What Is the AIAG CQI-27 Casting System Assessment and How Do You Use It?

If you work in automotive or aerospace supply chains, you have likely heard of CQI assessments. The AIAG CQI-27 Casting System Assessment is a specialized audit tool designed to evaluate and improve casting processes—a "special process" where quality cannot be fully verified by final inspection alone.

This article explains what CQI-27 is, how it works, and how to apply it effectively.

What It Is

CQI-27, formally titled Casting System Assessment, is a standard published by the Automotive Industry Action Group (AIAG). It provides a common framework for assessing a supplier's casting process management system. The assessment covers both ferrous and non-ferrous casting operations, including sand casting, die casting, investment casting, and others.

Unlike a typical product audit, CQI-27 evaluates the system around the process—people, equipment, tooling, maintenance, and documentation. It is intended to be used by suppliers to self-assess, by customers to audit suppliers, and by third parties to verify compliance. The goal is consistent, defect-free casting output through robust process control.

How It Works / Key Steps

CQI-27 is structured into three main sections:

1. Management Responsibilities & Quality – Covers plant leadership, quality planning, corrective action, and continuous improvement.
2. Facility & Equipment – Evaluates the condition of furnaces, dies, molds, handling equipment, and maintenance practices.
3. Process Control – The largest section, detailing specific requirements for each casting method (e.g., die casting, sand casting). It includes checklists for parameters such as melt temperature, mold temperature, cycle time, and inspection frequency.

The assessment uses a scoring system:

• "Full Conformance" – meets all requirements
• "Partial Conformance" – some gaps exist
• "No Conformance" – requirement not met
• "Not Applicable" – process not used

A typical audit follows these steps:

1. Pre-audit review – Gather process documentation, control plans, and PFMEAs.
2. On-site walkthrough – Observe the actual casting operations against the checklists.
3. Interview operators and engineers – Verify knowledge and adherence to procedures.
4. Score each requirement – Assign conformance levels.
5. Identify non-conformances – Record findings and require corrective action plans with deadlines.
6. Follow-up – Verify closure of non-conformances at a later date.

A Worked Illustrative Example

Example data (illustrative only):

A die-casting supplier performs a CQI-27 self-assessment. In the "Process Control – Die Casting" section, the auditor checks the requirement for "shot profile monitoring."

• The control plan specifies a shot speed of 2.5 m/s ± 0.2 m/s.
• The auditor observes that the machine records shot speed for every cycle, but the data is only reviewed weekly.
• The requirement states that shot parameters must be monitored and reviewed at a defined frequency, with reaction plans if out of range.

Scoring: The supplier has the monitoring system (Partial Conformance) but lacks a documented reaction plan for out-of-range conditions. The auditor scores this item as "Partial Conformance" and issues a corrective action request.

The supplier then:

• Adds a real-time alarm when shot speed deviates beyond ±0.2 m/s.
• Documents a reaction plan (stop production, quarantine parts, adjust process).
• Trains operators on the new procedure.

At the follow-up audit, the item is upgraded to "Full Conformance."

Common Pitfalls

• Treating CQI-27 as a one-time checklist – It is a continuous system assessment, not a pass/fail exam. Re-assess regularly.
• Ignoring "Not Applicable" justifications – If you mark an item N/A, you must have documented evidence why it does not apply to your process.
• Focusing only on the checklist – The real value is in the corrective actions and process improvement, not just the score.
• Lack of operator involvement – Operators often know the real process gaps. Interview them, not just managers.

Closing

CQI-27 is a powerful tool to reduce scrap, improve delivery, and satisfy customer requirements. To streamline your assessment and track corrective actions, try the free CQI-27 tool at 6sq.com – it helps you manage the assessment efficiently and keep your casting process under control.