What Is the AIAG CQI-23 Molding System Assessment and How Do You Use It?

If you work in plastic injection molding, you have likely heard of customer audits that go beyond a simple PPAP. These audits often reference a special process assessment standard developed by the Automotive Industry Action Group (AIAG). That standard is CQI-23, formally titled Molding System Assessment. This article explains what it is, how the assessment works, and how you can apply it in your facility.

What It Is

CQI-23 is a standardized assessment tool published by AIAG for evaluating the control and improvement of special processes in plastic injection molding. It is part of the AIAG "Special Process" series, which includes similar assessments for heat treating (CQI-9), welding (CQI-15), and plating (CQI-11).

The purpose of CQI-23 is not to replace your customer's specific requirements or your internal quality system. Instead, it provides a common framework to assess whether your molding process is robust, consistently controlled, and capable of meeting quality requirements. The assessment covers the entire molding system, including equipment, tooling, personnel, materials, and process controls.

How It Works / Steps

The CQI-23 assessment is divided into three main sections, which you complete in a structured manner:

1. Section A – General Questions: These are management and system-level questions. They cover topics like corrective action processes, control plans, preventive maintenance, and operator training. You answer "Yes," "No," or "N/A" with objective evidence.

1. Section B – Molding Process Specific Questions: This section dives into the actual molding operation. It includes questions on machine parameters (e.g., injection pressure, temperature, cycle time), process monitoring, material handling and drying, and mold maintenance. Each question requires evidence of compliance.

1. Section C – Part-Specific Questions: This section is completed for each part or mold family. It verifies that the control plan, work instructions, and process settings are aligned for that specific part. You must demonstrate that the process is run to the documented parameters.

Scoring: Each question is scored as "Yes" (conforming), "No" (non-conforming), or "N/A" (not applicable). A "No" answer requires a corrective action plan with a defined owner and due date. The overall assessment result is typically expressed as a percentage of "Yes" answers, but there is no single "passing score" defined by AIAG. Your customer may set their own threshold.

Assessment frequency: AIAG recommends conducting the assessment at least annually, or more frequently if there are significant process changes, customer complaints, or after a major equipment move.

A Worked Illustrative Example

Example data (illustrative only): Imagine you are assessing a molding cell that produces a small automotive connector housing. You are using the CQI-23 form.

• In Section A, you review the corrective action log. You find that a recent nonconformance for short shots was closed out with a documented root cause and a verified corrective action. You score this question "Yes."
• In Section B, you check the drying hopper settings. The material supplier specifies a drying temperature of 80°C for 4 hours. The machine display shows 80°C, but the hopper's timer log shows the material was only dried for 2.5 hours before the last run. You score this question "No" and issue a corrective action to update the material handling procedure and retrain operators.
• In Section C, you compare the control plan to the actual machine setup. The control plan lists an injection pressure range of 45–55 MPa. The machine's last 20 parts were run at 52 MPa, which is within range. You score this "Yes."

At the end, you tally your scores. Out of 50 applicable questions, you have 45 "Yes" and 5 "No." Your facility's score is 90%. You now create a corrective action plan for the 5 "No" items, assigning owners and due dates.

Common Pitfalls

• Treating it as a one-time audit: CQI-23 is meant to be a recurring, living assessment. If you only use it before a customer visit, you will miss the continuous improvement intent.
• Ignoring "N/A" justification: You cannot simply mark a question "N/A" to avoid a "No." You must be able to justify why the question does not apply to your process.
• Focusing only on the machine: Many questions relate to documentation, training, and management systems. A clean machine with poor records will still fail the assessment.
• Not linking to corrective action: A "No" answer without a documented corrective action plan is a major gap. The assessment is only valuable if you close the loop.

Closing

The AIAG CQI-23 Molding System Assessment is a powerful tool to systematically evaluate and improve your plastic injection molding process. By following its structured sections and acting on non-conformances, you can build a more robust and reliable process that meets customer expectations. To streamline your assessments and track corrective actions, try the free CQI-23 tool available at https://www.6sq.com/tools/cqi23/.