I am writing this document to help out managers, who think AS9100 is a very complicated system to install, implement and follow. They have an apprehension that it requires tons of documentation and record keeping. I will be bringing the basic outlines of how to implement a QMS (Quality Management System) from scratch, which adhere to AS9100 Rev C requirements in a very basic manner. This document alone cannot be used to implement the AS9100 Rev C; the aim of this document is to familiarize the managers about the basics of implementation of AS9100 Rev C. I have used many illustrations and also used project management concept to implement AS9100 Rev C.

1.
Guide
for
implementing
AS9100
Rev
C
By
ASHISH
JUDE
MICHAEL,
MBA,
IIM
Shillong

2. 2
Guide
for
implementing
AS9100
Rev
C
Introduction
I
am
writing
this
document
to
help
out
managers,
who
think
AS9100
is
a
very
complicated
system
to
install,
implement
and
follow.
They
have
an
apprehension
that
it
requires
tons
of
documentation
and
record
keeping.
I
will
be
bringing
the
basic
outlines
of
how
to
implement
a
QMS
(Quality
Management
System)
from
scratch,
which
adhere
to
AS9100
Rev
C
requirements
in
a
very
basic
manner.
This
document
alone
cannot
be
used
to
implement
the
AS9100
Rev
C;
the
aim
of
this
document
is
to
familiarize
the
managers
about
the
basics
of
implementation
of
AS9100
Rev
C.
I
have
used
many
illustrations
and
also
used
project
management
concept
to
implement
AS9100
Rev
C.
I
have
used
my
own
experience;
I
played
an
important
role
in
implementing
AS9100
Rev
C
in
my
SBU
(Strategic
Business
Unit),
which
is
EW&A
(Electronics
Warfare
&
Avionics)
at
Bharat
Electronics.
Our
SBU
was
one
of
the
first
SBUs
in
India
to
get
AS9100
certification
among
PSUs.
Our
Head
of
Team
for
Implementation
of
AS9100
was
our
QM
(Quality
Management)
DGM
Mr.
Satyanarayana
and
I
was
a
directly
reporting
to
him.
I
will
divide
this
document
in
14
steps
(These
steps
are
inspired
from
“How
to
implement
AS9100?”)
and
will
be
elaborating
on
each
step
and
add
if
any
thing
is
missing.

3. Guide
for
implementing
AS9100
Rev
C
3
Table
of
Contents
Management
Responsibilities
Step
1:
Determine
which
Quality
standard
to
adopted
Step
2:
Assemble
the
Team,
Purchase
the
Standard
&
select
registrar
Step
3:
Set
targets
and
periodically
review
them
Implementation
Team
Responsibilities
Step
4:
Review
support
literature
and
software
Step
5:
Make
a
strategy
Step
6:
Plan
the
implementation
Step
7:
Documentation
Step
8:
Draft
QMSP
(Level
1
Document)
Step
9:
Training
Departmental
Responsibilities
Step
10:
Level
2
,
3
&
4
level
Documents
Step
11:
Implement
&
adhere
to
Quality
Management
System
(QMS)
QM
Responsibility
Step
12:
Invite
registrar/auditor
for
a
pre-­‐assessment
Step
13:
Gain
registration
Step
14:
Continual
assessment
Conclusion

4. 4
Guide
for
implementing
AS9100
Rev
C
Management
Responsibilities
Step
1:
Determine
which
Quality
standard
to
adopted
This
is
a
strategic
decision
to
be
taken
by
senior
management.
One
should
not
seek
certification
for
the
sake
of
getting
it.
Understand
how
this
will
help
you
in
a
long
run.
AS9100
is
necessity
if
you
are
planning
to
enter
aerospace
&
defence
industry
or
space
industry.
ISO9001
is
just
70%
of
AS9100.
Let
me
give
you
a
brief
introduction
about
various
types
of
Certification
you
can
go
ahead.
1.
ISO9001:
is
a
quality
standard
maintained
by
the
International
Organization
for
Standardization
(ISO)
and
is
administered
by
accreditation
and
certification
bodies
like
PRI
Registrar.
The
rules
are
updated
periodically
to
accommodate
changes
in
the
business
environment.
Some
of
the
requirements
include:
• Procedures
that
cover
all
key
practices
in
the
business
• Monitoring
those
procedures
to
ensure
effectiveness
• Keeping
adequate
records
• Checking
output
for
defects,
and
implementing
corrective
actions
as
needed
to
Prevent
recurrence
if
defects
are
found
• Periodic
review
of
the
overall
quality
management
system
and
the
processes
within
the
system
to
measure
effectiveness
• Implementing
a
continuous
improvement
program
When
an
organization
is
certified
and
found
to
be
in
conformance
with
ISO
9001
that
organization
may
publicly
state
that
it
is
"ISO
9001
certified"
or
"ISO
9001
registered".
Certification
to
an
ISO
9001
quality
standard
does
not
guarantee
quality
of
end
products
and
services;
however,
it
certifies
that
formalized
business
processes
are
being
applied.
Although
the
ISO
9001
quality
standard
originated
in
manufacturing,
it
can
be
applied
to
a
variety
of
products,
not
just
physical
objects,
but
products
such
as
services
or
software.

