These changes, which became fully effective in 2025, fundamentally reshape how aerospace audits are conducted and managed.

What is AS9104 and Why It Matters

AS9104 is the backbone standard that governs how Certification Bodies (CBs) like KSQA conduct aerospace quality management system audits. 

While companies don't certify directly to AS9104, this standard determines how their AS9100, AS9110, and AS9120 certifications are audited and maintained. 

The 2022 revision represents the most significant overhaul since 2012, introducing substantial changes that affect audit planning, duration, and execution.

Major Changes Introduced by AS9104/1A:2022

1. Simplified Site Structure Classifications

Previous System: Organizations could be designated as Single Site, Multi-Site, Campus, Several Site, or Complex Structures.

New System: Only two classifications remain:

•        Single Site: All operations in the same geographical location (may include multiple buildings)

•        Multi-Site: Operations spread across different geographical locations

This simplification aligns with International Accreditation Forum (IAF) standards but may increase audit durations for organizations previously classified as "Campus" structures.

2. Enhanced Risk-Based Approach Through OCAP

The Organization Certification Analysis Process (OCAP) represents a revolutionary shift toward performance-based auditing. KSQA now evaluates six critical performance indicators to determine risk levels:

•        Organizational Complexity

•        Internal Audit Program Effectiveness

•        On-Time Delivery Performance

•        Product/Service Conformity Metrics

•        Customer Satisfaction Data

•        Historical PEAR (Process Effectiveness Assessment Report) Scores Based on this analysis, organizations receive a risk rating:

•        Low Risk: 10% reduction in audit duration

•        Medium Risk: No change in audit duration

•        High Risk: 10% increase in audit duration

The International Aerospace Quality Group (IAQG) estimates that approximately 85% of certified organizations will fall into the medium-risk category.

3. Standard Selection Alignment

AS9104/1A:2022 mandates that organizations must be certified to the appropriate standard based on their actual activities:

Organizations currently certified to an incorrect standard must transition to the appropriate certification.

4. Audit Duration and Planning Changes

Audit Planning Requirements: A minimum of 20% additional time must now be allocated for audit planning and reporting activities, standardizing what was previously handled inconsistently across certification bodies.

Potential Audit Time Reductions: Through risk analysis and performance-based processes, audit time can be reduced by up to 50% for qualifying organizations that demonstrate:

•        Completion of one full 3-year AQMS cycle

•        Consistent low/medium OCAP performance ratings

•        Robust internal audit programs compliant with ISO 19011

•        Internal auditor competency with TPAB-approved ASD Lead Auditor Course completion

•        Comprehensive ethics policies

•        No major nonconformities in the past 12 months

•        Six years without certification suspension

•        Documented customer satisfaction metrics

5. Remote Auditing Limitations

Current Status: AS9104/1A:2022 limits remote auditing to a maximum of 50% of total audit duration for organizations with physical sites. This marks the end of 100% remote auditing that was permitted during the COVID-19 pandemic.

Virtual Site Exception: Organizations operating as true "virtual sites" (non-physical locations where work is performed entirely through online environments) may continue with fully remote auditing, provided they meet IAF MD 1 criteria.

KSQA's Advantage: Our established virtual audit capabilities position us well to maximize the 50% remote auditing allowance, continuing to provide cost-effective certification services while maintaining compliance with the new requirements.

Implications for Small Aerospace Businesses

Cost Considerations

While some changes may increase audit complexity, the new performance-based approach offers significant opportunities for cost reduction. Small businesses that maintain strong quality systems and performance metrics can benefit from:

•        Reduced audit durations (up to 50% for exceptional performers)

•        More predictable audit scheduling

•        Enhanced focus on actual performance rather than documentation alone

Competitive Advantages

Organizations that adapt quickly to these new requirements can gain competitive advantages through:

•        Improved Customer Confidence: Enhanced focus on performance metrics directly translates to better customer satisfaction

•        Operational Excellence: The OCAP process encourages continuous improvement in key performance areas

•        Market Access: Proper standard alignment ensures access to appropriate market segments

How KSQA Supports Clients Through These Changes

As your certification partner, KSQA has implemented comprehensive measures to ensure smooth transitions:

1. Proactive Client Communication

We review each client's current certification structure and notify them of required changes, including:

•        Site structure redesignation

•        Standard alignment assessments

•        New documentation requirements

2. Technology-Enhanced Efficiency

Our automated online system continues to provide:

•        Real-time access to audit information

•        Rapid certificate issuance (7-14 days vs. industry standard of 30-45 days)

•        Transparent audit progress tracking

•        Direct auditor credential access

3. Risk-Optimized Audit Planning

KSQA's OCAP implementation focuses on:

•        Accurate performance data collection

•        Fair risk assessment based on documented evidence

•        Maximizing opportunities for audit time reductions

•        Supporting clients in maintaining low-risk profiles

4. Flexible Audit Delivery

We continue to leverage technology for cost-effective auditing:

•        Maximizing 50% remote audit capabilities where appropriate

•        Minimizing travel costs through strategic scheduling

•        Maintaining our low-cost business model for small businesses

Looking Ahead: Future Standards Evolution

The aerospace industry continues evolving toward the IA (International Aerospace) series standards. The upcoming IA9100 series, expected in 2027, will feature:

•        Unified international naming conventions

•        Enhanced cybersecurity requirements

•        Advanced Product Quality Planning (APQP) integration

•        Climate change and sustainability provisions  Improved alignment with ISO 9001 revisions

Preparing Your Organization for Success

To maximize benefits under the new AS9104/1A:2022 requirements:

1. Strengthen Internal Systems

•        Invest in robust internal audit programs

•        Implement comprehensive performance monitoring

•        Develop customer feedback collection systems

•        Establish clear process documentation

2. Focus on Performance Metrics

•        Track on-time delivery performance consistently

•        Monitor product/service conformity rates

•        Document customer satisfaction systematically

•        Address complaints promptly and effectively

3. Maintain Documentation Excellence

•        Ensure all required documentation is current and accurate

•        Establish systems for timely information submission

•        Keep performance data readily accessible

•        Maintain clear process interaction diagrams

4. Consider Strategic Partnerships

While KSQA doesn't provide consulting services, we can connect you with qualified aerospace consultants who can help optimize your quality management system for these new requirements.

Conclusion

The AS9104/1A:2022 updates represent a significant evolution in aerospace quality management system auditing. While these changes introduce new complexities, they also create opportunities for well-prepared organizations to reduce costs and demonstrate superior performance.

KSQA remains committed to our mission of making aerospace certification affordable and accessible for small businesses. Our technology-enhanced approach, combined with deep understanding of these new requirements, positions us to continue delivering exceptional value to our clients throughout this transition and beyond.

The future of aerospace quality management lies in performance-based assessment and continuous improvement. Organizations that embrace these principles today will be best positioned for success in tomorrow's increasingly competitive aerospace marketplace.

For questions about how these changes affect your specific certification or to schedule your next audit, contact KSQA at (775) 372-8348 or visit our website. Our experienced team is ready to help you navigate these changes while maintaining our commitment to transparent processes and expedited certificates.