AS9100

Master this essential documentation concept

Quick Definition

An aerospace industry quality management standard that extends ISO 9001 with additional requirements specific to aviation and defense manufacturing

How AS9100 Works

flowchart TD A[Document Creation] --> B{AS9100 Review} B --> C[Technical Review] B --> D[Quality Review] B --> E[Risk Assessment] C --> F[Configuration Control] D --> F E --> F F --> G[Document Approval] G --> H[Release & Distribution] H --> I[Implementation] I --> J[Monitoring & Measurement] J --> K{Change Required?} K -->|Yes| L[Change Control Process] K -->|No| M[Periodic Review] L --> B M --> N[Document Archive] N --> O[Records Retention] style B fill:#e1f5fe style F fill:#f3e5f5 style G fill:#e8f5e8

Understanding AS9100

AS9100 is a specialized quality management standard developed specifically for the aerospace industry, building upon the foundation of ISO 9001 while adding stringent requirements unique to aviation, space, and defense sectors. This standard addresses the critical need for enhanced safety, reliability, and regulatory compliance in aerospace operations.

Key Features

  • Enhanced documentation control requirements with strict version management and approval processes
  • Configuration management protocols ensuring product traceability throughout lifecycle
  • Risk-based thinking integrated into all documentation processes
  • Mandatory records retention for extended periods to support product liability
  • Supplier documentation requirements extending quality standards through supply chain
  • First article inspection documentation for new or modified products

Benefits for Documentation Teams

  • Standardized documentation processes reducing errors and inconsistencies
  • Clear audit trails supporting regulatory compliance and customer requirements
  • Improved collaboration through defined roles and responsibilities
  • Enhanced document security and access control mechanisms
  • Streamlined change management processes with proper impact assessment

Common Misconceptions

  • AS9100 is not just ISO 9001 with minor additions - it includes significant aerospace-specific requirements
  • The standard applies to all aerospace organizations, not just manufacturers
  • Documentation requirements extend beyond quality manuals to include technical and operational documents
  • Compliance is ongoing, not a one-time certification achievement

Ensuring AS9100 Compliance Through Standardized Documentation

When implementing AS9100 quality management systems in aerospace manufacturing, your teams often record video walkthroughs of critical processes to demonstrate compliance. These videos capture valuable knowledge about how your organization meets the rigorous requirements of AS9100, from risk management to configuration control processes.

However, relying solely on video demonstrations creates challenges during audits and certification reviews. AS9100 auditors typically require formal documentation that clearly outlines each process step, responsibility matrix, and control measures. Videos alone make it difficult to quickly reference specific requirements or demonstrate how your processes align with AS9100's aerospace-specific controls.

Converting these process videos into structured standard operating procedures gives your quality team searchable, referenceable documentation that directly maps to AS9100 requirements. This transformation helps ensure that critical aerospace manufacturing processes are consistently followed across shifts and facilities. When auditors request evidence of your AS9100 compliance, you can provide well-organized SOPs that clearly demonstrate how your organization implements required aerospace quality controls.

Learn how to efficiently transform your AS9100 process videos into audit-ready standard operating procedures →

Real-World Documentation Use Cases

Aircraft Component Manufacturing Documentation

Problem

A aerospace manufacturer struggles with maintaining accurate technical documentation for critical aircraft components, leading to quality issues and regulatory non-compliance during audits.

Solution

Implement AS9100 documentation controls with configuration management, ensuring all technical specifications, work instructions, and quality records are properly controlled and traceable.

Implementation

1. Establish document control procedures with unique identification systems 2. Create approval workflows for technical documentation 3. Implement configuration management for all product-related documents 4. Set up document revision tracking with change impact assessments 5. Establish records retention schedules per AS9100 requirements 6. Train teams on document control procedures

Expected Outcome

Achieved 100% traceability of component documentation, passed regulatory audits with zero non-conformances, and reduced quality issues by 40% through improved document accuracy.

Supplier Quality Documentation Management

Problem

An aerospace company cannot effectively manage and monitor supplier quality documentation, creating risks in the supply chain and potential compliance issues.

Solution

Deploy AS9100-compliant supplier documentation requirements with standardized formats, approval processes, and regular monitoring to ensure supply chain quality.

