Course overview
The revised 9104-1 CB’s standard
The 9104-1 standard defines the International Aerospace Quality Group (IAQG) scheme requirements for managing Aerospace Quality Management System (AQMS) certification (commonly referred to as the ‘ICOP scheme’) undertaken by accredited certification bodies (CBs).
This “CB standard” represents a comprehensive revision of the previous standard and is a significant step up in the drive to reduce AQMS (Aerospace Quality Management System) nonconformities with new criteria to allow audit reductions for consistently high‑performing organizations.
The alignment with ISO/IEC 17021-1:2015, ISO/IEC 17011:2017 criteria and IAF Mandatory Documents is preserved and supplemented by Aviation, Space & Defence industry unique ICOP sector scheme requirements.
The previous ‘site structures’ (Campus, Several Site and Complex) are replaced by single and multi-sites only. Where a physical location of a site exists, and Information & Communication Technology (ICT) is utilized, a maximum of half of the audit duration may be conducted remotely.
As a result of these significant changes, the CBs now require ‘active organization participation’ in the audit planning process by requiring them to submit AQMS performance and change data in advance of any audit. The CB process includes a review and documentation of the submitted data (by the lead auditor) prior to starting an audit. Organizations must justify the ‘non‑applicability’ of site processes and identify supporting IAQG standards they have implemented in their AQMS.
Organization Certification Analysis Process (OCAP)
The ‘Audit Calculator’ previously used to determine audit duration is replaced by a risk-based Organization Certification Analysis Process (OCAP) which uses data defining the organization context, core processes, certification structure (single or multi-site) and applicable IAQG standards to determine audit duration based on the IAF MB ‘baseline’.
With risk (Low/Medium/High) established at the organization/site level, audit duration is decreased/increased accordingly (minus 10% / no change / add 10%).
Performance Based Surveillance and Recertification Process (PBS/R)
There is also an option to utilize a Performance Based Surveillance and Recertification Process (PBS/R) which can lead to a reduction of up to 33% in audit duration for organizations/sites.
Entry to this process is allowed only after one certification cycle (3 years) and the organization must demonstrate –
Robust Internal Audit Program / ASD Lead Auditor Course for auditors
Low/No Complaints
Meet KPIs consistently
Good results with no major NCRs from CB audits
Once deployed, CBs evaluate and make appropriate process adjustments when organizations who are approved for PBS/RP are not in conformance with continuing requirements.
Empowerment training course
It is essential that organizations understand the new ‘rules’ and ‘analyses’ being used by CBs.
These changes offer an opportunity for an organization to take steps to optimize the effectiveness of its AQMS, minimize CB NCRs, boost customer satisfaction, and reduce the duration of CB audits and overall certification program costs
TEC’s 2-day Face-to-Face course provides a comprehensive explanation of the CB’s analysis and ‘risk scoring’ processes and gives details of ‘tried-and-tested’ tools and methodologies to meet OCAP & PBS/RP requirements and optimise your AQMS.
Learn how to –
re-define organization context, scope and certification structure
accommodate climate action changes
confirm additional aerospace standard(s)
reduce organization complexity
tighten up internal audits
maximize PEAR scores
meet/exceed customer KPI targets
create an Ethics Policy
implement processes for Change management (NOC), Counterfeit parts prevention, Safety Management System (SMS)
Course details
Face-to-Face (2-day) Course structure
There are two sections relating to OCAP and PBS/RP respectively
Section 1. Organization Certification Analysis Process (OCAP)
Section 2. Performance Based Surveillance/Recertification Process (PBS/RP)
Each section comprises two parts –
a. Explanations
Detailed descriptions of the 9104/1 requirements, evaluation/scoring criteria, use of the OCAP Tool, worked examples, calculations and Exercises – everything contained in clause 8 (Process requirements for certification bodies).
