PART #3: How to Implement AQAP 2110 Without Chaos. A Step-by-Step Guide for Foundries

When manufacturers hear about NATO’s AQAP 2110, the first reaction is often apprehension. “Mountains of paperwork.” “Endless inspections.” “Bureaucracy for the sake of bureaucracy.” The reputation of defense standards can be intimidating. But in reality, adopting AQAP 2110 does not have to be chaotic. With the right approach, implementation can be structured, manageable, and even beneficial.

For foundries that already operate under ISO 9001, the transition is evolutionary, not revolutionary. The foundation is there; the task is to build the second story. Here is a practical roadmap to making that journey without unnecessary stress.

Step 1: Conduct a Gap Analysis

Begin by comparing your current ISO 9001 system against the specific requirements of AQAP 2110. Identify the overlaps, the partial matches, and – most importantly – the gaps. Perhaps you already practice some form of traceability but not at the level of individual castings. Maybe you have quality procedures but no formal Quality Plan for each contract.

This analysis is more than an academic exercise. It provides a concrete checklist of what needs to be created, updated, or strengthened. Think of it as mapping the distance between where you are and where you need to be.

Step 2: Develop an Implementation Plan

With the gaps identified, build a structured plan of action. Assign responsibilities, set deadlines, and prioritize. Some requirements – like configuration management or supplier oversight – may demand more time and resources. Others can be addressed quickly by adapting existing procedures.

Top management buy-in is essential. AQAP 2110 touches multiple departments and often requires cultural change. Without leadership support, progress stalls.

Step 3: Train and Engage Personnel

Standards fail when they are perceived as “extra bureaucracy.” To prevent this, invest in communication and training. Explain to managers, engineers, and shop-floor workers why AQAP matters. Emphasize that this is not just about satisfying auditors but about qualifying for high-value defense contracts.

Training should be both conceptual and practical. Managers need to understand the logic behind AQAP. Operators should be shown how to apply new practices: marking castings for traceability, recording inspection results, or handling visits from government quality representatives (GQARs).

Step 4: Update Documentation

ISO 9001 documents remain the backbone, but they need reinforcement. AQAP 2110 introduces several key additions:

• Quality Plans: templates and procedures for contract-specific plans.
• Configuration management: formal processes for controlling and documenting changes.
• Supplier oversight: contractual clauses granting GQAR access, stricter evaluation criteria, and risk-based monitoring.
• Traceability procedures: marking systems, record retention, and linkages between materials, processes, and products.
• Nonconformance handling: rules for reporting defects to the customer and requesting concessions.

The goal is not paperwork for its own sake but clear, practical documents that people actually use.

Step 5: Test the System

Before facing external auditors, test the new system internally. Conduct a “trial run” on a live project – even a civilian one – by applying AQAP rules. Draft a Quality Plan, implement configuration changes through the new process, or trace a single batch of castings from melting to final inspection.

These exercises expose weaknesses early. If records are missing, if staff struggle with procedures, or if communication breaks down, better to discover it during rehearsal than during a NATO audit.

Step 6: Perform an Internal Audit

Once the system is running, conduct a comprehensive internal audit against AQAP 2110. Ideally, the auditor should not be the person who wrote the procedures – fresh eyes are more likely to spot shortcomings.

The audit should check more than documents. Interview personnel: do they understand their new responsibilities? Verify that processes are genuinely followed. Document all non-conformances and corrective actions. Treat this as a full dress rehearsal for certification.

Step 7: Undergo External Certification

When confident in compliance, invite accredited auditors. In many countries, certification combines ISO 9001 and AQAP 2110 into one audit. Expect a thorough review: not only your documents but also your factory floor, subcontractor management, and even communication logs with the GQAR.

Successful certification grants the AQAP 2110 certificate – a ticket to defence contracts and proof of readiness for one of the world’s most demanding markets.

Key Considerations Along the Way

• Pace yourself. Rushing invites superficial fixes. A measured rollout over several months yields a system that works in practice.
• Leverage consultants and peers. Companies already certified can offer invaluable lessons, from templates to audit insights.
• See beyond defense. While AQAP is a NATO requirement, the discipline it enforces often improves performance for civilian clients as well. Many firms report lower defect rates, better supplier reliability, and stronger customer trust after implementation.
• Think continuous improvement. Certification is not the finish line. Defense contracts bring ongoing audits, regular GQAR visits, and evolving requirements. Building a culture of continuous improvement is the only sustainable approach.

A Foundry Perspective

For a foundry, AQAP implementation reshapes daily routines. Heat numbers and furnace programs must be recorded in detail. Every casting must carry a traceable identifier linked to inspection data. Suppliers of alloys, molds, and testing services must accept the possibility of government audits. Quality managers must work side by side with GQARs, treating them less as inspectors and more as partners in assurance.

Yes, it is demanding. But it also professionalizes the organization. Operators become more attentive, engineers more disciplined, managers more transparent. The result is not only eligibility for NATO contracts but also a stronger, more competitive enterprise overall.

Conclusion: AQAP as an Investment, Not a Burden

Implementing AQAP 2110 can seem daunting, but the process becomes manageable when broken into clear steps: analyze gaps, plan, train, document, test, audit, certify. Each stage builds confidence and discipline.

Most importantly, AQAP should not be viewed as a bureaucratic burden. It is an investment – in market access, in reputation, and in operational excellence. Defense customers demand it, but civilian clients also recognize the value of such rigor.

For foundries, the journey from ISO 9001 to AQAP 2110 is a transformation. It elevates the company from “good enough” to “trusted without question.” And in industries where reliability defines success, that transformation is worth every effort.

Read the previous part – PART #2: AQAP 2110 vs. ISO 9001. Key Differences and What They Mean for Foundries