Achieving AS9100 certification is a vital milestone for any aerospace organization, ensuring that your company adheres to the highest standards of quality management. A significant part of this process is the internal audit, which helps organizations identify areas for improvement before the official certification audit. Conducting a thorough internal audit provides a clear view of compliance with AS9100 requirements and highlights any non-conformities that need to be addressed.

For organizations looking for expert support and resources in preparing for such audits, platforms like https://bprhub.com/ can offer invaluable guidance, ensuring that the internal audit process is streamlined and efficient. This blog will take you through an AS9100 internal audit checklist that ensures your organization is fully prepared for the certification audit.

Understanding AS9100 and the Importance of Internal Audits

Before diving into the checklist, it’s important to understand what AS9100 is and why internal audits matter. AS9100 is a set of quality management system requirements developed by the International Aerospace Quality Group (IAQG) for organizations within the aerospace sector. These requirements are designed to ensure that products and services meet the highest standards of safety, reliability, and quality.

Whether you are manufacturing aerospace parts, providing maintenance services, or offering engineering solutions, AS9100 certification helps assure customers and regulatory bodies of your commitment to quality. Internal audits are one of the most effective ways to ensure compliance with AS9100. Conducting internal audits before the official certification audit allows organizations to identify any gaps, correct non-conformities, and enhance the overall quality management system.

Key Components of the AS9100 Internal Audit Checklist

An internal audit checklist helps organizations methodically assess their compliance with AS9100 requirements. It typically focuses on the key elements of the standard, including documentation, processes, and overall system performance. Below, we break down the critical components of an effective AS9100 internal audit checklist.

1. Leadership Commitment and Quality Policy

Objective: Evaluate whether leadership demonstrates a commitment to the quality management system and the aerospace quality objectives.

Checklist Points:

• Verify that top management has defined a clear quality policy.
• Confirm that the policy is communicated to all levels of the organization.
• Assess if leadership is actively involved in the QMS and AS9100 implementation.
• Ensure that quality objectives are measurable, consistent with the quality policy, and regularly reviewed.

Leadership’s active role in quality management is crucial. A lack of engagement can affect the entire system’s effectiveness.

2. Planning and Risk Management

Objective: Examine whether the organization’s planning processes, including risk management, align with AS9100 standards.

Checklist Points:

• Check if risk management procedures are implemented across processes.
• Confirm that the organization has identified potential risks that could affect product quality.
• Ensure that there is a system for assessing and mitigating risks in the planning stage.
• Review the organization’s planning to confirm that they focus on the quality objectives and customer needs.

Planning is central to a smooth operational flow and customer satisfaction. Addressing risks early helps prevent issues that could jeopardize compliance.

3. Document Control and Management

Objective: Verify that document control systems meet the requirements for AS9100 compliance.

Checklist Points:

• Ensure that all documents and records related to the QMS are controlled and accessible.
• Check if document changes are appropriately reviewed and approved before implementation.
• Confirm that obsolete documents are removed from circulation to avoid confusion.
• Assess if there is proper version control, ensuring that employees are using the latest documentation.

Proper documentation management ensures that employees follow updated and approved procedures, reducing the risk of errors and non-conformities.

4. Product Realization and Process Control

Objective: Evaluate the effectiveness of processes involved in product realization, ensuring that customer specifications and requirements are met.

Checklist Points:

• Confirm that processes for product design and development are defined and controlled.
• Check if the organization conducts regular reviews of design outputs against customer requirements.
• Assess whether changes to product designs are systematically reviewed and approved.
• Ensure that process controls are in place to monitor the production and delivery of aerospace products.

Product realization involves ensuring that each phase of production aligns with customer specifications and quality requirements. Monitoring processes ensures that quality standards are consistently met.

5. Supplier Management and Purchasing Controls

Objective: Examine how the organization selects, evaluates, and monitors its suppliers to ensure compliance with AS9100 standards.

Checklist Points:

• Confirm that there is a documented process for selecting suppliers based on their ability to meet quality standards.
• Assess how the organization monitors supplier performance over time.
• Ensure that there is a process for evaluating the quality of purchased products or services.
• Verify that non-conformities are addressed promptly and corrective actions are implemented for suppliers.

Supplier relationships are critical in aerospace manufacturing. Effective supplier management ensures that external partners adhere to the same quality standards as the organization itself.

6. Training and Competence

Objective: Ensure that personnel have the necessary skills and qualifications to perform their tasks and contribute to maintaining the QMS.

Checklist Points:

• Verify that employees have received appropriate training for their roles.
• Confirm that competence is regularly assessed and training needs are identified.
• Ensure that training records are maintained and up-to-date.
• Check if personnel are aware of their roles in the quality management system and understand the significance of AS9100 requirements.

Competent personnel are essential to maintaining a high standard of quality. Training ensures that employees are knowledgeable and capable of meeting the expectations of the aerospace industry.

7. Internal Audit and Non-Conformance Management

Objective: Evaluate how the organization manages its internal audits and handles non-conformities.

Checklist Points:

• Check if internal audits are conducted according to a pre-established schedule.
• Ensure that audit findings are documented and that corrective actions are taken for non-conformities.
• Assess whether internal audit results are reviewed by top management.
• Confirm that there is an established procedure for addressing corrective actions and preventive actions.

Regular audits and effective non-conformance management allow for continuous improvement and ensure that any issues are identified and resolved promptly.

8. Measurement, Analysis, and Continuous Improvement

Objective: Verify that the organization is effectively measuring and analysing key quality metrics to drive continuous improvement.

Checklist Points:

• Ensure that performance metrics are clearly defined and aligned with organizational goals.
• Check if there is a system for collecting data on process performance, customer satisfaction, and product quality.
• Confirm that corrective actions and improvements are based on data analysis.
• Verify that top management reviews data and drives decisions based on measurable outcomes.

Measurement and analysis are crucial for understanding where improvements can be made. A data-driven approach ensures continuous growth and compliance with AS9100.

Final Steps: Preparing for the Certification Audit

Once the internal audit has been conducted and corrective actions have been implemented, it is time to prepare for the certification audit. Here are a few final steps to consider:

1. Review Internal Audit Findings: Ensure that all audit findings have been addressed and that corrective actions are effective. Double-check documentation and records to ensure compliance.
2. Management Review: Top management should review the effectiveness of the QMS and make any necessary adjustments before the certification audit.
3. Ensure Employee Awareness: All employees should be aware of their roles and responsibilities in the QMS and should be prepared for the certification audit process.

Conclusion: The Importance of Thorough Internal Audits

AS9100 certification is a critical step for any aerospace organization, and preparing for the certification audit requires a thorough internal audit process. By following the AS9100 internal audit checklist, you can identify any non-conformities, ensure that your quality management system is fully compliant, and make the necessary adjustments before the formal audit. This proactive approach will not only help your organization pass the certification audit but also improve overall quality and efficiency, ultimately driving success in the aerospace sector.