The explanations will ensure a comprehensive understanding of OCAP and PBS/RP requirements for quality professionals and their organizations.
b. Deployment
Implementation strategies, best-practice methodologies, tools and checklists –
everything needed to mitigate risk, enhance customer satisfaction, boost
performance, and subsequently reduce CB audit durations/cost
The deployment strategies provide the ‘know-how’ required to implement needed changes to optimize your AQMS.
SESSION #1a – Explanations
1. Conventions for standards/documents designation
Dated/Undated references
IAQG standards
2. Organization Certification Analysis Process (OCAP)
Course structure and objectives
Intention of this e-Learning course
3. Aerospace Quality Management System Risk Analysis – Elements
Aerospace Quality Management System Risk Analysis
4. Organization’s context and scope
Organization context
Organizational AQMS scope
Exercise: Explaining organization context & AQMS scope
5. Use of additional IAQG Standards
Use of additional aerospace standard(s)
Full listing of additional aerospace standard(s)
Use of additional aerospace standard(s)
Aeroengine manufacturers’ AQMS requirements (AS13100)
Exercise: Use of additional aerospace standard(s)
6. Organization’s complexity
Site configuration explanations (9104/1 definitions)
Exercise: Site configuration definitions
Organization’s complexity – structure and processes
Exercise: Organization’s complexity and its management system
7. Organization’s internal audit program
Basic requirements for internal audit program
Exercise: Organization’s internal audit program risk analysis
Organization’s internal audit program
8. Organization’s performance
Performance, Efficiency and Effectiveness
Exercise: Organization’s performance (terminology)
Organization’s performance
Exercise: Evaluating the effectiveness of AQMS processes (PEARs)
Exercise: Organization’s performance – Conformity of Delivered Product or Service
9. Overall organization’s risk determination
Overall organizational risk calculation
Exercise: Overall organizational risk determination
10. Overall organization’s audit duration
Baseline CB audit duration time
Audit duration risk adjustments
Exercise: Audit duration risk adjustments
Applicability of site processes
Site audit duration adjustment calculation
Example: Determination of ‘baseline’ for an organization
Further audit duration adjustments for ‘OCAP analysis’
Example: Full audit duration adjustments calculations
Exercise: Grand Audit Time calculation
SESSION #1b – Deployment strategies
11. Deployment Organization Certification Analysis Process (OCAP)
Reminder: Organization risk analysis elements
12. Confirming organization’s context and scope
Confirming organization’s context and scope
Climate action changes – Amendment 1
Climate action changes – other clauses and focus
Practicalities of SWOT analysis
Organization scope
Clarification – single/multi-site
Exercise: Organization context, scope, boundaries and certification structure
13. Confirming use of additional IAQG Standards
Confirmation of use of additional IAQG Standards
Exercise: Use of additional aerospace standard(s)
14. Confirming organization’s complexity
Organization’s complexity and its management system
Exercise: Organization’s complexity and its management system
Reducing organization risk level
Exercise: Potential reduction in organization’s complexity and its management system
15. Confirming organization’s internal audit program
Internal audit program risk analysis
Basic elements of the internal audit program
Exercise: Organization’s internal audit program risk analysis – necessary improvements
16. Confirming and boosting your organization’s performance
Availability of OCAP data to your CB
Defining organization’s customer performance metrics
Defining and managing customer satisfaction
Defining and managing customer satisfaction
Determining ‘effectiveness’ of AQMS processes
Understanding PEARs
Exercise: Scoring PEARs (three scenarios)
Performance metrics (KPIs) for operation processes
SCMH KPIs and definitions
Defining KPI Targets using ‘SMART’ criteria
Monitor and manage all KPI data
Institute P-D-C-A cycle
P-D-C-A standard operating procedure
Exercise – the Deming cycle
17. Overall organization’s risk determination and site audit duration
Overall risk determination
Audit duration risk adjustments
Exercise #1: Overall organizational risk determination
Exercise #2: Grand Audit Time calculation
SESSION #2a – Explanations
18. Explanation Performance Based Surveillance & Recertification Process (PBS/RP)
Fundamental qualification requirements for PBS/R
19. Performance Based Surveillance/Recertification Process – Qualification
Qualification and process flow for PBS/R
Qualification requirements and criteria for PBS/R
Site audit duration adjustment calculations for PBS/RP
PBS/RP process adjustments and certificate issues
19. Performance Based Surveillance/Recertification Process – Qualification
Qualification and process flow for PBS/R
Qualification requirements and criteria for PBS/R
Site audit duration adjustment calculations for PBS/RP
PBS/RP process adjustments and certificate issues
21. PBS/RP: Internal audit program and Auditor competency
9100: 9.2 Internal audit
PBS/RP: Internal audit – performance
PBS/RP: Internal audit – customer complaints
PBS/RP: Internal audit – risk
PBS/RP: Internal audit – change management
Internal auditor competency
IAQG TPAB approved ASD Lead Auditor course – IAQG syllabus
Exercise: Organization’s internal audit program risk analysis – necessary improvements
22. Ethics policy including communication and reporting processes
PBS/RP requirements for an ethics policy
Quiz: Your current ethics policy
23. Externally identified major nonconformities
PBS/RP: Externally identified major nonconformities
Quiz: Externally identified major nonconformities
24. No certificate suspension
PBS/RP: No certificate suspension rule
Reasons for certificate suspension
25. Meeting customer satisfaction metrics
PBS/RP: Customer satisfaction
Quiz: Customer satisfaction defined/quantified?
SESSION #2b – Deployment strategies
26. Performance Based Surveillance & Recertification Process (PBS/RP)
Summary: PBS/RP eligibility criteria
Exercise: Preliminary assessment for PBS/R
27. PBS/RP: Initial eligibility
Exercise: Eligibility for PBS/RP
Reminder: This is just an initial PBS/RP eligibility evaluation
28. Re-confirming the context of the organization & its AQMS ~ this is an essential pre-task!
9100: 4.1 Understanding the organization and its context
Understand purpose and strategic direction
Understand the context of the organization
SWOT analysis
Example: SWOT analysis
PESTLE analysis
Example: PESTLE analysis
9100: 4.2 Understanding the needs and expectations of interested parties
Exercise: Purpose, strategic direction & interested parties
AQMS and performance requirements of customers/CBs
General requirements of customers and interested parties
Requirements of additional aerospace standard(s)
Review exercise: General requirements and additional aerospace standard(s)
Performance-based customer/CB requirements
Review exercise: Performance-based customer performance and certification body PEAR scores
Scope of the organization’s AQMS
Organization’s description of its AQMS and processes
9100: 4. CONTEXT OF THE ORGANIZATION
Review exercise: Organization context, scope, boundaries and certification structure
The ISO QMP document – the basis of “quality”
Exercise: Rate your organization using the QMPs
29. Managing risk and OCAP risk analysis
Reminder: OCAP risk analysis – verifiable data
9100: the organization’s AQMS risk
Organization and its AQMS risk
Focus: Key sources of ‘operational’ risks
Focus: Customer-specific requirements risk sources
Quiz: Identifying applicable 9100 clauses
9100: Customer satisfaction risks sources
Customer satisfaction KPIs~Targets~Monitor
Operation processes risks sources
9100: Operation processes risks sources
Maintain high PEAR level scores
Operational risk management (DFMEAs and PFMEAs)
9100: Operational risk management
Operational planning and control
9145: Operational planning and control – standardized
APQP phases for a ‘generic’ organization
APQP ‘cascade’ through PBS (Product Breakdown Structure)
Quiz: Identifying your organization’s level in PBS
APQP activity – ‘responsibility’ matrix
External providers control/risk management
9100: External providers risk/performance management
Change management
Change management risks mitigation
Risk classification, management and mitigation
Monitor and manage all risk and KPI data
Institute P-D-C-A cycle
Exercise: Risk identification and management
30. Internal audit program and auditor competency
Internal audit: guidance and cycle
Primary targets of internal audits
Types of AQMS processes
Planning of an internal audit program
Adjustment of internal audit program
Internal auditor training, qualification and competency
Quiz: Internal audit program – Auditor competency
31. Ethics policy including communication and reporting processes
Ethics policy – the essential ‘drivers’
Communication and Reporting programs
Fostering ethical behaviour and a safety culture
Basis of an ethics policy
Counterfeit parts and Safety Management System
9100: 8.1.4 Prevention of counterfeit parts
Counterfeit parts prevention
9100: 8.1.3 Product safety
Safety Management System (SMS)
Human factors
Exercise: Just Culture, Ethical Behaviour, Human Factors, Counterfeit Parts and Safety Management System
32. Externally identified major nonconformities
PBS/RP: Externally identified major nonconformities
Institute rigorous internal audit program
Turtle diagram – planned arrangements & controlled conditions
Carry out ‘forensic’ audits of management reviews
Internal audits of corrective action processes
The corrective action processes
Quiz: Major nonconformities and corrective action
33. No certificate suspension
Avoiding reasons for suspension
9101: CB actions following issuance of a nonconformity
9101: Table 5
Certificate suspension ‘conditions’
Quiz: Avoiding suspension ~ reasons
34. Meeting customer satisfaction metrics
PBS/RP: Customer satisfaction
SC21 customer satisfaction criteria/metrics/targets
Quiz: PBS/RP – Defining and managing customer satisfaction
Understanding ‘leading’ and ‘lagging’ KPIs
Quiz: Identifying ‘leading’ and ‘lagging’ KPIs
PBS/RP: Customer complaints/feedback
35. Lean tools to enhance customer satisfaction and boost AQMS performance
Introduction to Lean principles and tools
5S Practice
The ‘Old’ and ‘New’ Quality Tools (overview)
Dr Ishikawa’s (old) seven quality tools
The (new) seven quality tools
Quiz #1: Identifying the ‘old’ quality tools
Quiz #2: Identifying the ‘new’ quality tools
AESQ & AS13100 – Core ‘defect prevention’ quality tools
Lean Tools, Concepts & Principles
7 Deadly Wastes
Quiz: 7 Deadly Wastes (match titles to descriptions)
Production (Service) Planning
Standard Work/Job
Quiz: Production Planning and Standard Work
Set-up Reduction (SMED)
Visual Management
Kanban System
Quiz: Production Planning, Standard Work/Job, SMED, Visual Management and Kanban System
Quiz: SMED, Visual Management and Kanban
Kaizen (Continuous Sustainable Improvement)
Poka-Yoke (Error Proofing)
Quality Function Deployment (QFD)
Quiz: Kaizen, Poka-Yoke and QFD
36. Formalized methodologies for continuous and breakthrough improvement
Popular continuous improvement methodologies
Total Quality Management (TQM)
Six Sigma
Juran’s trilogy for quality
Deming’s SoPK
Quiz: Popular continuous improvement methodologies
37. Benefits of deploying Lean & quality tools
Benefits of deploying Lean and the Quality Tools
Climate action changes (ISO 9001 amendment) strategies
38. Your training certificate
Students who successfully complete the two days will receive their Training Certificate in pdf format
Who should attend
TEC’s 2-day empowerment course is aimed at quality professionals, managers and consultants who need to understand the new 9104-1 standard ‘rules’ and ‘analysis’ being used by CBs.
Deliverables & benefits
The 9104-1 changes offer an opportunity for an organization to take steps to optimize the effectiveness of its AQMS, minimize CB NCRs, boost customer satisfaction, and reduce the duration of CB audits and overall certification program costs.
understand the 9104-1 ‘rules’ and ‘analysis’
TEC course provides a comprehensive explanation of the CB’s analysis and ‘risk scoring’ processes and gives details of ‘tried-and-tested’ tools and methodologies to optimise the AQMS.
make use of ‘tried-and-tested’ tools and methodologies to optimise the AQMS
This practical course is highly interactive and uses Quizzes and Exercises to achieve the above objective and guarantee understanding of the principles and practices involved.
Your Training Certificate pdf format) will be e-mailed immediately on completion of the course