AS9100 Work Instruction Template With Revision Control and Inspection Points
A work instruction tells the person at the machine exactly how to perform an operation, what to check and when to stop. This AS9100 work instruction template adds the controls auditors look for: revision history, effective date, tooling and gauge identification, inspection points, key characteristic flags and approval signatures.
Fill in
AS9100 Work Instruction Template
Work Instruction WI-MC-014: Machine and deburr bracket, op 20
Company: Acme Aerostructures Ltd Revision: C Effective date: 2026-10-20 Part / drawing: PN-48213 Rev F Work center: 5-axis machining cell 3 Classification: Key characteristic involved
1. Purpose and scope
Defines the controlled method to machine the mounting holes and deburr edges so that all drawing features meet requirements, including key characteristic KC-2 position of the main bore.
2. Tooling, fixtures and measuring equipment
Fixture FX-2210, 6.35 mm carbide end mill, 12.00 mm reamer, bore gauge BG-07 (calibrated), deburr tool kit DK-3.
Only use gauges that show a valid calibration label. If a gauge is out of calibration, stop and notify the supervisor.
3. Safety and handling
Wear required PPE for this work center. Protect finished surfaces from damage and contamination. Do not stack parts on machined faces. Follow foreign object damage (FOD) housekeeping rules at the start and end of each shift.
4. Operation steps
| Step | Action | Acceptance criteria / reference | Inspection point (Y/N) | Operator initials |
|---|---|---|---|---|
| 1 | Verify traveler, material lot and drawing revision match this instruction. | Part PN-48213 Rev F; certs on file | Y | |
| 2 | Clean the fixture, load the part and torque clamps to the setup sheet value. | Setup sheet SS-014 | N | |
| 3 | Run program and monitor first cycle. Stop on any chatter or alarm. | Program rev as released in traveler | N | |
| 4 | Measure the main bore after reaming. | Per drawing; record result on traveler | Y | |
| 5 | Deburr all edges, break sharp edges, remove chips. | Edge break per drawing note | Y | |
| 6 | Mark and bag parts, complete the traveler and move to inspection. | Identification per traveler | N |
5. Records and nonconforming product
Record measured values on the traveler or inspection sheet. If any feature is out of tolerance, tag the part, segregate it and raise a nonconformance report before continuing. Do not rework without an approved disposition.
6. Revision history
| Rev | Date | Description of change | Changed by |
|---|---|---|---|
| C | 2026-10-20 | Added in-process bore check after reaming; updated fixture number. | |
| B | |||
| A | Initial release |
7. Approvals
A starting point, not a controlled document until it is released through your own document control process. Add your form number, retention period and any customer flow-down. Special processes need the approved process specification and the correct accreditation or customer approval referenced.
Operator instructions from your ERP
Optional: see how routing and drawing data can feed controlled instructions at the machine.
Optional. The tool and every export work without this. No spam.
How to use the template
Fill in the header fields, describe the purpose, list the tooling and measuring equipment, then adapt the operation table to your real steps. Keep each step to one action and write acceptance criteria that an operator can check without interpreting the drawing. Mark inspection points clearly so the operator knows when to measure and record. When you export to Word or PDF, route it through your document control system for approval and issue, and withdraw the old revision from the floor.
- One action per step, in the order performed.
- State acceptance criteria and the record produced.
- Mark inspection points and key characteristics.
- Show the revision and effective date on every page.
What AS9100 expects from work instructions
AS9100D clause 8.5.1 requires production and service provision under controlled conditions, which includes available documented information that defines the product and the activities, the use of suitable equipment, monitoring and measurement at appropriate stages, and defined criteria for acceptance. Clause 7.5 covers control of documented information, so the version used at the point of use must be current and approved. Work instructions are one common way to meet these, but the standard does not demand a fixed format. Use enough detail for the competence of your operators, and add more for special processes, key characteristics and critical items.
