The system works smoothly most weeks. These are the situations that test it, and the way we have learned to handle each one.
| Situation | How we handle it | Why |
|---|---|---|
| Work is due tonight and nobody on the shift is qualified | Hold it, or bring in a qualified person; the production manager decides, and the decision is recorded. | 'Do your best' is how most second-shift escapes begin. |
| Someone declines a task they are not qualified for | Thank them, and support the decision in front of the team. | The rule only holds if refusing is safe. |
| A long-serving person does not pass an assessment | Treat it privately and practically: what was missed, more training, assess again. Keep them working at the level shown. | Experience and current competence are different things; dignity keeps people honest. |
| Nobody can be released for training | Put the coverage risk to the general manager as a decision: the training time, or the risk of the gap, with dates. | Training that waits for a quiet week never happens. |
| An expired stamp or authority is found in use | Suspend it today; check the product released since it expired; requalify; find why the register did not catch it. | Product accepted on lapsed authority is a nonconformance in its own right. |
| Work was stamped by someone who did not inspect it | Contain the product first. Then a management matter, handled outside the training records. | It is an ethics problem, not a competence one, and it must not be blurred into training. |
| A customer requires named, approved personnel | Keep the customer's list with the authorization register and check it before assigning work. | The customer's approval is part of the authorization. |
| Cover from another shift or site | Check their level on your matrix for your parts before they start; brief them on the area. | Competence on one machine or site does not transfer by itself. |
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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.
Aegis Insights are our own guidance, labeled wherever they appear: how we approach this work, not a requirement of any standard or customer.