Course overview
If you need to conduct effective internal audits against your own QMS plus AS9100 series of standards, customer-specific and regulatory requirements – then this is the course for you!
This is a PROBITAS Authentication certified course
TEC have packaged everything needed into a 2-day practical course to ensure that participants will have the knowledge and skills to plan, prepare, perform and report the results of internal audits based on AS9100, AS9110 and AS9120 using a ‘process-based approach’ – in the same way as the Certification Bodies.
TEC's course is unique because we also train and examine the Certification Body auditors (AATT 2016 course). Consequently you will be learning how to audit using the AS9101:2022 requirements as well as the ISO 19011:2018 guidance - in the same way as CB Auditors.
Our course addresses all of the stringent requirements of the AS9100:2016 series of standards. Specific reference is made to AS9100:2016 clauses 9.2 Internal audit and 10.2 Nonconformity and corrective action plus the 'root cause codes' now being used by the CBs. In addition, you will learn how to assess the ‘active’ management of customer satisfaction, QMS Q & D performance and process-level effectiveness (PEARs) – and how to audit your organization's Leadership! Auditing for the ISO amendment relating to climate change is included.
Note: This AS9100 Internal Auditor course is aimed at candidates who already have a basic knowledge & understanding of the AS9100 requirements and the influence of quality on a business management system. For individuals who do not yet have this knowledge, then we strongly recommend that they attend an AS9100 awareness or foundation training prior to attending the auditor course. Please follow this link to view TEC's 1-Day AS9100 Foundation Training.
This AS9100 (ASD) Internal Auditor Training Course is applicable to AS9100, AS9110 and AS9120 standards
Assessment of learning is achieved through structured exercises, real-world audit scenarios and an aerospace Case Study. Students undertake 'face-to-face' individual audit exercises with the tutor(s) in addition to team assignments. The tutors provide feedback and advisement to ensure that best-practice is fully understood in the context of the aerospace/defence industry.
continual assessment replaces the need for a written exam!
The course timings are –
Day 1: 08:00 – 17:00
Day 2: 08:30 – 17:00
This training course is available as both an on-site event conducted at your premises, and as a public event hosted at our training venue, The Woodland Grange Conference Centre, Leamington Spa, UK.
Course details
Throughout the e-Learning course you will need to make reference to your personal copy of the relevant standard (i.e. AS9100, AS9110 or AS9120). No other standards/guidance documents are required.
Within this course, the following sections are covered:
Registration, welcome and IAQG overview
Prior knowledge of the AS90100 series of standards
IAQG and the ‘OASIS database’
Supply Chain Management Handbook
IAQG Dictionary
IAQG Resolutions Log
Auditing-related terms, definitions and methodologies
What is an internal audit?
Explanation of audit-related terms
Test: explanation of audit-related terms
Understanding interested parties and their requirements
Guidelines and Standards relating to auditing
Relationship between elements of the QMS
Understanding QMS processes
Test: identifying types of QMS process
Examples of QMS process types
Visualizing QMS processes – sequence and interaction
Test: evaluating an organization’s description of its QMS processes and their sequence and interaction
QMS business benefits
Understanding the organization and its context
Exercise: Organization purpose, strategic direction & scope
Audit questions focused on purpose, strategic direction and scope
Climate action changes
Examples of climate-related audit questions
Benefits of a formal QMS
Exercise: identifying the benefits of a formal QMS
QMS documentation
AS9100 series QMS documentation requirements
Policy ~ Processes ~ Procedures
Identifying AS9100 series need for documented information
Test: identifying AS9100 series need for documented information
Determination of the processes needed for the QMS
Test: defining policy, processes & procedures
Auditing using a 'process-based' approach
Deriving process-based audit questions from applicable audit criteria
Test: deriving audit questions from audit criteria
Turtle diagram – visualization tool for process-based QMS internal auditing
Test: identifying the ‘elements’ of a Turtle diagram
Deriving process-based audit questions from Turtle diagram ‘limbs’
Test: mapping audit questions to Turtle diagram 'limbs'
Content and structure of AS9100 series referring to the P-D-C-A cycle
AS9100 series content: clauses and requirements
AS9100 series structure: referring to the P-D-C-A cycle
Test: Locating requirements for OPERATION, SUPPORT and ANCILLARY processes
Understanding and auditing the ‘effectiveness’ of a QMS
Auditing QMS ‘effectiveness’
Requirements for QMS ‘performance’
Test: locating specific requirements for monitoring
Auditing process effectiveness – using the ‘PEM’
Evaluating and scoring process effectiveness – using the ‘PEAM’
Test: scoring process effectiveness – the ‘PEAR’
Auditing conformity of a QMS
Understanding ‘conformity’ with QMS requirements
Test: locating AS9100 series requirements for auditing purposes
Requirements for OPERATION processes
Test: locating AS9100 series clauses applicable to OPERATION processes
Test: auditing MRB actions with customer-supplied nonconforming product
Requirements for SUPPORT processes
Test: locating AS9100 series applicable to SUPPORT processes
Requirements for ANCILLARY processes
Test: locating AS9100 series applicable to ANCILLARY processes
Auditing performance (P-D-C-A)
Quality objectives define QMS ‘performance’
Test: understanding quality objectives
Auditing quality objectives and the P-D-C-A cycle
Test: auditing customer satisfaction
Test: auditing supplier performance
Auditing risk-based thinking
Understanding/auditing risk-based thinking
Auditing risk-based thinking – “things to consider” ~ AS9100 series clauses
Exercise: auditing risk-based thinking – “things to consider” ~ AS9100 series clauses
Identifying and auditing risk sources and related methodologies
Test: operation process risks and things to look for
Audit planning
Audit planning considerations
Identifying ‘audit trails’
Test: establishing an internal audit plan
Different audit methods
Test: identifying different audit methods
Auditing the planning of an internal audit program
Guidance for estimating adequate time to conduct a full internal audit program
Test: estimating the time to conduct a full QMS internal audit
Justifying an audit program
Test: auditing the internal audit program
Planning and conducting a remote audit
Creating an audit work document
Creating an audit work document – format and contents
Personal assignment: creating an audit work document
Creating an audit work document from a Turtle diagram
You’re now ready to undertake an internal audit!
Conducting an opening meeting
Purpose of an opening meeting
Agenda items for an opening meeting
Personal assignment: creating an opening meeting agenda
Conducting an opening meeting
Test: opening meeting dos & don'ts
Performing the internal audit
The ‘evidence-based approach’ to auditing
Audit sample size determination
Test: choosing an appropriate sample focus (operators)
Test: choosing an appropriate sample criteria (POs – purchase orders)
Test: choosing an appropriate sample size (FAIRs – First Article Inspection Reports)
Managing interviews and recording evidence
Format and style of audit questions
Test: turning closed questions into open questions
Building rapport with the auditee
Auditing top management ~ “don’t be intimidated!”
Personal assignment: auditing top management and management review*
Collecting, evaluating, and recording objective evidence
Audit process summary – auditor & auditee activities
Test: dealing with auditee disagreements
Evaluating audit evidence and creating effective NCRs
Criteria for determining nonconformities
Reporting nonconformity using a nonconformity report (NCR)
Test: sections of the 'NCR Template'
Recording multiple instances of nonconformities on a single NCR
Test 1: identifying the applicable clause and formulating an effective NCR
Test 2: identifying the applicable clause and formulating a effective NCR
What if there’s insufficient evidence to determine – conformity? or nonconformity?
Grading NCRs
Test: grading NCRs (minor/MAJOR)
The ‘mock’ audit’ (Case Study material)
Mock audit of major operation process
Preparation for/conducting the mock audit (120-min)
Exercise: On-site/Human interaction
30-min per team face-to-face with tutor
10-min to 15-min per student with tutor
Concurrent team activities – simulated audit scenarios
Preparing for, and presenting, a closing meeting
Reviewing the audit findings and preparing conclusions
Conducting closing meeting
Personal assignment: creating a closing meeting agenda
Reporting the audit results
Audit report purpose and content
CB audit report contents
Test: Key items in the internal audit report
Conducting audit follow-up
Reminder: correction vs. corrective action
Responsibility for corrective actions
Test: NCR terminology and actions
Verifying the effectiveness of corrections and corrective actions
Test: verification of actions/corrective actions
Auditor selection, competence, and personal qualities
Responsibility for the internal audit program
Auditor competence – methodology
Auditor competence – sector/discipline
Selection of people for internal auditors
Quiz: identifying internal ‘auditor qualities’
This face-to-face course incorporates Quizzes, Tests and individual assessments to ensure students’ knowledge and skills are properly evaluated. The majority of the time is given over to these activities.
On successful completion of the course and its quizzes/tests/ individual assessments, students will be presented with their Training Certificate.
Who should attend
Individuals needing to be qualified to conduct internal and/or supplier audits, and those who want to monitor process effectiveness and QMS performance. Competent auditors can also undertake an in-depth ‘gap analysis’ of an organization’s existing QMS.
This is a PROBITAS Authentication certified course
Other individuals who have found this course useful are six sigma practitioners and consultants, team leaders and supervisors in aerospace/defence organizations, who are looking to broaden their awareness of quality issues in order to understand how they can improve overall business effectiveness.
It can also serve an essential bridging course for existing ISO 9001 Lead Auditors.
Deliverables & benefits
Individuals who successfully complete the course will -
know how the CBs undertake their audits, and what types of questions they ask
be better equipped to maintain compliance with AS9100:2016 series of standards requirements
be able to undertake an in-depth 'gap analysis' of an existing AS9100 series QMS
be confident in knowing that their audit questions address all important issues
identify weaknesses in QMS performance (e.g. quality and delivery), process-level effectiveness and leadership
identify risks and opportunities within the QMS
be able to accrue (16) CPD points because of the highly structured nature of this course
All students successfully completing the 2-day course will receive an individual training certificate containing the internationally-recognized TEC Transnational and PROBITAS Authentication logos.
The organization will –
be confident that their auditors are empowered to undertake effective AS9100 series internal audits
know that the outcomes of the audits will meet the expectations of aerospace and defence customers and Certification Bodies
be able to use 'root cause codes' now being demanded by the Certification Bodies
ensure conformity, maintenance and ongoing improvement of the QMS