Common mistakes
Auditors regularly find uncontrolled copies at the machine, instructions that no longer match the drawing revision, steps that say inspect without saying what, and no evidence that operators were trained on the latest revision. Another gap is missing links between the instruction, the traveler and the nonconformance process. Keep the training record tied to the revision, review instructions when the drawing or process changes, and avoid copying wording from customer or standard documents verbatim; reference them instead.
- Uncontrolled printouts left on the shop floor.
- Instruction revision out of step with the drawing.
- Vague inspection steps with no criteria or record.
- No operator training evidence per revision.
Frequently Asked Questions
Is a work instruction required by AS9100?
AS9100 does not name work instructions, but it requires controlled production conditions and documented information where needed. Most aerospace suppliers use work instructions to show how operations are defined, checked and kept consistent between operators.
How detailed should an AS9100 work instruction be?
Detailed enough that a trained operator gets the same result every time. Give more detail for special processes, key characteristics and steps where errors were found in the past, and less for routine tasks within normal skills.
How do I control revisions of work instructions?
Give each instruction a number, revision and effective date, record changes in a revision history, approve before release, remove obsolete copies from use and train operators on each new revision. Electronic point-of-use display makes this easier.
Should inspection points be in the work instruction?
Yes, where the operator measures or verifies something. Mark the step, state the criteria and record the result, so in-process checks link to your inspection plan and any first article or key characteristic requirements.
If your instructions live in an ERP or MES, we can add a private AI layer that finds the current revision and answers operator questions on your own servers. The template is free and complete without that.
Related Tools
Inspection Work Instruction Template
A fill-in inspection instruction that tells inspectors what to check, with which gage, how often, and what to do on failure.
Aerospace & DefenseAS9100 Document Control Procedure and Template Pack
One editable AS9100 pack: document control procedure, process interaction table, KPI list, audit plan and schedule, with sample wording you can adapt.
Aerospace & DefenseAS9100 Process Turtle Diagram Template
Fill-in turtle diagram for one QMS process, covering inputs, outputs, resources, methods, competence and performance measures.
Aerospace & DefenseAS9102 First Article Inspection Report (FAIR) Template
A fill-in AS9102 FAIR with Forms 1, 2 and 3, pre-filled with a sample machined bracket so you can see how each field and characteristic row is completed.
More Aerospace & Defense tools
See all- AS9102 Form 1 Part Number Accountability Template
- AS9102 Form 3 Characteristic Accountability Worksheet
- FOD Prevention Program Checklist
- Aerospace Key Characteristics Worksheet
- AS9102 Form 2 Product Accountability Template
- Nadcap Special Process Supplier Approval Tracker
- Aerospace Material Review Board Disposition Template
- Aerospace Delta FAI Trigger Worksheet
- Aerospace Supplier OTD and Quality Rating Calculator
Keep exploring
Free tools
- Inspection Work Instruction TemplateA fill-in inspection instruction that tells inspectors what to check, with which gage, how often, and what to do on failure.
- Shipper's Letter of Instruction TemplateFill in a clean Shipper's Letter of Instruction that tells your freight forwarder who is shipping what, where, under which terms, and how to file export data.
- Nadcap Special Process Supplier Approval TrackerEditable worksheet for tracking special process suppliers, their Nadcap or customer approvals, scope and days to expiry.
Guides
- How to Set Up AS9100 Compliance in SyteLineComprehensive guide to configuring Infor SyteLine for AS9100 aerospace quality management compliance. Set up first article inspection, special processes, key characteristics, and traceability requirements.
- AS9100 Contract Review Checklist for Aerospace Machine ShopsAS9100D contract review checklist for build-to-print machine shops: what to verify on every PO and RFQ, who signs, and the records an auditor expects.
- ERP for Aerospace Build-to-Print Machine Shops: What to RequireWhat an AS9100 build-to-print machine shop needs from ERP: revision control, traveler, lot traceability, outside processing, FAI and certs.