AS9100D Audit-Prep Kit for Small Machine Shops: Checklist, Audit, 8D, FAI & NCR Forms

Your registrar or prime is coming, and you don't have a full-time quality manager. This kit gives you a clear way to find your gaps and the core records auditors ask to see, without a $10,000 consultant or a 90-file document dump you will never read.

It was built by Matt Norman: 15 years as a U.S. Navy Aviation Structural Mechanic, then quality inspection and QA/QC supervision in commercial space and defense manufacturing. The kit is written in plain shop-floor language from general industry practice. It covers what auditors actually check at small shops, and the findings they write most often.

What's inside (Word + PDF, plus an Excel tracker):

- 00 How to Use This Kit: a 30-day audit prep plan, audit-day rules, and what to do after

- 01 Audit-Readiness Checklist by AS9100D clause: 48 checks covering clauses 4-10, each with what the auditor looks for and the evidence to have ready, plus the 12 findings small shops get most often

- 02 Internal Audit templates: annual program, audit plan, auditor working checklist, finding record, report

- 03 Corrective Action (8D/CAPA) form: D0-D8 with is/is-not, 5-Why for occurrence and escape, fishbone, and a page on writing a CAPA your customer will accept

- 04 First Article Inspection (AS9102) guide: when FAI is triggered, what Forms 1-3 capture, step-by-step, a 25-point pre-submission checklist, and the top rejection reasons

- 05 Nonconformance Report (NCR) template: disposition authority guide (rework, repair, use-as-is, scrap) and an NCR log

- 06 Excel Tracker Workbook: readiness scoring by section, NCR log, CAPA log with overdue flags, FAI characteristic log with automatic PASS/FAIL, audit schedule

Who it's for: owners, ops managers, and the "quality person who also does three other jobs" at AS9100-certified or certifying machine shops, sheet-metal shops, special-process houses, and build-to-print suppliers.

What it is not: a quality manual or full procedure set, or a copy of the AS9100 standard. Clause numbers are used for reference only; you still need your own licensed copy of AS9100D.

License: one company, all sites and users. Instant download. Free update when IA9100 (the next revision of AS9100) is published.

Not affiliated with or endorsed by SAE International, IAQG, ISO, or any current or former employer of the author. Using this kit does not guarantee certification.

Five bullets:

1. Clause-by-clause AS9100D readiness checklist (48 checks) that tells you what the auditor looks for and the exact evidence to have on the table.

2. Ready-to-use internal audit program, plan, checklist, finding and report templates, so your internal audit holds up to a registrar.

3. 8D/CAPA form with occurrence and escape root cause, plus a guide to writing corrective actions that customers don't reject.

4. AS9102 first article guide and 25-point pre-submission checklist that targets the most common FAI rejection reasons.

5. NCR template with a disposition authority guide, and an Excel tracker for readiness, NCRs, CAPAs, FAI characteristics, and the audit schedule.