5. Guide
for
implementing
AS9100
Rev
C
5
2.
AS9100:
is
an
aerospace
standard
based
on
the
ISO
9001
quality
system
requirements.
AS9100
takes
the
ISO
9001
requirements
and
supplements
them
with
additional
quality
system
requirements,
which
are
established
by
the
aerospace
industry
in
order
to
satisfy
DOD,
NASA
and
FAA
quality
requirements.
The
intent
of
AS9100
is
to
establish
a
single
quality
management
system
for
use
within
the
aerospace
industry.
The
standard
was
developed
by
Working
Group
11
of
ISO
TC20
and
was
supported
by
the
International
Aerospace
Quality
Group
(IAQG).
The
official
title
of
AS9100
is
"AS9100
Quality
Management
Systems
-­‐
Requirements
for
Aviation,
Space
and
Defense
Organizations".
The
AS9100
standard
is
recognized
worldwide,
however,
participating
countries
can
use
their
own
numbering
conventions.
For
example,
the
standard
was
released
as
EN9100
in
Europe.
Regardless
of
the
number,
the
standard
should
be
identical
in
content.
The
industry
has
moved
toward
requiring
their
subcontractors
and
suppliers
to
be
AS9100
compliant
and/or
certified.
By
becoming
registered
to
AS9100
or
by
conforming
to
the
standard,
suppliers
can
gain
a
competitive
advantage
and
benefit
from
the
improved
processes
and
continuous
improvement
that
is
the
foundation
of
ISO
9001
certified
Quality
Management
Systems.
3.
AS9110:
The
AS9110
aerospace
standard
is
based
on
AS9100
but
adds
specific
requirements
that
are
critical
for
the
maintenance
of
commercial,
private,
and
military
aircrafts.
This
standard
defines
the
quality
system
requirements
based
on
AS9100
and
includes
additional
criteria
for
maintenance
repair
and
overhaul
facilities
(MRO's)
serving
the
aircraft
industry.
The
AS9110
standard
was
published
by
SAE
International.
It
is
formally
titled
"AS9110
Quality
Maintenance
Systems
-­‐
Aerospace
-­‐
Requirements
for
Maintenance
Organizations"
by
the
Americas
Aerospace
Quality
Group
(AAQG).
The
prime
candidates
to
seek
certification
to
the
AS9110
standard
are
FAA
145
certified
repair
stations.
Those
seeking
Parts
Manufacturing
Approval
(PMA)
from
the
FAA
to
manufacture
aircraft
parts
and

6. 6
Guide
for
implementing
AS9100
Rev
C
components
are
also
likely
to
seek
AS9110
certification.
Some
of
the
areas
of
emphasis
in
the
AS9110
standard
include
detecting
and
preventing
counterfeit
and
suspect
unapproved
parts,
human
factors
(recognizing
human
factors
that
affect
workers),
safety
management
systems,
technical
data,
project
management
and
risk
management.
4.
AS9120:
Quality
Management
Systems
-­‐
Requirements
for
Aviation,
Space
and
Defense
Distributors."
is
an
aerospace
standard
based
on
AS9100
that
adds
specific
requirements
that
are
relevant
for
stockiest
or
pass-­‐through
distributors
for
the
aerospace
industry.
SAE
International
published
the
AS9120
standard.
This
standard
addresses
chain
of
custody,
traceability,
control
and
availability
of
records.
AS9120
would
be
applicable
for
organizations
that
resell,
distribute,
and
warehouse
parts
found
in
aircraft
and
other
aerospace
components.
The
standard
is
not
applicable
to
value-­‐added
distributors
due
to
customer-­‐product
changes
nor
is
it
intended
for
organizations
that
rework
or
repair
products.
Organizations
that
perform
work
that
affect
or
could
affect
product
characteristics
or
conformity
should
use
AS9100
or
another
general
quality
management
system
standard.
AS9120
is
based
on
ISO
9001
but
it
includes
nearly
100
additional
requirements
specific
to
aerospace
distributors.
AS9120
provides
suppliers
with
a
comprehensive
quality
system
focused
on
areas
directly
impacting
product
safety
and
reliability.
Some
of
the
areas
covered
in
AS9120
include
splitting
(specific
requirements
for
batch
and
lot
splitting),
control
of
records,
traceability
(tracking
from
receipt
of
product
to
delivery),
and
evidence
of
conformance
(distributors
must
meet
document
specifications).
5.
AS9003
The
intent
of
the
AS9003,
Inspection
and
Test
Quality
System;
is
to
ensure
that
the
inspection,
conformity
and
airworthiness
of
products
are
maintained.
The
AS9003
standard
contains
the
minimum
requirements
for
an
Inspection
and
Test
Quality
System
and
was
intended
for
use
by
small
build/machine
to
print
organizations.
A
quality
system
structured
to
include
the

