AS9100D Gap Analysis Template with Scoring and Action Plan
A gap analysis shows how far your quality management system is from AS9100D and what to do first. Score each requirement area, weight the ones that matter most, and read your overall compliance percentage and action list.
| Clause | Requirement area | Score (0 none, 1 partial, 2 full) | Weight (1 to 3) | Weighted score | Weighted gap | Action to close | Owner | Due date | |
|---|---|---|---|---|---|---|---|---|---|
2 | 2 | ||||||||
3 | 3 | ||||||||
0 | 6 | ||||||||
4 | 0 | ||||||||
2 | 2 | ||||||||
4 | 0 | ||||||||
0 | 6 | ||||||||
3 | 3 | ||||||||
3 | 3 | ||||||||
3 | 3 | ||||||||
4 | 0 | ||||||||
0 | 4 | ||||||||
2 | 2 | ||||||||
3 | 3 |
Rows summarize AS9100D areas, not the standard text. Add every clause relevant to your scope and customer requirements. Rows scoring 0 with weight 3 are your first actions.
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How to use the template
Replace the sample rows with your own findings. Score each area 0 when nothing exists, 1 when it is partly done or not followed consistently, and 2 when it is documented, implemented and effective. Weight the areas 1 to 3 by risk to product and certification. The worksheet multiplies score by weight, totals the result, and calculates the weighted gap. Fill in action, owner and due date for each gap, then sort by gap to build your plan.
Reading the percentage
Overall compliance is the weighted score divided by the maximum possible. A first pass often lands well below full compliance, and that is normal. The aim is a prioritized plan, not a pass mark. Use it with the AS9100D clause structure: if you already hold ISO 9001 certification, most of clauses 4 to 10 are in place and the gap concentrates in the aerospace additions.
- Product safety and counterfeit parts prevention
- Configuration management
- Key characteristics and first article inspection
- On-time delivery and quality performance monitoring
- Supplier flow-down and external provider control
Turning the gap into a plan
Group actions by owner and by time. Quick wins such as updating forms can finish in weeks, while systems work such as configuration management or supplier scoring needs months. Schedule an internal audit and management review before the certification body's stage audits, and keep records that show the system operating for a period, since auditors look for implementation rather than paperwork.
Common mistakes
Teams score what is written instead of what is practiced, skip the aerospace-specific areas, or fix documents without training staff. Another trap is a single person doing the whole analysis. Include process owners so scores reflect reality, and repeat the analysis after major actions close.
Frequently Asked Questions
What is an AS9100 gap analysis?
A structured comparison of your current QMS and practices with AS9100D requirements, showing which areas meet the standard, which partly do and which are missing, so you can plan the work before certification.
How is AS9100D different from ISO 9001?
AS9100D contains ISO 9001 and adds aerospace, space and defense requirements such as product safety, counterfeit parts, configuration management, FAI, special processes and on-time delivery monitoring.
How long does it take to close the gaps?
It depends on starting point. A plant with ISO 9001 often needs several months to add the aerospace elements and build records. A site with no QMS should plan for a year or more.
Should I do the gap analysis myself?
You can, with process owners. An independent review by an experienced auditor or consultant often finds gaps that insiders miss. Either way, use evidence not opinion when scoring.
Netray can add a private AI layer to your ERP and quality data, so on-time delivery, nonconformance and supplier metrics for AS9100 come from live data on-prem rather than manual spreadsheets.
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