Counterfeit part prevention remains a high priority for the aerospace, defense, and electronics sectors in 2025. Unauthorized parts when used in critical applications can lead to catastrophic failures. Counterfeit components can include remarked parts or cloned components that are illegally manufactured.
There is an escalating trend for counterfeit parts in most manufacturing sectors. Components at risk in the defense and aerospace industry include semiconductors, fasteners, electronic assemblies, and composite structures.
US Federal Governmental Actions
The US Government has instituted contractual requirements for defense contractors by way of DFARS 252.246-7007. This DFAR establishes requirements for contractors to implement and maintain risk-based policies and procedures for detection and avoidance. Contractors are required to flow down these requirements to all subcontractors, ensuring compliance at all levels of the supply chain. This regulation emphasizes the importance of sourcing electronic parts from trusted suppliers to minimize risks.
The CHIPS Act, enacted on August 9, 2022, was created to promote domestic semiconductor manufacturing and research. It also promotes semiconductor production and workforce development. This along with efforts from various U.S. agencies is striving to develop trusted supply chains for Original Equipment Manufacturers (OEMs) in the United States.
AS9100 Quality Management System
AS9100D is a Quality Management System (QMS) based on the structure and content of ISO 9001:2015 with the addition of requirements specific to the defense and aerospace industries. It includes provisions for customer and regulatory requirements. The standard is applicable to businesses of all sizes who need to consistently provide products and services to specified requirements. Additionally, it provides processes for systematic improvement of the management system and its ability to ensure customer satisfaction.
AS9100 requirements include counterfeit part prevention into manufacturing cycles. It requires that specific actions be undertaken. These actions include training, establishment of a parts monitoring program, use of authorized and approved sources, traceability requirements, verification methodologies, monitoring of counterfeit part reports, and reporting and quarantining of detected or suspected counterfeits.
AS5553 Standard for Supply Chain Security
AS5553 – Counterfeit Electronics Parts; Avoidance, Detection, Mitigation and Disposition was created in 2009. The newest revision, SAE AS5553D, was released in April 2022. It provides methods, requirements, and practices for parts management, supplier management, procurement, inspection, test/evaluation, and response strategies for designers and manufacturers of electromechanical parts (EEE).
These requirements are intended to be integrated throughout the supply chain. The standard calls for risk-based assessments to establish priorities for mitigation of counterfeit EEE parts. These assessments should consider vulnerabilities to crucial components, levels of desired performance, and necessary reliability of the product.
Private Sector Solutions
Industry and the aerospace sector in particular are developing solutions for counterfeit detection and supply chain integrity. In recent developments Boeing and Aeroxchange have replaced paperwork with files that are cryptographically secured. This system not only adds layers of security to the transfer of verifiable parts but reduces overall turnaround time.
Other companies are continuing the advancement of non-destructive analytical tests such as electrical spot checks, X-ray, and optical miscoscopy. Additional anti-counterfeit technologies that are in use include hologram and optical variable devices, security inks, RFID tags, blockchain authentication, and tamper evident labels and packaging.
Information Security in the Supply Chain
Adequate information security is essential in ensuring counterfeit part prevention of components, and assemblies in the supply chain. NIST SP 800-161 provides guidance on managing cybersecurity risks in the supply chain, including concerns about counterfeit parts that may contain malicious functionality or vulnerabilities due to poor manufacturing practices. Implementation of this standard is a contractual requirement for many government contractors, their subcontractors, and suppliers.
CVG Strategy Quality Management Experts
Our Exemplar Global Lead Auditor Consultants can help you with integrating multiple management systems. CVG Strategy has prepared, trained and implemented management systems for manufacturing companies in many business sectors.
Our quality strategy allows clients new to Quality Management Systems to rapidly implement a tailored system, because everything we do as consultants is processed based. Our Quality Experts have experience with ISO9001:2015, AS9100D, ISO 13485:2016, ISO 27001:2013 and Association of American Railroads (AAR) M-1003 and can readily deliver compliant procedures and work instructions.
CVG Strategy is a consultancy offering coaching, mentoring, training and program development focused on areas including Business Process Improvement, Export Compliance, Cyber Security and Product Test and Evaluation.