Advanced Manufacturing Corp - 100% ISO Compliance Across 12 Facilities

About Advanced Manufacturing Corp

Advanced Manufacturing Corp operates 12 manufacturing facilities producing precision aerospace and defense components with annual revenue of $780 million. The company holds ISO 9001, AS9100, and ITAR certifications critical for maintaining aerospace and defense contracts. With 3,400 employees producing over 45,000 unique part numbers, quality documentation and compliance are mission-critical. Manual quality management processes created audit risks, inconsistent documentation across facilities, and difficulty maintaining certifications.

12

Manufacturing Facilities

3,400

Employees

45,000

Part Numbers

The Challenge

Inconsistent Quality Documentation

Each facility maintained separate quality records with different formats and processes

⚠️ Audit findings across 8 of 12 facilities

Manual Inspection Records

Quality inspectors completing paper forms creating transcription errors

⚠️ 340 documentation errors annually

Audit Preparation Burden

Preparing for ISO audits required weeks of gathering documentation across facilities

⚠️ 6-8 weeks per facility for audit prep

Non-Conformance Tracking

Unable to identify patterns in quality issues across the organization

⚠️ Recurring defects and customer complaints

The AI Solution

Centralized Quality Management System

Single system across all 12 facilities with standardized processes

Unified documentation
Standardized workflows
Real-time visibility

Digital Inspection Forms

Mobile-friendly digital forms with automatic validation and calculations

Tablet-based inspections
Photo documentation
Digital signatures

Automated Audit Preparation

Instant generation of audit packages with all required documentation

Pre-built audit reports
Compliance dashboards
Evidence libraries

Advanced Analytics

Pattern recognition identifying systemic quality issues

Trend analysis
Root cause identification
Predictive quality

Implementation Journey

1. Requirements & Standards

4 weeks

Mapped ISO 9001 and AS9100 requirements
Standardized quality procedures across facilities
Defined quality metrics and KPIs
Created master inspection criteria

2. Pilot Facility Implementation

8 weeks

Deployed at largest facility (580 employees)
Digitized 850 quality forms and procedures
Trained 120 quality inspectors
Processed through first ISO audit successfully

3. Multi-Facility Rollout

16 weeks

Deployed to remaining 11 facilities
Migrated historical quality records
Trained 380 quality personnel
Standardized all quality processes

4. Analytics & Optimization

6 weeks

Implemented predictive quality analytics
Connected to ERP and MES systems
Built executive quality dashboards
Achieved full system optimization

Transformational Results

Metric	Before AI	After AI	Improvement
ISO Compliance Rate Zero audit findings across all 12 facilities in latest certification cycle	83% facility compliance	100% facility compliance	Perfect compliance
Documentation Errors Near-elimination of documentation-related audit findings	340 errors annually	28 errors annually	92% reduction
Audit Preparation Time Continuous audit-readiness, reduced business disruption	6-8 weeks per facility	3-5 days per facility	88% reduction
Quality Compliance Costs Reduced administrative overhead while improving compliance	$680K annually	$260K annually	$420K savings

What the Team Says

“For the first time in 15 years, we achieved zero findings across all facilities. The auditor said our quality system is the most mature they've seen in aerospace manufacturing. That's the Ademero difference.”

Robert Chen

VP of Quality & Compliance

“As a quality manager, I used to dread audits. Now I welcome them. Everything is documented, traceable, and instantly accessible. We spend our time improving quality instead of preparing for audits.”

Sandra Martinez

Quality Manager, West Coast Operations

“The analytics capabilities changed how we think about quality. We now predict and prevent issues instead of reacting to them. Our defect rates have dropped significantly.”

James Wilson

Director of Manufacturing Excellence

Key Lessons Learned

💡 Standardization Before Automation

Standardizing processes across facilities before digitizing prevented automation of bad processes

💡 Involve Quality Inspectors Early

Front-line inspector input during design created buy-in and better workflows

💡 Mobile-First for Shop Floor

Quality inspections happen on shop floor - mobile tablets essential for adoption

💡 Continuous Training Investment

Ongoing training and support key to maintaining system effectiveness

100% ISO Compliance Across 12 Facilities