7. Guide
for
implementing
AS9100
Rev
C
7
AS9003
requirements
provides
the
supplier
with
a
system
that
defines
activities
necessary
to
support
product
integrity
such
as:
1. Management
Responsibility
2. Documentation
of
the
Quality
System
3. Controlled
Contract
Review
and
communication
of
requirements
to
production
4. Document
and
Data
Control
5. Purchasing:
Guidelines
for
choosing
6. Control
of
Customer
Supplier
Product,
tooling
and
raw
materials
7. Product
Identification
and
Traceability
8. Process
Control
-­‐
Methods
for
controlling
manufacturing/build
processes
9. Inspection
and
Testing,
In-­‐process,
Final
Inspections,
Test
and
the
associated
documentation
of
status
and
results
10. Control
of
Inspection,
Measuring
and
Test
Equipment
11. Control
of
Nonconforming
Product
12. Corrective
Action
processes
13. Handling,
Storage,
Packaging,
Preservation
and
Delivery
14. Control
of
Records
-­‐
Internal
Quality
Audits
to
monitor
your
system
15. Training
#
OASIS
Database:
The
OASIS
database
is
a
product
of
the
International
Aerospace
Quality
Group
(IAQG).
OASIS
houses
supplier
and
audit
assessment
data
for
all
companies
who
hold
an
accredited
certification
in
any
of
the
AQMS
series
of
Standards
(i.e.
-­‐
AS9100,
AS9110
and
AS9120).
The
IAQG
has
set
firm
requirements
regarding
the
inclusion
of
aerospace
certified
suppliers
in
the
OASIS
database.
Simply
put,
it
is
not
optional
-­‐
if
you
hold
an
accredited
certificate
to
AS9100,
AS9110
or
AS9120
-­‐
you
must
be
entered
into
the
OASIS
database.
SAE
International
document
AS9104
details
the
Certification
Bodies'
requirements
for
Aerospace
Certification
Programs.
We
are
bound
by
these
requirements
as
stated
on
our
aerospace
certificates,
"The
audit
was
conducted
in
accordance
with
the
requirements
of
SAE
AS9104
Rev.
A."
(Reference
SAE
AS9104
-­‐
Requirements
for
Aerospace
Quality
Management
System
Certification
/
Registrations
Programs).

8. 8
Guide
for
implementing
AS9100
Rev
C
Additionally,
any
supplier
listed
in
the
OASIS
database
must
set
someone
up
as
the
OASIS
Administrator.
This
designated
person
will
be
the
contact
point
with
regards
to
OASIS,
and
is
responsible
for
maintaining
accurate
supplier
data
in
the
system
(i.e.
-­‐
supplier
name,
address,
etc.).
This
person
is
also
the
only
contact
who
can
grant
access
to
view
pertinent
audit
assessment
details.
An
OASIS
user
cannot
access
audit
data
without
first
gaining
permission
from
the
suppliers'
listed
OASIS
administrator.
If
any
aerospace
certified
supplier
refuses
to
be
a
part
of
OASIS,
or
refuses
to
set
up
an
OASIS
administrator,
Certification
Bodies
are
required
by
the
IAQG
to
revoke
the
certificate
of
registration.
The
very
first
step
to
get
involved
with
OASIS
is
to
become
a
registered
user.
Anyone
can
become
a
registered
user,
and
you
do
not
need
to
hold
an
active
aerospace
certificate
in
order
to
become
a
user.
Visit
the
OASIS
database
at
http://www.iaqg.org/oasis
and
click
on
the
"Register
to
get
Access"
link.
In
Brief:
Sl
No.
Standard
Applicable
Industries
1
ISO9001
All
manufacturing
and
any
industry
from
service
to
product
based.
2.
AS9100
Specifically
for
organizations
developing,
manufacturing
and
selling
aerospace
equipments/components.
3.
AS9110
For
organizations
into
maintenance
&
repairs
(MRO)
of
Aircrafts.
4.
AS9120
For
Organizations
which
sell
&
stock
airborne
equipment’s
or
components
such
as
stockiest
&
distributers.
5
AS9003
For
organizations
which
provide
third
party
inspection
or
testing
facilities
for
airborne
equipments/components.
One
has
to
be
prepared
for
the
cost
of
quality,
which
will
be
high
during
initial
phase
of
3-­‐4
years
but
after
that
you
can
reap
the
benefits
in
the
long
run.
But
if