Implementation

1. Define supplier documentation requirements based on AS9100 standards 2. Create supplier document submission and approval workflows 3. Establish supplier document review and acceptance criteria 4. Implement supplier performance monitoring through documentation metrics 5. Set up regular supplier documentation audits 6. Create corrective action processes for non-compliant suppliers

Expected Outcome

Improved supplier compliance rates by 60%, reduced supply chain quality issues by 35%, and established clear accountability throughout the supplier network.

Design Change Control Documentation

Problem

Engineering changes in aerospace products lack proper documentation control, leading to configuration mismatches and potential safety issues in the field.

Solution

Establish AS9100-compliant change control documentation processes that ensure all design modifications are properly assessed, approved, and implemented with full traceability.

Implementation

1. Create change request documentation templates with risk assessment sections 2. Establish multi-disciplinary review processes for all changes 3. Implement configuration management to track all affected documents 4. Set up approval workflows with appropriate authorization levels 5. Create implementation tracking and verification procedures 6. Establish post-implementation review and lessons learned documentation

Expected Outcome

Reduced configuration errors by 50%, improved change implementation timeline by 30%, and achieved full compliance with customer and regulatory change control requirements.

Training and Competency Documentation

Problem

An aerospace organization cannot demonstrate employee competency and training compliance as required by AS9100, creating audit findings and operational risks.

Solution

Implement comprehensive training documentation system that tracks competency requirements, training delivery, and ongoing qualification maintenance per AS9100 standards.

Implementation

1. Define competency requirements for all roles affecting product quality 2. Create training documentation templates and tracking systems 3. Establish training effectiveness evaluation procedures 4. Implement ongoing competency monitoring and requalification processes 5. Set up training records management with proper retention periods 6. Create reporting systems for training compliance monitoring

Expected Outcome

Achieved 100% training compliance across all quality-affecting roles, eliminated audit findings related to competency, and improved overall workforce capability and confidence.

Best Practices

✓ Implement Risk-Based Document Classification

Classify all documents based on their risk impact to product safety and quality, applying appropriate control levels for each classification tier.

✓ Do: Establish clear criteria for document risk classification, apply stricter controls to high-risk documents, and regularly review classifications as products evolve.
✗ Don't: Apply uniform controls to all documents regardless of risk level, or assume initial classifications remain valid without periodic review.

✓ Establish Configuration Management Integration

Integrate document control with product configuration management to ensure complete traceability between product changes and supporting documentation.

✓ Do: Link document versions to specific product configurations, maintain clear baselines, and ensure all changes are synchronized across documentation and product data.
✗ Don't: Manage documents independently from product configuration, or allow document changes without proper configuration impact assessment.

✓ Create Comprehensive Audit Trail Systems

Maintain detailed audit trails for all document activities including creation, review, approval, changes, and access to support compliance and investigation needs.

✓ Do: Automatically capture all document activities with timestamps and user identification, store audit data securely, and make it easily retrievable for audits.
✗ Don't: Rely on manual logging systems, allow audit trail gaps, or store audit information in formats that cannot be easily searched or analyzed.

✓ Develop Supplier Documentation Standards

Establish clear documentation requirements and standards for suppliers that align with AS9100 requirements and ensure supply chain quality.

✓ Do: Provide suppliers with detailed documentation templates and requirements, conduct regular supplier documentation audits, and maintain supplier qualification records.
✗ Don't: Accept supplier documentation without proper review, allow suppliers to use non-standard formats, or fail to verify supplier documentation capabilities during qualification.

✓ Implement Continuous Improvement Monitoring

Regularly monitor documentation processes for effectiveness and efficiency, using metrics and feedback to drive continuous improvement initiatives.

✓ Do: Establish key performance indicators for documentation processes, collect user feedback regularly, and implement improvement actions based on data analysis.
✗ Don't: Set up documentation processes without monitoring mechanisms, ignore user feedback about process inefficiencies, or resist changes to improve documentation effectiveness.

How Docsie Helps with AS9100

See How Docsie Can Help

Build Better Documentation with Docsie

Join thousands of teams creating outstanding documentation

Start Free Trial