Dennis Rosa, Senior Consultant, MAGNET

As manufacturers in the aerospace industry are aware, a new revision to the International Aerospace Quality Group's (IAQG) aerospace quality management system standard (AS9100) was adopted in early 2009. The new standard may be referred to as AS9100C, AS9100:2009 or AS9100 Rev C.

Although the revision was officially adopted more than a year ago, implementation of this new "C" revision is only just getting underway this summer. The reason: the IAQG was waiting for approval of other related standards—AS9101D (a checklist for the entire AS series of standards) and AS9104-1 (for Oversight of Aerospace Quality Management Systems). In addition, the course for training Aerospace certification body auditors only became available on April 30.

Certification body auditors must attend the approved training course, pass it, and obtain RABQSA approval. Certification bodies (registrar’s) must submit applications and be audited by ANAB and be accredited before performing AS9100C audits. So once the registrar’s are accredited and auditors are approved—just a matter of a few weeks or months— registrars will be able to begin conducting audits to the new "C" standard.

Advantages of AS9100C

This new standard is not just for aerospace (i.e. aviation and space). It is also includes "land and sea based defense applications" standard. By moving to AS9100C, suppliers will find it easier to compete in the international marketplace in all three categories: aviation, space and defense. Active aerospace programs in the Americas, Asia/Pacific and Europe will provide many opportunities to grow and diversify your markets.

Key changes in the AS9100C revision

To create this international standard required four years of consultations among civil aviation authorities, defense and space authorities, certification bodies, trade associations, suppliers and companies who are members of the International Aerospace Quality Group.
These stakeholders added six requirements, revised eight existing requirements and deleted three requirements from the previous standard. There are also a host of minor changes

Management and quality engineers will need to assure cross-functional time and resources are deployed to develop, implement and maintain the key new processes to meet the key changes.

Six Additions

Two key goals of the revision were to put emphasis on product and process improvement (e.g. risk management, critical items and project management) and to provide additional focus on IAQG's objective of on-time and on-quality deliveries.

The revision adds three new definitions and three new requirements.

The three new definitions:

• Risk: "An undesirable situation or circumstance that has both the likelihood of occurring and a potentially negative outcome."
• Special requirements: "Those requirements which have high risks to being achieved thus, requiring their inclusion in the risk management process."
• Critical item: "Those items having significant effect on product realization and the use of products that require specific actions to ensure they are managed."

The three new requirements:

• Customer Focus/Satisfaction: Measuring product conformity and on-time delivery performance and planning for appropriate actions when planned results are not achieved (clauses 5.2/8.2.1)
• Project Management: Planning and managing product realization in a structured and controlled way to meet requirements at acceptable risk (Clause 7.1.1)
• Risk Management: Implementing a risk management process covering: responsibility, criteria, mitigation and acceptance (Clause 7.1.2)

The IAQG also made six key revisions to the standard:

• Configuration Management (Clause 7.1.3)
• Work Transfer (Clause 7.1.4)
• Recognition of Supplier Data (Clause 7.4.1)
• Approval Status of Suppliers (Clause 7.4.1)
• Production Process Verification (Clause 7.5.1.1)
• Sampling Inspection (Clause 8.2.4)

For complete details on all the changes to the standard, download IAQG 9100:2009 Revision Overview (Revision 3), by the IAQG 9100 Team, May 14, 2010. PDF (630k)

Timeline

Registrars have until July 2011 to complete the process of training trainers, training auditors and obtaining their accreditation to the "Rev C" standards. So, until July 1, 2011, audits can still be conducted to the AS9100B standard. After that, audits will be conducted only to the AS9100C standard. After July 1, 2012, the "B" standard will be cancelled.

Timing your company's upgrade to AS9100C will require careful consideration. If your company recently received recertification to the "B" standard, it may make sense to wait until your next annual surveillance audit to upgrade to the "C" standard. Organizations may also upgrade during the triannual reassessment audits.

Note: Additional audit time will be required above the normal (AS9100B) surveillance or re-assessment audit days to assure your quality system meets the new AS9100C requirements.

However, there are two reasons not to wait too long.

• 1. Registrars and auditors will soon get very busy with AS9100C certifications. You might find your company has to wait in line for your turn.
• 2. If, during the certification process, your auditor issues findings for any corrective actions, your company will need enough time to close those out before the July 1, 2012 deadline.

Two years might seem like a long way away. But the deadline will arrive sooner than you think! So allow for the unexpected, pay attention to messages from your registrar and follow their suggestions.

Source: IAQG 9100:2009 Revision Overview (Revision 3), by the IAQG 9100 Team, May 14, 2010.

About the Author: Since joining MAGNET in 1992, Dennis Rosa has helped more than one hundred manufacturing organizations improve their bottom lines through quality and productivity improvement efforts. He received his BS in industrial engineering from Cleveland State University. Dennis has managed both Manufacturing Engineering and Quality functions at CE Cast Equipment, Lubriquip and KT/Swasey (Warner & Swasey).

For more information about how MAGNET can help your company implement a quality management system project, contact Dennis Rosa or call (216) 391-7506.