9. Guide
for
implementing
AS9100
Rev
C
9
you
are
into
Aerospace
&
Defence
/Space
business,
AS9100
is
critical
for
your
future.
For
implementing
AS9100
senior
management
should
support
its
Quality
Management
Department
to
fullest.
Initially
things
will
be
difficult
to
implement
but
perseverance
pays
off,
you
have
to
understand
“Rome
was
not
built
in
a
Day”
and
so
is
for
AS9100
implementation.
Unless
you
adhere
it
from
within
the
organization
its
difficult
to
maintain.
Step
2:
Assemble
the
Team
&
Purchase
the
Standard
The
road
to
implementing
starts
with
assembling
the
right
team.
Depending
upon
your
organization,
you
can
make
an
official
of
a
rank
DGM/AVP/Manager
to
head
of
team,
the
team
should
be
cross-­‐functional
with
employees
representing
each
department.
Head
of
team
should
have
first
hand
experience
of
implementing
AS9100
and
has
good
personal
skills.
Provide
him
necessary
resources.
Try
to
visit
the
companies,
which
have
already
established
AS9100
certified
systems,
have
a
look
on
their
processes.
Next
thing
is
to
purchase
the
Standard,
and
to
select
a
registrar
such
as
UL
etc.
Consult
the
registrar
whenever
it
is
required
so.
Give
enough
time
for
the
team
to
understand
the
standard,
the
standard
itself
is
vast
and
requires
lots
of
time
to
read
all
the
clauses
and
requirements.
Step
3:
Set
targets
and
periodically
review
them
Set
the
targets
for
Implementation
team
and
review
them
periodically
to
ensure
that
we
are
on
right
track
and
this
will
also
help
the
team
to
put
forward
their
requirements
or
suggestions
where
senior
management
can
help
them.
I
suggest
we
should
apply
project
management
concept
while
implementing
AS9100
Rev
C.
Lets
define:
Project:
AS9100
Rev
C
Implementation

10. 10
Guide
for
implementing
AS9100
Rev
C
First
we
should
use
PPM
(Project
Priority
Matrix)
to
define
our
utmost
priorities
in
this
project.
For
example
in
given
illustration
of
PPM
maximum
priority
is
given
to
performance
then
comes
time
and
finally
cost/Budget.
This
means
we
want
that
we
have
to
by
all
means
improve
systems
to
implement
AS
9100
Rev
C
and
it
may
take
a
little
bit
more
time
and
we
want
to
reduce
the
cost
by
saving
more,
provided
we
are
successful
in
implementing
our
project
AS9100
Rev
C.
Above
is
the
PERT
Activity
Diagram,
is
gives
the
activities
and
gives
the
most
effective
time
for
each
activity.
You
can
refer
the
illustration
in
figure,
which
defines
this
PERT
Network
Diagram.
A
(5)
B
(5)
C
(5)
D
(4)
E
(1)
F
(5)
G
(5)
H
(5)
I
(5)
J
(5)
K(3)
L(6)
M(6)
N(6)
O(6)
P(5)
Q(5)
R(4)
S(5)
T(5)
Constrain
Accept
Enhance
Time
✖
✔
✖
Cost/Budget
✖
✖
✔
Performance
✔
✖
✖

11. Guide
for
implementing
AS9100
Rev
C
11
Activity Task
Optimistic(
Time((To)
Pessimistic(
Time((Tp)
Most(Likely(
time((Tm)
Effective(
Time((Te)
Precedence(
Activity
A
Derermine Quality Standard to be
implemented 4 6 5 5 NULL
B
Assemble Team,Purchase Standard &
Select Registrar 4 6 5 5 A
C Recruit Quality Manager 4 6 5 5 B
D Assemble Team 3 5 4 4 C
E
Purchase Standard &Select
Registrar 0.5 1.5 1 1 D
F
Set Targets & Schedule Periodical
Reviews 4 6 5 5 E
G Review support Literature &Software 4 6 5 5 F
H Make Strategy 4 6 5 5 G
I Plan The Implementation 4 6 5 5 H
J Draft QMSP 4 6 5 5 I
K Training 2 4 3 3 J
L Prepare Level 2,3& 4 documents 4 8 6 6 K
M Send to QM department for Checking 4 8 6 6 L
N
Upgrade documents & Get them
approved 4 8 6 6 M
O Implement & Adhere to QMS 4 8 6 6 N
P Internal Assesment 4 6 5 5 O
Q
Invite Registrar/Auditor for Pre-
Assesment 4 6 5 5 P
R Implement feedback of Auditors 3 5 4 4 Q
S Registration Assessment 4 6 5 5 R
T
Implement suggestions &
Improvements of Auditor 4 6 5 5 S
96TotalJExpectedJImplimentationJTimeJinJDays
Above
illustration
gives
the
details
for
PERT
Activity
Diagram.
Implementation
Team
Responsibilities
Step
4:
Review
support
literature
and
software
provided
with
Standard
There
are
a
large
number
of
tools
that
can
be
very
helpful
at
every
stage
of
the
process
of
implementing
AS9100
there
are
many
suggested
formats,
which
we
have
to
modify
as
per
requirement.
We
have
to
segregate
the
formats
which
we
can
use
as
it
is
and
on
which
we
have
to
do
some
modification.
Step
5:
Make
a
strategy
I
again
will
stress,
process
towards
implementing
AS9100
must
start
with
commitment
from
top
management.
As
part
of
this,
an
organizational
strategy
should
be
developed,
and
an
implementation
by
the
team
formed.
Think
of
constrains
which
you
are
going
to
face
and
find
the
solutions
before

