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:
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) cqi27 casting system assessment xls upd
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
: 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 The CQI-27 Special Process: Casting System Assessment (CSA)
: 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
The fluorescent lights of the Quality Lab hummed at a frequency that matched Elias’s headache. On his dual monitors, the CQI-27 Special Process: Casting System Assessment spreadsheet stared back at him—a digital labyrinth of tabs, checkboxes, and red-font warnings.
"Is the update live?" Sarah leaned over his cubicle wall, a steaming mug of coffee in her hand.
"Almost," Elias muttered, his fingers dancing across the mechanical keyboard. "The AIAG released the new revision, and I’m mapping our current foundry workflows to the updated 'XLS' template. It’s not just a facelift, Sarah. They’ve tightened the screws on the Process Control Tables."
He clicked through the Section 1: Management Responsibility tab. The goal was simple: ensure their casting operations weren't just functional, but bulletproof. In the world of high-pressure die casting, a single overlooked variable in the assessment could mean a million-dollar recall.
"Look at this," he pointed to a new row in the spreadsheet. "The updated assessment requires more granular data on pyrometry and melt chemistry. If we don't check 'Satisfactory' on these sub-clauses, the whole dashboard goes red." IATF 16949 – Clause 8
Sarah squinted at the screen. "And the 'upd' tag in the filename?"
"That’s my version control," Elias explained. "I’ve integrated a macro that pulls real-time data from the furnace sensors. If the temperature dips during a pour, the XLS flags it before the inspector even walks onto the floor."
With a final click of the 'Save' icon, the red cells flashed green. The assessment was complete. He pushed back from his desk, the hum of the lights finally fading into the background. The foundry was ready for the audit, and for the first time in weeks, so was he.
Since there is no official release called "CQI-27" by AIAG (the Automotive Industry Action Group)—the current standard for casting is CQI-9 (Special Process: Heat Treatment System Assessment) which covers casting heat treatment, or CQI-15 (Special Process: Welding System Assessment) which is sometimes confused numerically—it is highly likely you are referring to the CQI-9 (4th Edition) update regarding castings, or possibly the earlier CQI-19 (Secondary Aluminum Process Assessment).
However, the most common "XLS update" request in the casting industry concerns the CQI-9 Assessment Excel spreadsheet, specifically regarding the tables for heat treatment of castings (Tables A, B, C, and D).
Below is a comprehensive article regarding the current CQI assessment landscape for castings, the Excel assessment tool structure, and how to handle the latest updates.
A summary sheet that automatically visualizes overall compliance percentage, section-by-section heat maps, and a red-yellow-green status indicator.
To maximize the lifespan and utility of your casting system assessment tool: