From audits of small and mid-sized aerospace shops, these are the nonconformance findings that come up again and again. Each has a simple fix inside the kit.
| Finding | Why it happens | The fix in this kit |
|---|---|---|
| Untagged product in the hold area or on the floor | Tagged later, or the tag fell off | Tag where found (D18, checklist 1); weekly reconciliation |
| Hold area does not match the log | Product moved without a record | Count both ways every week (D18) |
| Disposition with no name or no authority | Decided in a corridor | Authorized-by column flagged when blank (D19); authority matrix (D20) |
| Use-as-is released without the customer authorization the contract required | Contract not checked; release before the answer | Contract column and release line on the MRB record (D20) |
| Repair with no approved instruction | Done by the best operator, from memory | Instruction reference required on the MRB record |
| Scrap still usable | Tag but no destruction | Scrap checklist (D18, checklist 3); NCR closed only after |
| Suspect part returned to the supplier | Treated as an ordinary reject | Separate path (D03); authority matrix row |
| Customer not told about shipped product | Nobody decided whether it shipped | Containment location list (B11); escalation times (D15) |
| NCR with no corrective action decision | Only big ones get the question | CAPA required? on every line, flagged when blank (D19) |
| Same defect repeatedly repaired or accepted | Each case judged alone | The board's pattern question; Paretos (F09); repeat register (B10) |
| Very old open NCRs | No age limit; no board rhythm | Age bands and days waiting (D19, D20); weekly board |
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A management aid, not certification or a registrar audit. Using it does not by itself show conformity to AS9100D or any other standard, and your customers' requirements may add to it.
Clause numbers refer to AS9100D (SAE AS9100 Rev D) unless another document is named. The standards' text is not reproduced here: use your own licensed copy.
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