12. 12
Guide
for
implementing
AS9100
Rev
C
hand.
Its
better
to
spend
more
time
in
planning
and
perfecting
the
things
than
rush
into
implementation
phase
and
mess
up
the
things.
Step
6:
Plan
the
implementation
AS9100 Rev C Implementation
XYZ Today's Date: Thursday
(vertical red line)
Project Lead:
Start Date: Monday
[42] First Day of Week (Mon=2): 2
WBS Tasks
Task
Lead Start End
Duration(Days)
%Complete
WorkingDays
DaysComplete
DaysRemaining
1
Management
Responsiblities CEO 1/2/12 1/25/12 24 100% 18 24 0
1.1
Derermine Quality
Standard to be
implemented 1/2/12 1/6/12 5 100% 5 5 0
1.2
Assemble Team,Purchase
Standard & Select
Registrar 1/7/12 1/11/12 5 100% 3 5 0
1.2.1
Recruit Quality
Manager 1/12/12 1/16/12 5 100% 3 5 0
1.2.2 Assemble Team 1/17/12 1/20/12 4 100% 4 4 0
1.2.3
Purchase Standard
&Select Registrar 1/21/12 1/21/12 1 100%
1.3
Set Targets & Schedule
Periodical Reviews 1/21/12 1/25/12 5 100% 5 5 0
2
Implementation Team
Responsiblities Manager Quality 2/2/12 2/24/12 23 100% 17 23 0
2.1
Review support Literature
&Software 2/2/12 2/6/12 5 100% 3 5 0
2.2 Make Strategy 2/7/12 2/11/12 5 100% 4 5 0
2.3 Plan The Implementation 2/13/12 2/17/12 5 100% 5 5 0
2.4 Draft QMSP 2/20/12 2/24/12 5 100% 5 5 0
2.5 Training 2/24/12 2/28/2012 3 100% 4 3 0
3
Departmental
Responsiblities Demartmantal Heads 3/1/12 3/28/12 28 100% 20 28 0
3.1
Prepare Level 2,3& 4
documents 3/1/12 3/6/12 6 100% 4 6 0
3.2
Send to QM department for
Checking 3/9/12 3/14/12 6 100% 4 6 0
3.3
Upgrade documents & Get
them approved 3/16/12 3/21/12 6 100% 4 6 0
3.4
Implement & Adhere to
QMS 3/23/12 3/28/12 6 100% 4 6 0
4 QM Responsibility Quality Manager 4/2/12 4/27/12 26 100% 20 26 0
4.1 Internal Assesment 4/2/12 4/6/12 5 100% 5 5 0
4.2
Invite Registrar/Auditor for
Pre-Assesment 4/7/12 4/11/12 5 100% 3 5 0
4.3
Implement feedback of
Auditors 4/12/12 4/15/12 4 100% 4 4 0
4.4 Registration Assessment 4/17/12 4/21/12 5 100% 4 5 0
4.5
Implement suggestions &
Improvements of Auditor 4/23/12 4/27/12 5 100% 5 5 0
24/11/11
30-Jan-12
06-Feb-12
02-Jan-12
09-Jan-12
16-Jan-12
23-Jan-12
27-Feb-12
05-Mar-12
12-Mar-12
19-Mar-12
16-Apr-12
23-Apr-12
30-Apr-12
02/01/12
Ashish Jude Michael
13-Feb-12
26-Mar-12
02-Apr-12
09-Apr-12
20-Feb-12
Use
the
scheduling
tools
as
Gantt
chart
to
schedule
the
implementation.
Better
to
go
through
modular
approach.
Which
means
implement
in
phases.
First
concentrate
on
management
Responsibilities
then
comes
Implementation
Team
Responsibilities
next
comes
departmental
responsibilities
and
finally
the
Quality
Management
Responsibilities
in
last
phase.
In
the
above
figure
I
have
shown
an
example
of
scheduling
of
activities
for
AS9100
implementation.
Once
Implementation
plan
is
ready
its
time
to
start
documentation.
But
first
of
all
QMSP
(Quality
Management
System
Procedure)
should
be
drafted
before
going
into
department
level.

13. Guide
for
implementing
AS9100
Rev
C
13
Step
7:
Documentation
In
AS9100
we
generally
follow
four
levels
of
documentation.
1. Level
1:
An
Organizational
level
Quality
Manual:
We
can
call
it
a
QMSP
(Quality
Management
System
Procedure).
If
it
is
too
big
you
can
make
it
in
volumes.
It
is
a
controlled
copy,
and
must
clearly
define
the
Major
Quality
Procedures
followed
by
each
department
in
an
organization.
It’s
the
responsibility
of
Head
of
Implementation
of
AS9100
team
to
get
inputs
from
the
department
heads
and
formulate.
Its
like
a
“Master
document
for
the
QMS
(Quality
Management
System)”.
It
should
contain
the
generalized
procedures
and
formats
such
as
CA/PA
(Corrective
Action
/Preventive),
Engineering
Change
Request
(ECR),
Approved
Deviation,
Process
Improvement,
Document
Upgrading
Requirement
etc.
We
should
also
give
details
about
the
yearly
cycles
of
periodic
assessments
both
internal
and
external.
2.
Level
2:
Department
level
Quality
Documents:
This
includes
the
Turtle
Charts;
Risk
Mitigation
plans
for
each
department.
Turtle
chart
is
a
one-­‐page
document,
which
defines
the
all
the
activities
in
a
department
as
process.
There
are
inputs/Outputs,
Process,
Targets,
Suppliers,
and

