CQI-27 Casting: Run a Special Process System Assessment
What is CQI-27?
CQI-27, 'Casting System Assessment', is the AIAG standard method for systematically evaluating casting special processes in the automotive industry. It belongs to the CQI family alongside CQI-9 heat treat and CQI-11 plating, using a uniform scoring sheet to judge whether supplier processes are controlled, and is a common requirement for special process management under IATF 16949. The assessment covers the man, machine, material, method, environment and measurement elements, and aims to identify process risk and drive improvement rather than simply find fault.
When to Use It
Use CQI-27 for casting supplier sourcing decisions and annual performance rating, for pre-audits before OEM or customer audits, and for internal foundry self-assessment. It pairs well with layered process audits (LPA) and VDA 6.3 process audits to build a three-layer audit system covering daily patrol, process audit and special-process assessment. Run it whenever there is a major quality incident, a process change or a customer complaint.
How to Use It (Step by Step)
Open the tool, select the casting assessment sheet, and work through process tables A-H covering core making, melting, pouring, shakeout, cleaning and heat treatment sub-processes. Each item follows a question-evidence-score structure on a 0-1-2-3 scale: 3 fully conforming, 2 partially conforming with an improvement opportunity, 1 non-conforming, 0 not implemented. The tool totals each process table's score and conformity rate, then exports a non-conformance list as input to corrective action planning.
Key Formulas / Example
CQI-27 is a scored checklist rather than a calculation. Each process table reports a conformity rate, and any item scored 1 or 0 is a non-conformance that requires a corrective action with an owner and due date. When the overall conformity rate is low, plan a systematic improvement program and schedule a re-assessment within the agreed time.