AS9100D is ISO 9001 plus controls that aerospace failures taught the industry: configuration, counterfeit parts,
FOD, first articles, special processes, product safety and on-time delivery. A company that is ISO 9001 certified
usually lacks most of these. scripts/as9100_gap.py produces a worksheet for the AS9100-specific requirements and
grades the gaps the way registrars do.
Trigger Conditions
Activate this skill when the user:
- Is upgrading from ISO 9001 to AS9100 / EN 9100
- Has won (or wants) work from an aerospace or defence prime
- Asks about FAI, counterfeit-part prevention, FOD or configuration management requirements
- Received an AS9100 audit or customer finding
Use iso-9001-gap-analyzer as well for the ISO 9001 base text.
Workflow
1. SCOPE -> design responsibility? post-delivery support? special processes in-house or outsourced?
2. WORKSHEET -> python scripts/as9100_gap.py --template > as9100.csv
3. ASSESS -> status + evidence per row (core-aerospace-controls.md shows what "implemented" looks like)
4. SCORE -> python scripts/as9100_gap.py as9100.csv
5. CLOSE -> majors first: counterfeit prevention, FAI, configuration, FOD, special processes, provider register
6. OPERATE -> 3 months of records, internal audit per AS9101 method, management review with OTDGap Codes (as9100_gap.py)
| Code | Grade | Meaning |
|---|---|---|
| AG001 | major | Core aerospace control not met (8.1.1-8.1.4, 8.4.1, 8.5.1 FOD, 8.5.1.2, 8.5.1.3, 8.7.1) |
| AG002 | minor | Other requirement not met |
| AG003 | minor | Partially implemented |
| AG004 | check | Met without evidence, missing row or invalid status |
| AG005 | error | n/a where not allowed (only 8.3.4.1, 8.3.5, 8.5.5 when no design / post-delivery responsibility) |
AG005 [error] 5.3 Management representative: cannot be not applicable
AG001 [major] 8.1.4 Prevention of counterfeit parts: core aerospace control missingAdditions by theme with audit focus, and the related AS standards: as9100-additions.md. What FAI, configuration management, counterfeit prevention, FOD, special processes, operational risk and OTD look like when implemented: core-aerospace-controls.md.
Output Format
Deliver:
- Scope - design responsibility, post-delivery, special processes, sites.
- Readiness - % and gap counts from
as9100_gap.py. - Majors - each with the control to build and its evidence.
- Plan - owner and date per gap; customer-specific requirements of each prime added.
Scripts
python scripts/as9100_gap.py --template > as9100.csv
python scripts/as9100_gap.py as9100.csvRequirements are paraphrased; use the standard for exact wording. Exit codes: 0 no major gaps, 1 major gaps or errors, 2 usage or read error.
Additional Resources
| File | Content |
|---|---|
| as9100-additions.md | AS9100 additions by theme, certification scheme, related standards, IA9100 |
| core-aerospace-controls.md | FAI, configuration, counterfeit, FOD, special processes, operational risk, product safety, OTD |
8d-problem-solving-report-writer
Write and review 8D problem-solving reports for customer complaints and serious nonconformities (automotive and aerospace practice: Ford Global 8D, VDA, GM, Stellantis formats): D0 emergency response, D1 cross-functional team and champion, D2 problem description with 5W2H and is / is-not and no cause in the statement, D3 interim containment within 24 hours with verification and clean point, D4 verified occurrence and escape (non-detection) root causes plus systemic cause, D5 permanent corrective actions for each cause verified before implementation, D6 implementation, validation with production data and removal of containment, D7 PFMEA, control plan and read-across to similar products, D8 closure and recognition. Checks an 8D discipline by discipline for missing content, human-error root causes, missing escape cause or action, late containment and dates out of order.
acceptance-sampling-plan-selector
Select and evaluate acceptance sampling plans for incoming, in-process and final inspection: ANSI/ASQ Z1.4 / ISO 2859-1 single sampling under normal inspection (code letter from lot size and inspection level I, II, III, S-1 to S-4; sample size, Ac and Re from AQL, following the table's arrows to the correct plan; 100% when n reaches the lot size; AQLs above 10 per 100 units), operating characteristic curves (Pa at any quality, producer's quality level, indifference point, LTPD, AOQ and AOQL, binomial or hypergeometric), plans designed from producer and consumer risk, and c = 0 zero-acceptance plans. Covers AQL choice by defect class, switching rules between normal, tightened and reduced inspection, when sampling is not appropriate, and random sampling.
approved-supplier-list-manager
Manage and audit an approved supplier list (ASL) / external provider register for ISO 9001 8.4.1, IATF 16949 8.4 and AS9100 8.4.1: supplier status (approved, conditional, probation, pending, disqualified), scope of approval by commodity and process, risk class, certification and expiry, re-evaluation intervals by risk, conditions with end dates, single-source contingency, approver and customer-directed sources. Audits the list for expired or expiring certificates, overdue re-evaluations, conditional or probation status past its decision date, high-risk suppliers without the required certification, single-source suppliers without backup and missing approvers, and checks purchase orders for suppliers that are off-list, disqualified or pending, or buying outside the approved scope. Covers ERP blocks, PO requirements, off-list and emergency purchases.
apqp-phase-planner
Plan and track Advanced Product Quality Planning (AIAG APQP 3rd edition, IATF 16949) for a new or changed automotive part: back-schedule the five phases (plan and define, product design, process design, product and process validation, launch and feedback) from the start-of-production date by program complexity, with overlap, PPAP lead and safe-launch period; list the deliverables and gate for each phase (DFMEA, DVP&R, feasibility, process flow, PFMEA, control plans, MSA, Ppk, run at rate, PPAP, safe launch, lessons learned); adjust for build-to-print suppliers; flag compressed timelines and late or untracked deliverables against a status list. Covers gate reviews, red/yellow/green status reporting, run at rate and safe-launch exit criteria.
audit-report-writer
Write internal, supplier and pre-certification audit reports with the content ISO 19011:2018 6.5 expects: audit objectives, scope, criteria with revisions, dates, team and auditees, method and sampling statement, specific strengths, findings table and three-part finding details (requirement, evidence, statement), conclusion on the degree of fulfilment of criteria, diverging opinions, follow-up deadlines and distribution. Builds a Markdown report from a JSON audit record, generates the conclusion from the findings (major / minor / none) and flags reports missing required content or findings without clause or evidence. Covers conclusion wording, closing meetings, response expectations and verifying corrective actions.
capa-effectiveness-checker
Verify whether a corrective action actually worked (ISO 9001 10.2.1 d, IATF 16949, 8D D6) with statistics instead of 'no complaints so far': before/after defect-rate comparison with an exact conditional binomial test for Poisson counts and a minimum practical reduction, zero-defect demonstration size (n = ln(1-C)/ln(1-p), rule of three) with progress so far, and exact Clopper-Pearson upper bounds on the post-action defect rate. Returns effective, not yet demonstrated (with the units still needed) or not effective. Covers setting effectiveness criteria when the CAPA is opened, choosing the window by problem frequency, leading indicators for rare failures (Cpk, SPC stability, error-proofing checks, LPA), and traps such as volume changes, detection changes and containment masking.