14. 14
Guide
for
implementing
AS9100
Rev
C
Customers
etc.
OTD
(On
Time
Delivery)
and
Risk
Mitigation
Plan
are
the
two
important
parameters,
which
are
specially
focused
in
AS9100
Rev
C.
Process'Name:' Process'Owner:'
Cri1cal'Success'Factors:' Start'event:'
End'Event:'
Process'Input'
'
'
'
'
'
Resources/material'
(with'what?)'
Process'personnel'
(with'whom?)'
Interfaces'for'
input'
'
'
'
'
'
'
'
Supplier'for'
process'/'
Previous'
process'
Process'indicators'
(how'many?)'
Process'objec1ves'/'
Purpose'
Process:'
'''''''''Process'steps/main'ac1vi1es'
BLANK PROCESS TURTLE DIAGRAM
Interfaces'for'
Output'
'
'
'
'
'
'
'
Process'
Output'
'
'
'
' Customer'of''
process'/'
Next'process'
TOOL''which'can'help'in'defining'the'process'as'per'Rev.C'and'a'tool'for'conduc1ng'internal'audit'
SWOT'
Analysis'
'
Process'
Improvement'
'
Reference'Documents'(how?)'
'
'
Process'map' Notes'
How?%
How$is$this$process$controlled,$including$the$use$of$
procedures,$work$instruc5ons,$and$methods?$
Control$of$produc5on$and$Service$provision$(7.5.1)$
Control$of$Produc5on$Process$changes$($7.5.1.2)$
Control$of$Produc5on$Equipment,$Tools$and$
SoGware$Programes(7.5.1.3)$
Nonconforming$product$procedure$($8.3)$
Document$contorl/records(4.2.3/4)$
%%%%%%%%%%%%%%%%What%Results%?%
$Measurements/analysis$of$the$product$of$
$this$process$and$of$this$process$effec5veness$
Monitoring$and$measurement$$
of$product$($8.2.4)$
Customer$Sa5sfac5on$(8.2.1)$
Monitoring$and$measurement$of$processes$(8.2.3)$
Analysis$of$data$(8.4)$$
with%What%?%
What%are%the%Materials,%Equipment%and%other%resources%needed%by%
this%process?%
Plant$and$machinery$(6.3)$
Process$equipment$($6.3)$
Measuring$equipment$(7.6)$
Packaging$Storage$(7.5.5)$
Customer$Property$(7.5.4)$
Transporta5on$of$materials$in$this$process$(6.3)$
Raw$materials$needed$in$this$process($7.4)$
with%%Who%?%
Who% owns %this%process,%who%works%in%this%process,%
and%who%directly%assists%this%process?%
%
Responsibility$and$authority$($5.5.1)$
Competence$criteria$($6.2.1)$
Training$records$($6.2.2)$
Training$effec5veness$($6.2.2)$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$
$
(Who$Helps?$
Departments$and$
Individuals)$
IT$
HR$
Logis5cs$$
Sales$
Quality$$
Maintenance$$
Personnel$
Inputs%
What%is%the%need%the%customer%of%this%process%
has%and%what%are%the%requirements%to%meet%
that%need?%
Product$needs$to$be$produced$according$to:$
Customer$requirements$($7.2.1)$
Statutory/Regulatory$
Requirements$($7.2.1)$
Organiza5onal$requirements$($7.2.1)$
Outputs%
$
The$ customer s$ need$ is$ met$ at$ the$
characteris5c$level.$
A$sa5sfied$customer$($8.2.1)$
Receives$product$from$the$process$that$
conforms$ to$ the$ requirements$ in$ the$
input$($7.2.1)$
Process%%
(Suppor5ng$Processes)$
$
Computer$equipment$
support$processes$$
Training$
Hiring/Firing$
Purchasing$Processes$
Materials$movement$
Processes$Inspec5on$
Calibra5ng$
$
The$term$procedure$and$process'are$not$necessarily$synonymous.$A$$procedure$may$be$one$way$to$describe$a$$process$in$text;$however,$most$organiza5ons$have$many$more$
processes$than$the$procedures$required$by$the$standard.$

15. Guide
for
implementing
AS9100
Rev
C
15
The
beauty
of
turtle
diagram
is
that
you
can
see
the
overall
holistic
view
of
a
department
and
can
be
represented
on
a
single
sheet
of
paper
concise
,
complete
and
crisp.
We
can
define
entire
department
as
a
process,
we
can
clearly
see
in
the
above
illustration.
A
unique
reference
number
should
link
all
Level
2
documents
to
QMSP,
which
reflect
the
revision
number
and
date
of
revision.
3. Level
3
Documents:
Process
Definition
Documents
(PDDs),
Standard
Operating
Procedures
(SOPs),Work
Instructions
(WI):
These
are
basically
the
set
of
documents,
which
are
used
by
operators
to
perform
various
processes.
These
are
made
&
controlled
by
related
section
head
or
process
engineer
but
approved
by
Quality
Management
Department.
4. Level
4
Documents:
Checklists,
Process
Validation
Reports
&
PRCs
(Product
Route
Card)/OARCs
(Operation
Analysis
Route
Card):
These
are
mostly
the
records
maintained
to
keep
control
on
product/process
quality
and
traceability.
Traceability
is
very
important
parameters,
which
is
required
for
Aerospace
Products
as
they
are
very
critical.
By
looking
a
batch
number
or
SL.
No
of
a
product
we
should
be
able
to
find
all
related
checklist,
PRC
(Product
Route
card)/OARC
(Operation
Analysis
Route
Card)
and
reports
with
details
as
who
was
the
operator
and
who
was
the
inspector
responsible.
The
difference
between
PRC
&
OARC
is
that
PRC
only
records
the
details
of
the
precedence
activities
done
on
project
and
by
whom.
Where
else
OARC
is
an
ERP
generated
document,
which
gives
instructions
and
also
records
the
details
of
the
precedence
activities
done
on
project
and
by
whom.

