Product realisation is the connected set of activities that turns requirements into a conforming product or service. In AS9100D the relevant controls are principally within Clause 8 — Operation. It is wider than manufacturing: contract review, configuration, design where applicable, external providers, production, special processes, inspection, test, FAI, nonconformance control, release and delivery all contribute.
AS9100D relationship
8.1 operational planning and control provides the framework. Aerospace-specific controls include operational risk management (8.1.1), configuration management (8.1.2), product safety (8.1.3) and prevention of counterfeit parts (8.1.4). Requirements are addressed in 8.2, design in 8.3, external providers in 8.4, production in 8.5, release in 8.6 and nonconforming outputs in 8.7.
Quality's role
Quality provides assurance that the realisation system is planned, evidence-based and effective. The aim is not to “inspect quality in” at the end; it is to ensure requirements, risks, controls, competence, resources, verification and records are established throughout the lifecycle.
Vertical product / process-trail audit
A powerful assurance technique is to select a real customer order and product serial number or batch, then trace it from contract and requirements through configuration, purchasing, manufacture, special processes, inspection/test, nonconformances, FAI and final release. This tests whether the system actually produced the authorised product.