Aerospace Manufacturer Achieves AS9100 Certification in 90 Days
The Challenge
A mid-size aerospace precision parts manufacturer in the Carolinas was at risk of losing a $12M defense subcontract. The prime contractor mandated AS9100D certification within 120 days — roughly half the industry-average timeline. The company had a basic ISO 9001 system but lacked aerospace-specific controls for product safety, counterfeit part prevention, configuration management, and first article inspection (FAI) per AS9102.
Our Approach
Conducted a rapid 3-day gap analysis comparing the existing ISO 9001 QMS against every AS9100D clause, identifying 47 gaps requiring closure.
Deployed a phased implementation plan with weekly milestones, prioritizing high-risk clauses: Operational Risk Management (8.1.1), Product Safety (8.1.3), Counterfeit Parts Prevention (8.1.4), and Configuration Management (8.1.2).
Developed 23 new procedures and updated 15 existing ones, including a comprehensive First Article Inspection process aligned with AS9102 Rev C.
Delivered intensive 2-day internal auditor training to 8 team members, qualifying them to conduct aerospace-specific audits independently.
Conducted two full internal audit cycles and one management review before the registrar's Stage 2 audit, ensuring the system was mature and producing objective evidence of conformity.
Provided on-site support during the 4-day certification audit, serving as the management representative liaison.
The Results
Achieved AS9100D certification in 90 days — 50% faster than the 6-month industry average.
Zero major non-conformances during the Stage 2 certification audit.
Only 2 minor observations noted, both closed within 48 hours.
Secured the $12M defense subcontract within 2 weeks of certification.
Reduced internal scrap rate by 18% in the first quarter post-certification due to improved process controls.
Eight team members qualified as certified internal auditors, creating a self-sustaining audit program.
“We were told by two other consultants that 120 days was impossible. Exceleor not only made it happen in 90 — they built a system our team actually understands and can maintain. The auditor said it was one of the most well-prepared Stage 2 audits he'd seen.”
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