard now requires organizations to identify risks throughout their processes and mitigate them effectively. This includes

• Risks in the supply chain
• Production processes
• Even customer interactions

Incorporating risk-based thinking helps companies become more proactive in identifying potential issues before they impact product quality or customer satisfaction. It also ensures a more consistent and reliable approach to meeting aerospace industry standards.

2. Focus on Life Cycle Management

AS9100D also emphasizes life cycle management, ensuring that quality is maintained throughout the product’s entire life cycle—from concept and design to manufacturing, delivery, and post-delivery services. This change aligns with the increasing focus on sustainability in aerospace manufacturing, where the entire life cycle of a product must be considered, including end-of-life disposal or recycling.

By focusing on life cycle management, aerospace companies can optimize their 

• Product quality
• Reduce environmental impact 
• Maintain compliance throughout the product’s journey.

3. Supply Chain Management Requirements

Supply chain management has become a critical area in aerospace quality management. AS9100D requires organizations to ensure that their suppliers meet quality standards. This includes:

• Evaluating supplier performance
• Conducting regular audits 
• Requiring suppliers to comply with specific aerospace quality criteria.

This change is in response to the increasing complexity and globalization of supply chains. Aerospace companies are often reliant on a network of suppliers across different regions, making it essential to have a robust process in place to monitor supplier performance and ensure compliance.

4. Enhanced Documentation Requirements

AS9100D introduces changes to the documentation requirements for quality management systems (QMS). The standard emphasizes the need for organizations to maintain clear and concise documentation related to their QMS processes, procedures, and policies. This includes creating documented evidence of actions taken to address nonconformities and corrective actions.

The emphasis on documentation helps organizations demonstrate compliance with the standard and ensures a clear trail of accountability throughout the QMS. It also supports continuous improvement efforts by providing data to analyze performance and identify areas for enhancement.

5. Context of the Organization

AS9100D introduces the concept of "context of the organization," which requires organizations to assess both internal and external factors that can impact their QMS. Including evaluating:

• Market conditions
• Regulatory requirements
• Technological advancements 
• The competitive landscape. 

By understanding the broader context in which the organization operates, companies can tailor their QMS to address potential challenges better and capitalize on opportunities.

This change helps aerospace companies better align their quality management system with the dynamic environment in which they operate.

6. Expanded Focus on Performance Evaluation

AS9100D strengthens the requirement for organizations to monitor, measure, analyze, and evaluate the performance of their QMS. This includes the use of key performance indicators (KPIs) to track the effectiveness of processes and identify areas for improvement.

By emphasizing performance evaluation, AS9100D encourages organizations to adopt data-driven decision-making and take a more proactive approach to improving quality and efficiency.

7. Alignment with ISO 9001:2015

AS9100D is now fully aligned with ISO 9001:2015, which means it follows the same high-level structure (HLS) for quality management systems. This alignment simplifies the certification process for organizations that are already ISO 9001 certified, as they can more easily transition to AS9100D by implementing additional aerospace-specific requirements.

This alignment also ensures that aerospace companies adhere to the same global quality standards as companies in other industries, making it easier to integrate quality management practices across different sectors.

These revisions strengthen internal processes and align aerospace companies with current industry and sustainability trends. Let’s examine the steps to implement the AS9100 transition effectively. By following a clear and structured approach, aerospace companies can smoothly align their operations with the new AS9100D standards.

How to Prepare the Transition Steps for AS9100 

Transitioning to AS9100D can feel like a daunting task, but with the right approach, it’s an opportunity to streamline operations, enhance product quality, and improve overall efficiency. Here’s how you can prepare for a smooth and successful transition.

1. Evaluate Your Current Quality Management System (QMS)

Start by assessing your existing quality management system. Conduct a gap analysis to compare your current processes with the new AS9100D requirements. This evaluation will help you identify areas that need improvement. Focus on key aspects like risk management, documentation, and supplier control.

Practical Tip: Set up a cross-functional team that includes members from quality, operations, and compliance. They can help conduct the evaluation and ensure that every area is covered.

2. Implement Risk Management Practices

A major change in AS9100D is the increased emphazis on risk-based thinking. AS9100D requires organizations to proactively identify and mitigate risks throughout the entire product lifecycle—from design to post-delivery services. To get started, map out potential risks across all areas of your operations, including supply chain, production, and customer interactions.

Practical Tip: Develop a risk management plan that includes a risk assessment process and defines mitigation strategies. Use tools like risk matrices to prioritize risks and assign responsibilities.

