As aerospace standards evolve and customer requirements tighten, U.S. manufacturers must treat AS9100 certification as a strategic priority rather than a box to check. For aerospace suppliers, particularly those in Ohio and across the Midwest, preparing early and methodically is the best way to ensure success.
This guide explains how to prepare for an AS9100 audit in 2025, what an audit includes, and which steps every manufacturer should follow to achieve certification. It’s designed to help you navigate questions such as:
- How should our aerospace manufacturing plant prepare for an AS9100 audit?
- What does an AS9100 D audit include in 2025?
- Which steps does an Ohio manufacturer need to pass AS9100 certification?
Let’s walk through a complete AS9100 audit preparation checklist for U.S. manufacturers.
1. Understand the AS9100 D Standard
AS9100 D builds on ISO 9001 but adds requirements specific to the aviation, space, and defense industries. It focuses on risk management, configuration control, traceability, and product safety—core areas that define aerospace quality.
By 2025, auditors are expected to focus even more on supplier risk control, production traceability, and digital record management. That means plants should ensure their quality management systems (QMS) are not only compliant but also data-driven and transparent.
Understanding how AS9100 D aligns with customer requirements is the foundation of effective audit readiness.
2. Build Your AS9100 Audit Preparation Checklist
An “AS9100 audit preparation checklist manufacturing USA” should guide your team through every audit requirement. Key items include:
- Define the scope of your QMS—identify which sites, products, and customer contracts are covered.
- Perform a detailed gap analysis against AS9100 D clauses to find missing processes or documentation.
- Update documentation—QMS manual, procedures, work instructions, forms, and records must be current and controlled.
- Ensure leadership involvement—executive management should review metrics, quality objectives, and risk mitigation plans.
- Review supplier management systems—make sure requirements flow down to vendors and subcontractors.
- Strengthen risk management—document risk assessments and demonstrate how actions are tracked and verified.
- Verify corrective and preventive action (CAPA) systems—all past issues should show root cause, corrective action, and follow-up.
- Plan for internal audits and management review—ensure all internal audits are completed and reviewed prior to the external audit.
- Prepare audit logistics—schedule team availability, confirm document access, and brief staff on potential auditor questions.
Completing this checklist ensures every requirement is addressed before the certification body arrives.
3. How to Get AS9100 D Certified as a U.S. Aerospace Supplier
For manufacturers in the United States, the AS9100 D certification process typically follows these steps:
- Commit and plan. Leadership confirms certification goals, assigns a quality manager, and defines scope.
- Conduct a gap analysis. Compare existing systems against AS9100 D clauses to identify what’s missing.
- Implement improvements. Update documentation, train employees, and strengthen process controls.
- Perform internal audits. Verify every process is compliant and effective before engaging a certification body.
- Hold a management review. Review audit results, performance data, and readiness to proceed.
- Schedule the external audit. A certification body conducts a two-stage audit—Stage 1 (document review) and Stage 2 (on-site evaluation).
- Address nonconformities. If issues arise, submit corrective actions and evidence of resolution.
- Receive certification. Once requirements are met, the organization becomes AS9100 D certified.
- Maintain and improve. Conduct ongoing internal audits, management reviews, and surveillance audits.
For Ohio aerospace manufacturers, this process also helps demonstrate capability to regional aerospace primes and defense suppliers.
4. Internal Audit Best Practices for Ohio Manufacturing
Internal audits are one of the most powerful tools for AS9100 compliance. They confirm your system works before the certification audit. Here are best practices tailored for Ohio manufacturers:
- Plan internal audits annually. Prioritize high-risk processes such as machining, special processes, and supplier management.
- Ensure auditor independence. Internal auditors should not audit their own work areas.
- Use process-based auditing. Follow the flow of materials and information from start to finish rather than auditing by department.
- Focus on effectiveness. Don’t just confirm documentation—verify that processes achieve intended results.
- Close findings quickly. Every nonconformity should have root cause analysis, corrective action, and follow-up verification.
- Train auditors. Cross-train employees in AS9100 D requirements so they understand how their roles contribute to audit success.
By making internal audits a proactive, team-driven activity, manufacturers can uncover weaknesses early and build confidence before external review.
5. What an AS9100 D Audit Includes in 2025
An AS9100 D audit evaluates both documentation and implementation. In 2025, auditors are expected to place increased emphasis on risk, performance metrics, and digital traceability.
Stage 1: Documentation Review
Auditors review QMS documentation, records, and process maps to ensure completeness and compliance.
Stage 2: On-Site Assessment
The audit team visits the facility to interview employees, observe operations, verify traceability, and confirm process effectiveness. They may also examine supplier controls, calibration, training records, and risk mitigation.
Focus Areas for 2025
- Product safety and counterfeit part prevention
- Supply chain and external provider control
- Process performance metrics
- Evidence of continual improvement
- Management’s engagement in quality objectives
Auditors will issue findings as major, minor, or opportunities for improvement. Corrective actions must be completed before certification is finalized.
6. Steps Ohio Manufacturers Should Follow to Pass Certification
For aerospace manufacturers in Ohio, the path to certification success includes:
- Define QMS scope and identify applicable processes.
- Conduct a detailed readiness review with leadership.
- Close any open nonconformities from internal audits.
- Train employees on QMS awareness and customer requirements.
- Maintain organized, accessible records for auditors.
- Confirm calibration, traceability, and supplier approvals.
- Prepare key personnel for auditor interviews.
- Conduct a mock audit or third-party pre-assessment.
- Demonstrate measurable improvement since your last review.
These steps ensure both compliance and confidence when facing auditors.
7. Final Recommendations
Preparing for an AS9100 D audit in 2025 requires more than good documentation—it demands a culture of quality and risk-based thinking across every level of the organization.
By following a structured AS9100 audit preparation checklist, executing strong internal audits, and engaging leadership in continuous improvement, manufacturers can not only pass their audits but strengthen their competitive position in the aerospace market.
Contact Effective Quality Services today to start your AS9100 audit preparation plan and ensure your team is ready for certification success.
