Benefits Vs. Costs: Achieving The AS9100 Certification

Enhancing a job shop's competitive edge can be achieved through various strategies, including the adoption of new technology, workflow optimization, and effective customer communication. One specific way to stand out, especially in the aerospace industry, is to obtain an AS9100 certification. This certification, which outlines best practices for quality management, can lead to increased customer satisfaction, improved efficiency, and minimized irregularities. However, shops must also consider the significant costs involved, such as consultant fees, process changes, employee training, and ongoing post-certification expenses.

The competitive landscape for job shops is challenging but also filled with opportunities for those willing to innovate and adapt. Investing in advanced technology and automation systems, optimizing workflow and processes through lean manufacturing, using scheduling software, excelling in customer communications, and focusing on quality are all ways to improve your shop’s competitive edge.

AS9100 certification outlines best practices for product safety and performance in the aviation, space, and defense sectors. Completing AS9100 certification can significantly enhance your job shop's competitive edge but also comes with hefty costs. Let's conduct a cost-benefit analysis to determine if AS9100 is needed for your shop.

What is AS9100?

The AS9100 is a standard for implementing a Quality Management System (QMS) for use by aerospace industry users. Many companies within this industry prefer to work exclusively with AS9100-certified partners. Organizations responsible for the design or manufacture of aerospace products are required to adhere to the requirements.

AS9100D incorporates 75% of the ISO 9001: 2015 requirements, complemented by 105 additional requirements specific to aerospace manufacturing. These include critical aspects such as configuration management, risk management, project management, critical items, special requirements, and supplier scope of approval.

The certification establishes rigorous quality control processes to ensure that every product meets or exceeds customer expectations. Obtaining relevant certifications like ISO 9001 and AS9100 can demonstrate a commitment to quality and help attract new customers.

AS9100 benefits

• Increased customer satisfaction: One key indicator of QMS performance is customer satisfaction. The AS9100 will focus your attention on understanding customer feedback, leading to better customer satisfaction and more repeat business in the future. This involves gathering feedback, analyzing trends, and taking appropriate action to address issues.
• Improved efficiency: AS9100 is grounded in a process approach. It emphasizes understanding the interactions between these processes, products, and services. By adopting this comprehensive view of your entire business process, you can identify and eliminate inefficiencies within your system, leading to improved delivery of your products and services. Additionally, you can expect accurate, clear documentation.
• Minimized irregularities: Regularly measuring product quality will minimize risks, failures, and waste and ensure product and service consistency and traceability. Continuously increasing supply chain quality ensures that all components and materials meet the required standards, contributing to the overall quality of the final product.
• Becoming preferred: AS9100 certification helps build consumer trust and global recognition, signaling that the organization adheres to international quality standards. Gaining supplier preference ensures that your organization has access to high-quality materials and components essential for maintaining product standards. Gaining a competitive edge positions your organization favorably in the marketplace.

Your shop may require AS9100 certification. If so, you can look forward to reaping these benefits. However, let’s cover the costs of AS9100 certification as well.

AS9100 Costs

• Fiscal loss: AS9100 typically takes around four months for a small business. Certification costs for a 100-person company can be around $20,000, with a consultant starting at $20,000. One cost is for the certification, and another is for the consultant. Consultant costs vary based on their expertise and the scope of their services.
• Process changes: Documentation is a significant cost factor in AS9100 certification. Organizations must create, update, and maintain quality manuals, procedures, work instructions, and records. Producing, publishing, and distributing these documents can be costly, especially if major revisions are necessary.

Additionally, AS9100 certification often requires process adjustments to meet quality standards, which can lead to production downtime. Implementing AS9100-compliant processes may require new equipment, technology, and additional personnel training.

• Employee training: Another expense is employee training on AS9100 and the quality management system. This includes costs for training materials, trainers, and the time employees spend in training sessions.
• Post-certification costs: Organizations must fund ongoing surveillance audits and recertification. Failure to account for these ongoing expenses can jeopardize certification and result in lost business opportunities.

Software that can help

JobBOSS² has both a built-in quality module and advanced quality through uniPoint. With JobBOSS², you can track serial numbers from assembly start and link production data to each serial number. We provide comprehensive lot tracking for all board components. This adds visibility to your production, which will be needed when documenting the AS9100. We also have an open API for you to integrate with other technology so all your technology components can be interlinked. If needed, we can help with both the documentation creation and consulting in the preparation for the audit.