16. 16
Guide
for
implementing
AS9100
Rev
C
Above
illustration
shows
a
sample
checklist,
which
fulfills
all
requirements
of
AS9100
Rev
C.
All
level
3
&
4
documents
needed
to
be
upgraded
as
and
when
the
product
requirement
change.
All
these
documents
are
to
be
linked
to
Level
3
&
4
documents
by
a
unique
reference
number,
which
reflect
the
revision
number
and
date
of
revision.
All
Level
1,
2
,3
&
4
documents
are
controlled
copies
and
are
needed
to
be
controlled
by
designated
authority
that
will
be
responsible
for
them.
Also
they
are
auditable
and
the
documents
are
to
be
retained
for
a
minimum
period
of
5
years
or
as
defined
in
P.O.
(Production
Order)
terms
by
customer
which
ever
is
minimum.
All
documents
needed
to
be
complete
and
ensured
that
no
loopholes
are
left.
It
is
said
for
AS9100
documentation
“They
say
what
you
do
and
you
do
what
they
say”.
QUALITY(MANAGEMENT/_____(
((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((Ref:(No:(12345Crimp/CKL/V(0((
(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((Date:(
Crimping(Tool(Part(No:. ( ( (Tool(Sl.No.(
Locater(PN: ( ( ( (Locater(PosiLon:(
Contact(PN: ( ( ( (Wire(Size(
UTM(Asset(No:. ( ( (((((((((((((((((((((((((((((((((((((UTM(CalibraLon(Date:(
(
Procedure:(
1.Annexure(1((Crimping(Process(validaLon(((Ref(PQRS/ABC/QP/IXYZVO:(dt:(
2.(Five(samples(of(plug(to(be(crimped.(
3.(Five(samples((of(socket(pins(to(be(crimped.(
4.(Every(week(on(Monday(this(acLvity(to(be(done.(
5.(A^er(Samples(are(collected(they(are(to(be(sent(to(MTD,(QA(for(pull(test(with(SAP(request.(
6.(Collect(the(reports(from(MTD,QA(and(verify(if(they(are(meeLng(the(requirements(and(collect(the(samples.(
7.(If(reading(are(meeLng(proceed(to(next(step(els(go(to(step(1(and(repeat(the(acLvity(unless(required(results(are(achieved.(
8.(Visually(inspect(the(samples(before(pull(test(and(mark(them(with(SL.Nos.(
9.Insepct(the(samples(a^er(pull(test(and(fill(Table(1.(
( Sl#
No. Sample#Details Visual#Inspec4on#
before#pull#test
Type#of#separa4ons#
observed. Pull force Applied
1 Plug(pin(sample(1
2 Plug(pin(sample(2
3 Plug(pin(sample(3
4 Plug(pin(sample(4
5 Plug(pin(sample(5
6 Socket(pin(sample(1
7 Socket(pin(sample(2
8 Socket(pin(sample(3
9 Socket(pin(sample(4
10 Socket(pin(sample(5
Type#of#separa4on Deno4on
Slip((Pull(out) A
Conductor(broken(in(crimp(area. B
Contact(broken(in(crimp(area. C
Conductor(broken(outside(crimp(area. D
Contact(broken(outside((crimp(area. E
Any(other(defect((Specify(in(Remarks) F
Remarks#
Inspector(
Name:(
Staff(No(
Operator(
Name:(
Staff(No:(

17. Guide
for
implementing
AS9100
Rev
C
17
Step
8:
Draft
QMSP
(Level
1
Document)
Take
help
of
department
heads
and
give
responsibility
to
each
related
team
member
of
related
department
to
formulate
module
for
his/her
department.
It’s
the
responsibility
of
Team
Lead/Head
to
verify
and
compile
the
QMSP
as
a
complete
document.
Once
QMSP
is
finalized
discuss
it
with
the
registrar/auditor
and
take
his
feedback.
Step
9:
Training
Plan
for
awareness
training
for
the
entire
organization,
better
to
be
done
in
modules
such
as
for
QM,
Production
Control,
Engineering,
Manufacturing,
Marketing,
Material
management,
Plant
Maintenance,
Finance,
Purchase,
Sub-­‐
contract
&
Human
Resource
etc.
Better
keep
QM
all
levels
(1,2
&3)
documents
ready
so
that
they
may
use
them
as
sample
documents
and
related
persons
can
make
their
own
level
2
&
3
level
documents.
Step
10:
Level
2
,3
&4
level
Documents
These
documents
are
to
be
prepared
by
related
department
heads
&
process/line
in-­‐charge
or
engineers.
It
is
responsibility
of
the
representative
of
department
in
AS9100
implementation
team
to
scrutinize
and
help
in
development
of
these
documents.
Step
11:
Implement
your
Quality
Management
System
Once
the
foundations
have
been
laid,
you
should
implement
your
quality
management
system.
Its
important
that
you
make
the
process
owners
and
the
operators
believe
in
the
new
system.
They
should
be
trained
and
told
how
it
will
beneficial
for
them.
AS9100
requires
lots
of
records
to
me
maintain
and
the
operators
and
process
owners
have
lot
of
Inertia
to
do.
They
think
it
is
done
to
keep
check
on
them
and
will
be
used
as
evidence
against
them.

