Avoidance
Prevent high-risk items entering the supply chain through authorised sources, approved suppliers, traceability, contract flow-down, obsolescence management and trained personnel.
SPI
Special Processes Institute
sp-i.org
Counterfeit Prevention Project Report
Counterfeit Detection, Mitigation & Avoidance Project App
Learn how counterfeit and suspect counterfeit items enter aerospace, defence, space and other high-integrity supply chains. Apply recognised prevention principles, assess procurement and product risk, define source controls, build an inspection and test plan, manage suspected incidents, record evidence and generate a controlled project report.
Trusted-source prevention Risk-based detection plan Evidence preservation No return-to-supplier without control
Avoid
Use authorised and approved sources, traceability and contractual controls
Detect
Apply proportionate document, visual, physical and laboratory verification
Contain
Quarantine, preserve evidence, assess product impact and prevent escape
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Current project completeness
What Counts as Counterfeit?
Intentional misrepresentation is the central distinction.
A counterfeit item is an item deliberately misrepresented as to identity, source, manufacturer, material, age, condition, configuration, certification, performance or conformance. A suspect counterfeit item presents credible indicators but has not yet been conclusively authenticated or rejected.
Detection
Use layered verification including document review, packaging and marking inspection, dimensional and material checks, electrical or functional testing and specialist laboratory methods.
Mitigation & disposition
Quarantine, preserve evidence, control communication, assess affected product, report where required and prevent suspect items being returned to an uncontrolled supply chain.
Common Counterfeit Modes
| Mode | Typical example | Possible indicators | Primary controls |
|---|---|---|---|
| Remarking / relabelling | Commercial electronic part marked as military or aerospace grade. | Sanding, resurfacing, inconsistent font, date-code anomalies, coating residue. | Authorised source, visual inspection, solvent testing where permitted, X-ray, electrical testing, decapsulation. |
| Used sold as new | Components recovered from scrapped assemblies. | Reworked leads, solder residue, oxidation, inconsistent packaging, mixed lot codes. | Chain of custody, microscopy, solderability, X-ray, destructive physical analysis. |
| Material substitution | Lower-grade alloy substituted for specified aerospace material. | Wrong chemistry, hardness, density, grain structure or coating. | Positive material identification, hardness, metallography, certificate verification. |
| False documentation | Fabricated CoC, mill certificate, calibration or special-process certificate. | Template mismatch, invalid approval, impossible dates, altered values, unverifiable signatory. | Direct verification, secure portals, heat/lot correlation, accreditation and approval checks. |
| Overproduction / unauthorised source | Genuine-looking product made or sold outside controlled authorisation. | Unrecognised distribution route, no OEM traceability, unexplained excess stock. | Authorised distribution, supply-chain disclosure, controlled surplus and return processes. |
| Fraudulent repair or modification | Repaired unit represented as new or unmodified. | Broken seals, mismatched serials, rework evidence, firmware/configuration discrepancy. | Serialization, tamper evidence, configuration verification, functional test. |
Critical principle: Detection cannot compensate for weak procurement. The strongest control is to avoid unnecessary exposure by buying from the original manufacturer, authorised distributor or another demonstrably trusted source with full traceability.
Standards and Frameworks
How the Standards Fit Together
| Need | Primary framework | Application |
|---|---|---|
| Organisation-wide counterfeit control | AS9100 and contract/customer requirements | Risk, awareness, supplier control, verification, traceability, nonconformance and prevention of counterfeit parts. |
| Electronic parts programme | SAE AS5553 | Programme requirements for avoidance, detection, mitigation and disposition of counterfeit electronic parts. |
| Independent distributor controls | SAE AS6081 | Controls for brokers and independent distributors handling electrical, electronic and electromechanical parts. |
| Electronic test methods | SAE AS6171 family | Risk-based inspection and test methods for suspect counterfeit EEE parts. |
| Non-electronic material and product | SAE AS6174 / AS6496 as applicable to contractual scope | Prevention and control approaches for fraudulent or counterfeit material and non-electronic items. |
| General quality management | ISO 9001 | Externally provided product, identification, traceability, competence, documented information and nonconforming outputs. |
| Laboratory competence | ISO/IEC 17025 | Competence, method control, traceability and validity of laboratory testing used to authenticate items. |
Layered Detection Methods
Select tests based on product, source, criticality and counterfeit mechanism.
Evidence and Investigation Controls
Preserve the evidence
- Quarantine the complete lot, packaging, labels and paperwork.
- Photograph condition before destructive testing.
- Maintain chain of custody and unique evidence identification.
- Prevent commingling, rework or unauthorised return.
Control the technical conclusion
- Differentiate nonconforming, suspect counterfeit and confirmed counterfeit.
- Use competent specialists and validated methods.
- Record limitations, sampling basis and uncertainty.
- Seek OEM or original manufacturer authentication where practical.
Practical Examples
Obsolete flight-control IC
Risk: Broker source, obsolete part, short lead time and safety-critical application.
Controls: Full traceability request, package/marking inspection, X-ray, XRF, electrical test and sample decapsulation.
Outcome: Commercial die found beneath military markings; lot quarantined and reported.
Aerospace fastener
Risk: Unusual low price and incomplete manufacturer traceability.
Controls: Head-mark comparison, dimensional/thread inspection, XRF/OES, hardness, coating verification and mechanical testing.
Outcome: Lower-strength alloy and incorrect heat treatment confirmed.
False special-process certification
Risk: Certificate claims Nadcap-approved heat treatment, but supplier route is unclear.
Controls: Verify processor approval and scope, certificate number, dates, furnace/load records and purchase-order flow-down.
Outcome: Certificate was fabricated and processing could not be substantiated.
Counterfeit bearing
Risk: Branded bearing purchased from an online marketplace.
Controls: Packaging authentication, laser-mark review, dimensional inspection, internal geometry/material examination and manufacturer comparison.
Outcome: Used bearing repackaged with copied branding.
Aluminium raw material
Risk: 7075-T6 certificate supplied through a stockist with a broken chain of custody.
Controls: Heat-number verification, PMI/OES, hardness and conductivity/temper checks.
Outcome: Material identified as 6061; affected work-in-progress traced and contained.
Firmware/configuration fraud
Risk: Electronic module serial number matches paperwork, but function differs.
Controls: Secure firmware signature, configuration checksum, functional test, internal inspection and OEM authentication.
Outcome: Repaired legacy module represented as new production.
Counterfeit Risk Assessor
Score source, product and programme exposure, then define the verification level.
| Risk factor | Assessment | Score |
|---|
Complete the assessment to generate a suggested control level.
Counterfeit Control Project Builder
Scope phase0% complete
Counterfeit Prevention Project Report
Generated from the project builder and risk assessment.
Complete the project builder and select Generate Report.