AIAG CQI-27 Special Process: Casting System Assessment (CSA)
, currently in its 2nd Edition (updated in March 2018), is a self-assessment tool used by automotive foundry suppliers to ensure robust processes and minimize casting defects. The updated assessment is typically completed using an Excel-based template
provided by AIAG, which features 10 specific process tables covering various casting methods. Https://Www.En-Standard.Eu Core Structure of CQI-27 (2nd Edition)
The assessment is divided into two main sections: the general quality management system assessment and specific technical process tables. INFOTECH STANDARDS Management System Assessment:
Covers overarching organizational requirements such as documentation, training, equipment maintenance, and corrective actions. Process Tables (A–J):
Detailed technical checklists for specific casting processes: Sand Casting (Iron/Steel) Centrifugal Castings Centrifugal Liners Investment Castings (Iron/Steel) Aluminum SPM Cylinder Heads Aluminum Sand Castings Aluminum Metal Mold Aluminum High Pressure Die Cast (HPDC) Magnesium HPDC INFOTECH STANDARDS CQI-27 Casting System Assessment Guide | PDF - Scribd
The CQI-27 Special Process: Casting System Assessment (2nd Edition) is a standardized framework published by the AIAG to help automotive foundries ensure robust process controls and minimize defects. Key Features & Updates (2nd Edition)
The updated manual includes an Excel file designed for simpler assessment completion and editing:
Consolidated Requirements: Similar tables from the 1st Edition have been merged for better efficiency.
Expanded Process Coverage: New tables added to cover a wider range of casting processes, including sand, investment, and high-pressure die casting.
Mandatory Focus: Greater emphasis on requirements generally regarded as mandatory and on customer-authorized deviations.
Editable Excel Sheets: Unused rows, columns, and sheets are now unprotected to allow for easier customization and editing. Included Process Tables The assessment includes 10 specialized process tables: Table A: Sand Casting (Iron/Steel) Table B/C: Centrifugal Castings & Liners Table D: Investment Castings cqi27 casting system assessment xls upd
Table E-H: Aluminum processes (Cylinder Heads, Sand Cast, Metal Mold, High Pressure Die Cast) Table I/J: Magnesium & Zinc High Pressure Die Cast Critical Audit Areas
The assessment checklist focuses on technical controls such as:
Casting Simulation: Mandatory use of solidification modeling software (e.g., MagmaSoft, AnyCasting).
Tooling Maintenance: Requirements for cycle-based tracking and non-abrasive cleaning methods.
Metal Control: Guidelines for storage, magnesium treatment, and temperature management. CQI-27 | Special Process: Casting System Assessment - AIAG
The CQI-27 Special Process: Casting System Assessment (CSA) is a standard developed by the Automotive Industry Action Group (AIAG) to provide a common framework for foundries supplying automotive castings. It is designed to identify areas for improvement and reduce the risk of casting defects across the supply chain. Key Overview of CQI-27
The assessment is intended to be a self-assessment or customer audit performed at least annually to ensure the foundry's manufacturing processes—such as melting, pouring, and solidification—meet rigorous industry expectations.
Objective: Develop robust processes to eliminate root causes of defects, reduce variation, and prevent failures.
Target Processes: It covers multiple casting methods, including sand, centrifugal, investment, and high-pressure die casting for iron, steel, aluminum, magnesium, and zinc.
Assessor Qualifications: Auditors should have a minimum of 5 years of experience in casting processes and be experienced internal quality auditors (e.g., ISO 9001 or IATF 16949). The CSA Assessment Workbook (XLS)
The assessment is completed using a standardized Excel file, which typically includes the following sections: AIAG CQI-27 Special Process: Casting System Assessment (CSA)
Assessment Header: Details about the facility, contacts, and audit scope.
Questions Section: General questions regarding quality management, documentation, equipment maintenance, and corrective actions.
