Costly Errors in the AS9100 Certification Process and How Professional Guidance Prevents Them

Entering the aerospace industry is exciting but challenging. The AS9100 certification process proves your company meets strict quality and safety standards.

However, many organizations underestimate its complexity. Small mistakes in planning, documentation, or audits can quickly lead to delays, repeat findings, and higher costs.

In this blog, you will see common AS9100 mistakes, how they impact your business, and why professional guidance can help you succeed.

AS9100 Certification Errors: Where Companies Go Wrong

Many companies begin the AS9100 certification process assuming it is simply an extension of ISO 9001. In reality, AS9100 is a globally adopted aerospace standard, followed by more than 24,000 certified organizations worldwide.  (Source)

Because of this global scale and industry focus, relying on ISO-based assumptions often leads to ineffective preparation and multiple audit nonconformities.

Some Common Errors You Might Make Include:

• Relying on Outdated or Generic ISO Documents

Many organizations attempt to reuse existing ISO 9001 documents without adapting them for aerospace-specific requirements. AS9100 has additional clauses that are critical for aviation safety, such as risk assessment and traceability of materials. Without these updates, documentation may fail audits.

• Ignoring Aerospace-Specific Clauses

AS9100 includes requirements for supplier control, product safety, and special processes. Overlooking these can lead to gaps that auditors immediately flag. Proper understanding of these clauses is essential to ensure compliance and maintain a high level of operational quality.

• Treating Certification as a One-Time Task

Certification is not just about preparing for the audit; it requires consistent implementation of processes every day. If your procedures are only focused on the audit period, you risk nonconformities and repeat audits, increasing costs and delays.

• Focusing Only on Audit Preparation

Preparing documents and processes solely for the audit day can result in systems that do not reflect actual operations. AS9100 auditors expect evidence of ongoing compliance, and temporary fixes will not satisfy their requirements.

By identifying these common mistakes early, you can prevent delays, reduce unnecessary costs, and establish a stronger quality system. Professional guidance ensures your processes are correctly designed from the start, which saves time and effort during certification.

Why Do AS9100 Audits Fail Without Experts?

Audits are intended to confirm that processes are consistently effective, not just documented on paper. As the AS9100 certification market grows from USD 6.97 billion in 2024 to USD 7.46 billion in 2025, more companies of all sizes are entering the certification process. (Source)

This rapid growth increases competition and complexity, and without proper expertise, many organizations fail audits due to weak documentation, untrained staff, or incomplete risk management. 

1. Key Factors That Cause Audit Failures Include

• Weak Internal Audits: Without structured internal audits, gaps in processes remain unnoticed, and issues accumulate over time.

• Employees Unprepared for Auditor Questions: Staff may not know how to respond to questions about procedures, corrective actions, or risk management, leading to audit findings.

• Incomplete Corrective Action Records: Identifying problems is not enough; documentation of actions and their effectiveness is essential for compliance.

• Lack of Traceability in Supplier Management: Auditors require clear evidence that suppliers are properly evaluated and controlled. Missing documentation can create significant findings.

2. Professional Guidance Addresses These Issues Effectively By

• Conducting structured internal audits that reveal gaps before the main audit

• Training employees to confidently answer audit questions

• Ensuring that corrective actions are properly documented and verified

• Aligning processes with AS9100 standards to meet auditor expectations

With these measures, audits are smoother, nonconformities are minimized, and your company avoids costly repeat audits. Investing in professional guidance at this stage ensures that you are fully prepared and reduces the stress associated with audit readiness.

Documentation Gaps That Increase Certification Costs

Documentation is one of the most critical components of the AS9100 certification process. Even if your operations are strong, weak documentation can lead to audit failures and additional costs.

1. Common Documentation Gaps Include

a) Missing mandatory procedures

b) Poor version control, leading to confusion over current documents

c) Incomplete corrective action records

d) Weak supplier documentation and evaluation reports

e) Unclear work instructions or process guides

These gaps can result in multiple audit findings, delays in certification, and additional resource costs. Companies often underestimate the time and effort required to create accurate, comprehensive, and compliant documentation.

Here’s a comparison showing the impact of professional guidance:

Professionals help you create structured, consistent, and audit-ready documentation. This ensures alignment with your operational processes and reduces the risk of nonconformities.

With proper documentation in place, audits are faster, stress is minimized, and your company avoids unnecessary costs associated with rework and repeated audits.

Risk Management Mistakes Impacting Aerospace Compliance

Risk-based thinking is a core requirement of the AS9100 certification process, yet many companies fail to implement it effectively. Poor risk management not only affects audit results but can also compromise quality, safety, and overall operational efficiency.

• Common Mistakes Include

1. Risks not linked to production or quality processes

2. Lack of clear mitigation plans

3. Irregular or ineffective reviews

4. Employees unaware of critical risks or their responsibilities

Professional guidance ensures that risk management is properly implemented and integrated into daily operations.

• Key Benefits Include

1. Identification, assessment, and mitigation of risks related to production and quality

2. Regular reviews to ensure risk controls remain effective

3. Employees trained to understand and act on risks proactively

4. Risk management used as a tool to improve processes, not just satisfy audit requirements

With professional support, risk management becomes a practical, ongoing system that strengthens compliance, improves safety, and enhances operational efficiency. This proactive approach reduces audit findings and creates a more resilient quality management system.

Professional Guidance Versus Managing Certification Alone

Handling the AS9100 certification process alone may seem cheaper initially but often costs more in the long run.

Professional guidance ensures your systems are robust, repeatable, and positioned for long-term success. It helps you complete certification efficiently, avoid costly errors, and maintain compliance with aerospace standards.

Frequently Asked Questions (FAQs)

1. What is the AS9100 certification process?

The AS9100 certification process ensures aerospace companies meet strict quality and safety standards. It involves documentation, risk management, internal audits, and compliance verification.

2. How long does it take to get AS9100 certified?

The timeline depends on company size and readiness. With KSQA, the process is faster and more predictable.

3. Why is professional guidance important for AS9100 certification?

Professional guidance helps you prepare documents, train employees, and conduct audits efficiently. It reduces errors, delays, and unnecessary costs.

4. What are common reasons companies fail AS9100 audits?

Failures usually occur due to weak documentation, incomplete risk management, or untrained employees. Professional support ensures these gaps are addressed beforehand.

Final Thoughts

The AS9100 certification process is complex, and attempting it alone often leads to costly errors, delays, and stress. Working with professionals provides clarity, structure, and confidence.

KSQA specializes in guiding companies through the AS9100 process efficiently, helping you complete certification faster, reduce risk, and build strong, reliable systems that support long-term aerospace success.

Partnering with KSQA ensures your organization meets industry standards and positions you for growth in the competitive aerospace sector. Call now!