3. Update Documentation and Process Requirements

The AS9100D revision introduces changes to both documentation and process requirements. You'll need to update your existing QMS documentation to ensure it aligns with AS9100D standards. This includes revising quality manuals, procedures, work instructions, and records.

Practical Tip: Review all current documents and map them to the new AS9100D clauses. Use this mapping to create a checklist of documents that need to be updated. Consider utilizing software tools to manage this revision process efficiently.

With BPRHub’s Document Hub, you can streamline document management and ensure that your QMS is always up-to-date and compliant.

4. Train Your Team on New Requirements

AS9100D introduces significant shifts in the management of quality management systems, particularly in risk management and life cycle thinking. Your team must be aware of these changes and well-trained to implement them. Plan and conduct targeted training sessions to ensure everyone understands the new requirements.

Practical Tip: Focus on role-specific training. For instance, the quality team should explore the technical aspects of AS9100D more deeply, while the leadership team should focus on strategic decision-making and compliance leadership.

5. Align Your Supply Chain with AS9100D Standards

Supply chain management is a critical component of the AS9100 transition. AS9100D places increased responsibility on organizations to ensure their suppliers meet the necessary quality standards. Evaluate your supplier base and verify that they are AS9100D-compliant, or begin guiding them through the certification process.

Practical Tip: Create a supplier compliance checklist and audit schedule. Consider integrating a supplier management system that tracks supplier performance, certification status, and audits to stay ahead of any potential issues.

6. Monitor Progress and Conduct Internal Audits

Once you’ve implemented the necessary changes, it's essential to monitor progress regularly. Set clear milestones and use internal audits to ensure your systems are functioning as intended. These audits will help identify areas that need adjustment before undergoing external certification audits. IAQG mandates that these audits occur at least once every 12 months.

Contact BPRHub today to leverage their Audit Hub, which helps to track and schedule internal audits and ensures seamless compliance before external certification.

Practical Tip: Develop an internal audit schedule and assign specific teams to monitor different areas of your QMS. Document findings and corrective actions, making continuous improvement a key part of the transition process.

Organizations can use compliance software like BPRHub to implement these steps effectively. Let’s explore how it simplifies the process and ensures a seamless transition.

Seamlessly Adapt to AS9100 Transition With BPRHub

The AS9100 transition and AS9100D are critical for aerospace companies to maintain compliance, ensure product quality, and meet evolving industry standards. Adapting to these changes can be complex, but BPRHub makes the process seamless. With features like real-time insights and automated updates, BPRHub ensures your quality management system stays aligned with the latest AS9100D standards. 

Its real-time compliance checking and customizable audit checklists empower your team to identify gaps and ensure adherence at every stage. Additionally, BPRHub’s seamless integration with existing systems and robust evidence-collection tools help streamline the transition, ensuring smooth implementation and better decision-making throughout the process.

Ready to streamline your AS9100D transition? Let BPRHub guide you to seamless compliance and operational excellence!

FAQ’s

1. What is AS9100, and why is it important for aerospace companies?

Ans: AS9100 is a widely adopted quality management standard specifically designed for the aerospace industry. It ensures that companies meet the sector's strict regulatory, safety, and operational requirements. Compliance with AS9100 helps businesses improve efficiency, minimize risk, and enhance customer satisfaction through consistent, high-quality products and services.

2. How can BPRHub help aerospace companies during the AS9100 transition?

Ans: BPRHub simplifies the AS9100 transition by automating compliance tracking, managing documentation, and ensuring alignment with updated quality standards. Its workflow automation and real-time reporting streamline the process, reducing errors and improving efficiency, helping companies achieve AS9100D certification more effectively.

3. What is the latest revision of AS9100?

Ans: The latest revision of AS9100, released in 2016, is AS9100D. It incorporates updated requirements focused on risk-based thinking, the organization's context, and enhanced leadership involvement. AS9100D also emphasizes stronger supply chain management and streamlines compliance processes, aligning with ISO 9001:2015 standards.

4. What are the key changes in AS9100D?

Ans: AS9100D introduces risk-based thinking, a focus on organizational context, stronger leadership involvement, and improved supply chain management. These updates aim to streamline processes, enhance compliance, and align with ISO 9001:2015, ensuring better quality management across the aerospace sector.

5. Can BPRHub assist in managing supplier compliance during the AS9100 transition?

Ans: Yes, BPRHub can significantly help manage supplier compliance during the AS9100 transition. The platform’s supplier management tools allow you to monitor supplier performance, track certifications, and ensure that all suppliers meet the rigorous quality standards required by AS9100D. This ensures a smoother transition by reducing risks related to non-compliance across the supply chain.