18. 18
Guide
for
implementing
AS9100
Rev
C
We
should
make
them
very
clear
that
it
is
only
for
process
improvement.
AS9100
gives
us
process
approach.
We
should
always
remember
no
operator
or
process
owner
commits
a
mistake
deliberately
is
always
a
loophole
in
process,
which
has
made
him
commit
mistake,
so
make
process
perfect.
If
you
can
understand
the
above
statement
you
got
the
real
understanding
of
AS9100
that
its
never
about
product/people
its
only
about
process
you
follow.
Step
12:
Invite
registrar/auditor
for
a
pre-­‐assessment
A
pre-­‐assessment
normally
takes
place
about
6
weeks
into
the
implementation
of
the
quality
system.
The
purpose
of
the
pre-­‐assessment
is
to
identify
areas
where
you
may
not
be
operating
to
the
standard.
This
allows
you
to
correct
any
areas
of
concern
you
may
have
before
the
initial
assessment.
Take
their
feedback
and
implement.
Step
13:
Gain
registration
Once
the
preparation
and
implementation
has
been
completed,
registration
to
the
standard
can
take
place.
The
key
to
this
is
a
registration
assessment.
During
this
process,
the
registrar
will
comprehensively
review
your
management
system,
and
should
you
pass,
you
will
be
recommended
for
registration
and
be
awarded
your
certificate.
You
need
a
Management
Representative
on
behalf
of
senior
management
he
may
be
an
Additional
General
Manager/
COO.
Certification
allows
you
to
advertise
your
success
and
promote
your
business
and
its
commitment
to
quality
management.
Step
14:
Continual
assessment
Maintaining
your
registration
requires
only
that
you
continue
to
use
and
be
committed
to
your
quality
system.
This
will
be
periodically
checked
by
your
registrar
it
can
be
done
bi-­‐annually
or
annually.
But
number
of
man-­‐days
fixed
for
a
year
for
assessment
is
constant.

19. Guide
for
implementing
AS9100
Rev
C
19
Beside
that
you
need
to
do
minimum
of
two
internal
audits
as
per
the
schedule
or
frequency
defined
in
QMSP.
Once
you
are
certified
you
will
receive
a
score
and
you
should
always
try
to
improve
upon
the
score.
You
can
use
the
AS9100
certified
logo
and
show
the
entire
industry
about
your
capabilities.
Conclusion:
I
sincerely
hope
that
this
document
has
definitely
brought
some
clarity
about
the
process
of
implementing
AS9100
Rev
C
in
your
own
organizations,
cleared
some
apprehensions
about
AS9100
Rev
C.
One
thing
I
will
assure
you
that
if
you
implement
AS9100
Rev
C
and
make
the
install
systems
that
meet
the
requirement,
life
will
be
very
easy
for
you.
Initial
cost
of
implementation
can
be
a
bit
high
but
you
can
see
the
returns
within
5
years.
One
of
the
best
ways
to
maintain
AS9100
Rev
C
system
is
by
implementing
ERP
systems.
It
will
reduce
your
record
keeping
and
standardize
the
processes
as
well.
***

20. 20
Guide
for
implementing
AS9100
Rev
C
Compiled
By:
MBA from IIM Shillong with 5 Years of Experience in
Aerospace /Electronics Industry (Quality & Production)
ASHISH JUDE MICHAEL
! 5 years of experience in Quality, Manufacturing & SCM
activities of Aerospace /Electronics Industry.
! One Year MBA in International Business from Indian
Institute Of Management, Shillong and a Mechanical
Engineering Graduate.
! Worked with companies such as Bharat Electronics Ltd, ITC
Ltd.
! Served clients such as Boeing, UTC, Indian Air Force, Indian
Navy.
! Worked on prestigious Light Combat Aircraft (LCA) Project
which is of national importance.
Skill Set:
TQM, AS9100, ISO14001,ISO9001,AS9102, 8D, SPSS, Mini-Tab, PPAP,FMEA,
GAP Analysis, APQP, RRCA, Quality Clinic, Project Management, Kaizen, LEAN
manufacturing, SPC, Vendor Management, Process Improvement, Poka-Yoke,
Benchmarking, FAI, Production Management, Cross Culture Team Management,
Negotiation Skills.