AQAP 2110 in EU Foundries: NATO Quality Requirements

What is AQAP 2110? An Overview

AQAP 2110 (Allied Quality Assurance Publication 2110) is a NATO standard that establishes the Quality Management System (QMS) requirements for organizations involved in the design, development, and production of defence supplies. For foundries aiming to supply castings and cast components for defence contracts, implementing AQAP 2110 is becoming a critical condition for competitiveness and customer trust. Many military tenders in NATO countries now directly require compliance with or certification to AQAP 2110. This article provides an overview of the standard and the specifics of its application in foundries across the European Union.

Relationship with ISO 9001 and the Standard’s Independence

The AQAP 2110 standard is fundamentally based on the international standard ISO 9001 but supplements it with a series of specific NATO requirements. In other words, an organization is required to have an effectively functioning ISO 9001 QMS plus meet the additional conditions of AQAP.

AQAP 2110 directly incorporates all requirements of ISO 9001 (in the edition current at the time of the AQAP’s publication), so an organization must, at a minimum, comply with ISO 9001. However, AQAP 2110 is considered an independent system because it contains provisions specifically relevant to military products. For instance, the standard reinstates the mandatory role of a management representative for quality, who has specific authority and the duty to liaise with the Government Quality Assurance Representative (GQAR) on all quality matters. This emphasis goes beyond the scope of ISO 9001:2015, where this role is only mentioned indirectly.

It is important to note that, unlike civilian ISO standards, AQAP requirements are imposed contractually. If a foundry signs a contract for defence products, the terms of AQAP 2110 may become part of the agreement, and failure to comply is equivalent to a breach of contract. Military customers, through the GQAR, have the right to reject a supplier’s quality system if they deem it non-compliant with the standard and can demand corrective actions.

Therefore, AQAP 2110 should be seen not just as an add-on but as a superstructure built upon an ISO 9001 QMS, essential for meeting the stringent demands of defence customers.

Structure and Key AQAP 2110 Requirements for Foundries

The structure of AQAP 2110 largely mirrors the sections of ISO 9001 and is focused on ensuring the reliability and safety of military products throughout their entire lifecycle. For foundries, this means strict quality control – from mold preparation and alloy melting to the final finishing and acceptance of castings.

• Quality Management System and Leadership. Management must demonstrate its commitment to quality and appoint a representative responsible for ensuring the QMS complies with NATO requirements and for liaising with the GQAR. For a foundry, this means top management is actively involved in ensuring casting quality and allocates the necessary resources.
• Planning and Risk Assessment. AQAP 2110 mandates detailed quality planning for each defense contract. The organization must identify and analyze risks related to product quality (e.g., risks of casting defects, equipment failure) and document a Risk Management Plan, applying the principles of ISO 31000. The GQAR has the right to request evidence of risk consideration and may reject the plan if it is deemed inadequate.
• Configuration Management and Documentation. It is necessary to meticulously manage the product’s configuration: identify every version of drawings, control changes, and maintain records. A Configuration Management Plan (CMP) is typically required. For a foundry, this is crucial when involved in tooling design or process changes; any modifications to mold design, alloy composition, etc., must undergo formal control.
• Production, Testing, and Traceability. The standard reinforces requirements for operational control. Special processes (e.g., heat treatment or welding to repair defects) must be validated. Identification and traceability are critical: the organization must uniquely identify each casting and its source materials. For components whose failure could lead to loss of equipment or life, traceability is mandatory at all stages. In practice, this means marking castings and keeping records of the melt, alloy batch, and manufacturing process for each unit.
• Final Inspection and Acceptance. Only products confirmed to meet all requirements are permitted for shipment. The company issues a Certificate of Conformance (CoC), certifying that the products were manufactured and tested according to specifications. If the contract requires GQAR participation in acceptance, the supplier must provide advance notification. Responsibility for product conformity always rests with the supplier.
• Management of Nonconformities. The organization must have an effective process for root cause analysis of defects. If a nonconforming product has already been shipped, the company must immediately notify the GQAR. Nonconforming products must be segregated and cannot be shipped without formal customer authorization (a waiver or concession).
• Metrological Control. Requirements for calibrating measurement equipment are stricter than in ISO 9001, with the use of ISO 10012 recommended. If a measuring device fails, the supplier must assess the impact on previously shipped products and inform the GQAR of the risk.
• Supplier Management. AQAP 2110 requires a thorough evaluation of subcontractors and associated risks. All applicable standard requirements must be flowed down to them. The GQAR has the right of access to subcontractor facilities for assessment. The foundry, however, retains full responsibility for the final product’s conformity.

Practical Aspects of Implementing AQAP 2110

Implementing the standard’s requirements imposes several additional duties on a foundry.

1. Developing Contract-Specific Documentation. For each defense order, the company must prepare and agree upon a Quality Plan with the customer. This document serves as a quality assurance “roadmap” for the specific contract, detailing how the requirements of AQAP 2110 will be met. Other documents, like a Configuration Management Plan or Risk Management Plan, may also be required.
2. Interaction with the GQAR. Communication with the customer becomes formal and regular. A Post-Award GQA Meeting is often held to discuss all organizational aspects of quality assurance. The company must promptly inform the GQAR of any changes that could affect quality and provide advance notice for final inspections.
3. Readiness for External Audits. Beyond certification, the company is under constant surveillance. Military customers can conduct unannounced audits at the supplier’s and its subcontractors’ facilities. Documentation must be kept in order, and personnel must be trained to answer auditors’ questions confidently.
4. Quality Culture and Risk Management. Implementing AQAP 2110 often requires a shift in corporate culture. It encourages a proactive approach: anticipating defects using risk analysis tools (like FMEA) rather than waiting for them to occur. This leads to improved internal processes and overall technological discipline.

Application of AQAP 2110 in the European Union

In EU countries, AQAP 2110 serves as a universal quality benchmark for defence suppliers. Many ministries of defence (e.g., in Germany, Poland, Italy) include its requirements in contract terms. Customers expect foundries to demonstrate predictability, process control, and full transparency, including providing any records on demand and reporting problems immediately.

When working with UK customers, AQAP 2110 is often included alongside special DEFCON (Defense Conditions), such as DEFCON 602A or 602C. These clauses mandate that the supplier provide a detailed Deliverable Quality Plan, which becomes an official contractual document.

Recommendations for Implementing AQAP 2110

• Strengthen Your ISO 9001 Foundation. Ensure your basic QMS is functioning effectively.
• Conduct a Gap Analysis. Study the AQAP 2110 requirements and identify what needs to be improved or implemented.
• Train Personnel. The standard’s requirements must be understood by management and production teams, not just the quality department.
• Develop Document Templates. Prepare standard forms for the Quality Plan, Configuration Management Plan, and various reports.
• Establish a Collaborative Relationship with the GQAR. Proactive and transparent communication is highly valued by customers and simplifies joint work.

Conclusion

For a foundry in the EU, implementing AQAP 2110 is a significant challenge but also a major competitive advantage. The standard transforms a conventional ISO 9001 QMS into a comprehensive, military-grade system capable of guaranteeing high quality and product traceability. With an AQAP 2110 certificate, a foundry gains access to international defence projects and earns a reputation as a reliable NATO supplier.