In an AS9100 quality management system, nonconformances are inevitable. What separates effective aerospace organizations from struggling ones is how those nonconformances are identified, documented, investigated, and resolved.
AS9100 requires organizations to establish processes for controlling nonconforming outputs to prevent unintended use or delivery of products that do not meet specified requirements. Proper management of nonconformances protects customers, reduces risk, and supports continual improvement throughout the organization.
What Is a Nonconformance?
A nonconformance occurs when a product, process, service, or quality management system requirement fails to meet a specified requirement.
Examples include:
- Dimension out of tolerance
- Incorrect material used
- Missing inspection records
- Unapproved process changes
- Incomplete training records
- Supplier defects
- Documentation errors
Nonconformances may be identified during receiving inspection, in-process inspection, final inspection, internal audits, customer audits, or daily operational activities.
AS9100 Requirements for Nonconformance Control
AS9100 Clause 8.7 requires organizations to ensure nonconforming outputs are identified and controlled to prevent unintended use or delivery.
Organizations must:
- Identify nonconforming products or processes
- Segregate affected items when appropriate
- Document the nonconformance
- Evaluate disposition options
- Obtain required approvals
- Verify corrective actions when necessary
- Maintain records of actions taken
Failure to control nonconforming outputs can result in customer dissatisfaction, audit findings, increased costs, and potential product safety concerns.
Common Nonconformance Categories
Product Nonconformances
These involve physical defects or failures to meet engineering requirements.
Examples include:
- Dimensional discrepancies
- Surface finish defects
- Incorrect assembly
- Welding defects
- Material certification issues
Process Nonconformances
These occur when required procedures or work instructions are not followed.
Examples include:
- Skipped inspections
- Unapproved process changes
- Incomplete process verification
- Missing operational controls
Quality System Nonconformances
These involve failures within the quality management system itself.
Examples include:
- Missing internal audits
- Ineffective corrective actions
- Inadequate document control
- Lack of management review activities
Nonconformance Disposition Options
After evaluation, organizations typically determine one of the following dispositions:
Rework
The product is modified to fully meet original requirements.
Repair
The product is altered to achieve acceptable performance, often requiring customer approval.
Use-As-Is
The product is accepted despite the nonconformance through an approved concession process.
Scrap
The product is permanently removed from production and cannot be used.
Proper disposition decisions help ensure quality requirements and customer expectations remain protected.
Root Cause Analysis and Corrective Action
Addressing the immediate issue is only part of the process. Organizations must also determine why the nonconformance occurred.
Common root cause tools include:
- 5 Whys
- Fishbone Diagram (Ishikawa)
- Process Mapping
- Failure Mode Analysis
- Cause and Effect Analysis
Once root causes are identified, corrective actions should focus on preventing recurrence rather than simply correcting the individual defect.
Preventing Future Nonconformances
Organizations can reduce recurring issues through:
- Employee training
- Strong document control
- Effective supplier management
- Risk-based thinking
- Internal audits
- Process monitoring
- Preventive maintenance
- Management review activities
A proactive approach helps identify weaknesses before they become significant quality problems.
Common AS9100 Audit Findings Related to Nonconformance Control
Auditors frequently identify issues such as:
- Incomplete nonconformance records
- Missing disposition approvals
- Ineffective corrective actions
- Lack of root cause analysis
- Failure to verify corrective action effectiveness
- Poor segregation of nonconforming material
Maintaining a structured nonconformance process helps organizations demonstrate compliance while improving operational performance.
Conclusion
Effective AS9100 nonconformance management is essential for maintaining product quality, customer confidence, and regulatory compliance. By identifying issues quickly, determining root causes, implementing corrective actions, and monitoring effectiveness, aerospace organizations can reduce risk and drive continual improvement throughout their quality management system.
