How To Transition From AS9100c to AS9100 Rev. D

#1
Good afternoon. I have visited Elsmar for many years and used the valuable tools offered to improve my work experiences and those of the people around me. I hoping for more assistance and words of wisdom today as well.

I have been the Quality Manager for 5.5 years here at a small machine shop and we produce build to print components for aviation, space and defense, medical and other commercial industries. There was previously two owners up until August of last year when one of the owners passed away unexpectedly one weekend. He was responsible for complete knowledge of the ISO Quality system as at the time I was Quality Manager, Quality Inspector, and Human Resources Manager. We shared in the ISO responsibilities but it was more of a 85% him and 15 % me. Now that he is gone I have to prepare us for the transition to AS9100D from As9100C. We haven't had any Management Review meetings or Internal Audits since his passing.

3 weeks ago we had a Nadcap Auditor who was the brother of someone we closely work with for our outside processing come in to perform an Internal Audit on our system. He suggested that we should not perform an internal audit until we have prepped our system for AS9100 rev. D. We sat down and over a two day period performed a Gap Analysis. I have added the revision D requirements to our current Quality manual/ document but am stuck on what to do next. Our ISO Audit will be conducted on the 26-28 of June, 2018. I don't like to fail so I want to be prepared for the Audit without my mentor being here anymore. I have been involved in the last 6 Iso Audits we have had so am familiar with the process. Some of the terminology gets me confused though.

I just would like to know what's the next move. Do I change all of the numbering of our documents to match the new standard and ditch the current Quality manual? Do I keep the current Quality manual as our top tier document but add a matrix at the end to help the Auditor and myself to associate what is going on in our system from the old standard to the new? I have a Counterfeit parts program developed but that is about it. Any help would be appreciated. Thank you.
 
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John Broomfield

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#2
Good afternoon. I have visited Elsmar for many years and used the valuable tools offered to improve my work experiences and those of the people around me. I hoping for more assistance and words of wisdom today as well. I have been the Quality Manager for 5.5 years here at a small machine shop and we produce build to print components for aviation, space and defense, medical and other commercial industries. There was previously two owners up until August of last year when one of the owners passed away unexpectedly one weekend. He was responsible for complete knowledge of the ISO Quality system as at the time I was Quality Manager, Quality Inspector, and Human Resources Manager. We shared in the ISO responsibilities but it was more of a 85% him and 15 % me. Now that he is gone I have to prepare us for the transition to AS9100D from As9100C. We haven't had any Management Review meetings or Internal Audits since his passing. 3 weeks ago we had a Nadcap Auditor who was the brother of someone we closely work with for our outside processing come in to perform an Internal Audit on our system. He suggested that we should not perform an internal audit until we have prepped our system for AS9100 rev. D. We sat down and over a two day period performed a Gap Analysis. I have added the revision D requirements to our current Quality manual/ document but am stuck on what to do next. Our ISO Audit will be conducted on the 26-28 of June, 2018. I don't like to fail so I want to be prepared for the Audit without my mentor being here anymore. I have been involved in the last 6 Iso Audits we have had so am familiar with the process. Some of the terminology gets me confused though. I just would like to know what's the next move. Do I change all of the numbering of our documents to match the new standard and ditch the current Quality manual? Do I keep the current Quality manual as our top tier document but add a matrix at the end to help the Auditor and myself to associate what is going on in our system from the old standard to the new? I have a Counterfeit parts program developed but that is about it. Any help would be appreciated. Thank you.
payneiii,

From what you say you’ve worked on the documentation but not the processes.

For this you need the support of top management and their process owners to change the organization and it’s processes to conform to your updated documentation.

Normally, you would have engaged them in updating your system documentation so remain ready to listen and make changes for buy-in and willing conformity. When you listen carefully you may find that processes already conform to the updated standard but not exactly as you had documented from the standard.

You may also find this advise useful:

AS9100 Rev D: 12 step transition process from Rev C

Lastly, make sure your internal audit team is up to speed on AS9100D and organize them to verify conformity and effectiveness of the system and its processes.

BTW, top management reviewing and addressing the differences between C and D should be recorded as a Management Review meeting complete with the resulting action plan with dated targets to bring about and verify timely success. Hold at least two reviews (beginning and end of the transition project) before your registrar audits.

Good luck,

John
 
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Mike S.

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#4
We sat down and over a two day period performed a Gap Analysis. I have added the revision D requirements to our current Quality manual/ document but am stuck on what to do next.

I just would like to know what's the next move. Do I change all of the numbering of our documents to match the new standard and ditch the current Quality manual? Do I keep the current Quality manual as our top tier document but add a matrix at the end to help the Auditor and myself to associate what is going on in our system from the old standard to the new?
First, take a deep breath. Second, remember to add some paragraph spacing -- it would make your post much easier to read.

Above is some good advice.

Mine will be much more direct and directed to your questions.

Next, I would work on filling the identified gaps. List the gaps, assign who will do what by when. Track progress regularly.

If it helps you, re-format your manual to the new standard. If it doesn’t, don’t.

I found it helpful to have a matrix (Excel spreadsheet) to show how we address every shall in the standard. If you find you have not addressed a shall, you found a gap you missed. YMMV.
 
#5
First, take a deep breath. Second, remember to add some paragraph spacing -- it would make your post much easier to read.

Above is some good advice.

Mine will be much more direct and directed to your questions.

Next, I would work on filling the identified gaps. List the gaps, assign who will do what by when. Track progress regularly.

If it helps you, re-format your manual to the new standard. If it doesn’t, don’t.

I found it helpful to have a matrix (Excel spreadsheet) to show how we address every shall in the standard. If you find you have not addressed a shall, you found a gap you missed. YMMV.
When people talk of gaps, it always helps to identify what is a "gap". Too frequently, the gap is considered a simple documentation issue and that becomes the focus of the closure activities...

In my experience, there are two other forms of gap:

Implementation and effectiveness (even to AS9100C)
 

John Broomfield

Staff member
Super Moderator
#6
Andy,

In my experience a gap is either:

1. A missing process

2. A process as yet unrecognized by the documented parts of the management system (but it [the work] actually exists as part of the organization as a system);

3. A missing control from an existing process.

John
 
#7
Andy,

In my experience a gap is either:

1. A missing process

2. A process as yet unrecognized by the documented parts of the management system (but it [the work] actually exists as part of the organization as a system);

3. A missing control from an existing process.

John
Agreed, plus don't overlook that some organizations a) have a documented process and b) what they're doing isn't effective. Think corrective action, for example...
 
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