Process Tables (A-J): Specialized checklists for specific casting types. For example: Table A: Sand Casting (Iron/Steel) Table E: Aluminum SPM Cylinder Heads Table H: Aluminum High-Pressure Die Casting
Job Audit Section: Verification of the process on the shop floor for a specific part number, confirming that actual practices match documented control plans. Latest Updates (2nd Edition)
The 2nd Edition (published around 2018) introduced several refinements to improve usability:
CQI-27 – Special Process: Casting System Assessment: the method
CQI-27 Special Process: Casting System Assessment (2nd Edition)
is the current global standard for automotive foundry suppliers to evaluate and improve their management systems. Released in March 2018, this update replaced the original version to better address common failure modes that lead to non-conforming castings. www.cqi-support.de Key Updates in the 2nd Edition
The 2nd Edition introduced several enhancements to streamline the assessment process and improve quality outcomes: Consolidated Process Tables
: Tables with similar requirements were merged to reduce redundancy. Expanded Coverage
: New tables were added to cover a wider range of casting processes, including ten specific process tables (A through J) for materials like iron, steel, aluminum, magnesium, and zinc. Mandatory Emphasis and damaged brand reputation. Enter CQI-27
: There is a greater focus on content regarded as mandatory and a strict requirement that deviations must be authorized by customer Product Engineering. Improved Clarity
: Unclear wording from the 1st Edition was revised to ensure consistent interpretation across the supply chain. Assessment XLS Functionality The assessment is typically completed using an Excel-based template provided with the manual from the AIAG Store User Editing
: In the 2nd Edition, unused columns, rows, and sheets are generally not protected, allowing for easier common Excel editing by the user. Core Components : The assessment file typically includes sections for a Cover Sheet (facility info, assessment dates, and findings summary), Process Tables (detailed technical requirements), and a Mandatory Submissions
: Suppliers are often required by OEMs to conduct this self-assessment at least once a year to maintain compliance with IATF 16949 standards. www.cqi-support.de Available Process Tables
The update defines requirements for the following specific casting types: : Sand Casting (Iron/Steel) : Centrifugal Castings & Liners : Investment Castings (Iron/Steel) Table E/F/G/H : Aluminum (SPM, Sand, Metal Mold, High Pressure Die Cast) : Magnesium & Zinc High Pressure Die Cast
For formal certification or to obtain the official template, you can visit the AIAG CQI-27 page or consult specialized providers like TopQM-Systems for support and training. for one of the process tables, such as High Pressure Die Casting CQI-27 | Special Process: Casting System Assessment - AIAG
| Pitfall | Solution in Updated XLS | |--------|--------------------------| | Forgetting to update N/A justification | N/A column requires a text explanation | | Missing furnace uniformity testing | Pre-filled reminder cells with due dates | | Heat treat not aligned with CQI-9 | Annex D links directly to CQI-9 checklist | | No evidence of internal audit | Separate tab for “Internal Audit History” | | Corrective actions not tracked to closure | Auto-expiring due date flags after 30 days |
🔧 Action Plan for Teams:
📎 Attachment: CQI27_Assessment_v2.3_2024.xls (Excel 2016+ compatible, macros disabled for security).
In the high-stakes world of automotive and industrial manufacturing, casting defects are not merely an inconvenience—they are a liability. Porosity, inclusions, and dimensional inaccuracies can lead to catastrophic product failures, costly recalls, and damaged brand reputation.
Enter CQI-27, the Casting System Assessment (CSA) standard developed by the AIAG (Automotive Industry Action Group). This specialized auditing framework is designed specifically for foundries and casting suppliers. It provides a structured methodology to evaluate process controls, prevent defects, and ensure metallurgical integrity.
However, the true power of CQI-27 lies not just in understanding the standard—but in implementing it effectively. That is where the "cqi27 casting system assessment xls upd" comes into play. This file—an updated, dynamic Excel-based scorecard—has become the go-to operational tool for quality engineers, process auditors, and supply chain managers.
In this comprehensive article, we will dissect everything you need to know: from the structure of CQI-27 to the specific advantages of using the latest XLS UPD version for real-time compliance tracking.