A Guide to Aerospace Compliance

Step-by-Step: AS9100 Internal Audit Process

1. Audit Planning

• Define audit scope, frequency, and responsibilities.
• Prioritize processes based on risk and criticality.
• Prepare an audit schedule for the year.

2. Preparing the Audit

Gather relevant documentation, such as:

• Quality Manual
• Procedures and work instructions
• Previous audits, nonconformities, and actions

Use an AS9100 internal audit checklist to guide consistency.

3. Conducting the Audit

• Interview process owners
• Review evidence and documentation
• Observe actual activities and controls
• Evaluate process performance against objectives

4. Documenting Audit Findings

Capture:

• Conformities and strengths
• Nonconformities (linked to specific AS9100 clauses)
• Opportunities for improvement

Use a standardized internal audit report template to record results.

5. Corrective Action Process

• Initiate Corrective Action Requests (CARs)
• Perform root cause analysis
• Implement and verify effectiveness of fixes

6. Management Review & Follow-Up

Audit results must be reviewed by leadership, and unresolved issues must be tracked and re-audited.

AS9100 Audit Checklist

An effective AS9100 audit checklist helps auditors stay aligned with AS9100 Rev D and ensures coverage of all relevant clauses. Your checklist should include:

• Organizational Context (Clause 4)
• Leadership and Quality Policy (Clause 5)
• Planning and Risk Management (Clause 6)
• Operational Control and Configuration Management (Clause 8)
• Performance Monitoring and Nonconformity (Clause 9 & 10)

Internal Audit Template

A practical internal audit template should include:

• Audit Plan (process, auditor, date, scope)
• Evidence/Observation Log
• Clause reference numbers
• Nonconformity log with severity
• Signoff and corrective action summary

This ensures that audits are traceable, repeatable, and audit-ready for external certification bodies.

How It Ties into ISO 19011 Audit Process

AS9100 internal audits should follow the principles of ISO 19011:2018, the international standard for auditing management systems. ISO 19011 emphasizes:

• Auditor competence and impartiality
• Risk-based audit planning
• Evidence-based conclusions
• Ethical conduct and confidentiality

Following ISO 19011 makes your audits stronger and more aligned with registrar expectations.

Aerospace QMS Audit Expectations

The aerospace QMS audit, internal or external, is stricter than many other industries. Auditors focus on:

• Risk-based thinking throughout operations
• Counterfeit part prevention
• Configuration management and traceability
• Supplier controls and tiered oversight
• Evidence of continual improvement and leadership engagement

A strong internal audit process ensures you’re ready for OASIS database registration and third-party certification audits.

Avoiding Common Mistakes

• Auditing your own department (violates objectivity)
• Skipping interviews or on-the-floor observation
• Not linking findings to customer impact or risks
• Ignoring follow-up on past issues

Tools to Make It Easier

Our upcoming IA9100 Preparedness Kit includes everything you need to pass your internal audit:

• Pre-formatted AS9100/IA9100 checklists
• Audit planning & reporting templates
• Editable forms for CARs, NCRs, and KPIs
• Physical binder + USB or DoD SAFE delivery
• Optional branding for your company

Conclusion

The AS9100 internal audit process isn’t just about compliance—it’s your organization’s best opportunity to identify problems before your customers or regulators do. By using the right checklists, templates, and audit approach, you can maintain certification, improve processes, and stay ahead of the competition.

Need help transitioning to the new IA9100 requirements? Download the free checklist below.