Why Aerospace AS9100 Demands More Than Automotive IATF - even in Cable and Wire Harnesses

AS9100: Why Aerospace Manufacturing Demands the Highest Standards

In aerospace manufacturing, the stakes are incredibly high—even more so than in the automotive industry. Every single part, from a simple connector to a complex wiring harness, must meet uncompromising standards for safety, reliability, and traceability. This is why aerospace suppliers must comply with AS9100, the globally recognized quality management system for the aerospace industry.

While automotive suppliers follow IATF 16949, AS9100 raises the bar significantly. It adds critical requirements that address the unique risks inherent in aviation, defense, and space.

Key Requirements That Set AS9100 Apart

Built on the foundation of ISO 9001, AS9100 incorporates several aerospace-specific additions that reflect the mission-critical nature of its products. These include:

• Product Safety & Airworthiness: Ensuring every part meets flight-critical reliability standards.

• Configuration Management: Maintaining strict control over part designs, revisions, and documentation to prevent deviations.

• Risk Management: Proactively identifying and mitigating risks throughout every stage of the process.

• Counterfeit Part Prevention: Implementing mandatory controls to prevent fraudulent components from entering the supply chain.

• Human Factors: Recognizing how human error can impact product quality and safety.

• Supplier Oversight: Imposing more rigorous auditing and monitoring of sub-suppliers compared to automotive standards.

• Full Traceability: Requiring every component and process step to be traceable, which is essential for investigations and compliance.

Simply put, while automotive standards focus on defect prevention, aerospace standards elevate the focus to safety, risk management, and full traceability at every level.

The Critical Role of Cable and Wire Harness Assemblies

Aerospace cable assemblies and wiring harnesses are the nervous system of an aircraft, connecting everything from avionics and flight controls to sensors and safety systems. Manufacturing these components requires:

• Precision assembly and 100% functional testing.

• Specialized materials for fire resistance, weight reduction, and durability.

• Complete documentation of every step, from raw materials to final inspection.

Because their production is so labor-intensive, sourcing them from high-cost regions can quickly make programs unaffordable.

The Cost-Effective Solution: High-Skill Manufacturing in Southeast Asia

To meet both strict compliance and cost requirements, aerospace OEMs are increasingly turning to regions with low-cost, high-skill manufacturing. Countries like Indonesia and Malaysia offer a strategic advantage by providing:

• Significant cost savings for labor-intensive harness assembly.

• An abundant supply of skilled technical labor experienced in complex wiring harness production.

• The necessary export infrastructure to support global aerospace supply chains.

When these capabilities are paired with an AS9100-certified process, manufacturers can meet the highest safety and quality standards without sacrificing cost-effectiveness.

Sanbor Manufacturing’s Advantage

At Sanbor Manufacturing, we combine these two strengths to give aerospace OEMs a competitive edge:

• AS9100-certified systems applied to cable assemblies, wiring harnesses, and PCBAs.

• Cost-effective manufacturing in Indonesia and Malaysia for labor-intensive products.

• A global manufacturing footprint that supports supply chain diversification and resilience.

With Sanbor, aerospace OEMs no longer have to compromise. You get the uncompromising safety standards of AS9100 combined with the cost advantages of Southeast Asian production. We're ready to discuss your specific needs when you are. Contact us today!