Cqi27 Casting System Assessment Xls Upd File

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. cqi27 casting system assessment xls upd

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

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). The CQI-27 Special Process: Casting System Assessment (2nd

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

Step 3 – Automate Scoring Formulas

Example formula for summary sheet:

=SUMIFS(Detailed!D:D, Detailed!A:A, ">=0") / (COUNTIF(Detailed!A:A, "Process Control")*10) *100

3. Purpose of the CQI-27 Assessment

The assessment serves three primary functions: Step 3 – Automate Scoring Formulas Example formula

  1. Supplier Quality Evaluation – Customers (e.g., Ford, GM, Stellantis) require tier suppliers to complete and share the CQI-27 Excel file.
  2. Internal Process Control – Foundries use it to self-audit their melting, molding, core making, pouring, and post-casting operations.
  3. Corrective Action Planning – Low-scoring sections trigger a PFMEA (Process Failure Mode Effects Analysis) and control plan updates.

CQI-27 Casting System Assessment – File Documentation

File Name: cqi27_casting_system_assessment.xls Version: Updated (UPD) Applicable Standard: AIAG CQI-27, 2nd Edition (or current revision)

The Future of CQI-27: Beyond XLS UPD

While the Excel format remains dominant due to its flexibility and low cost, the industry is slowly evolving. AIAG is piloting digital assessment tools including:

However, for the next 3-5 years, the CQI-27 Casting System Assessment XLS UPD will remain the backbone of casting quality audits. It is affordable, portable, and universally understood by quality technicians from Detroit to Shanghai.

Core Structure of a CQI-27 Excel Assessment File

A practical Excel-based CQI-27 tracking system contains at least three main sheets:

5. Corrective Action Register (CAR)

Once a "Red" item is identified, the XLS UPD can auto-populate a CAR worksheet with required fields: root cause, containment, permanent correction, and due dates.

3. Multi-Language Support

Many updated XLS versions include drop-downs for English, Spanish, Chinese, and German—critical for global auditing teams.

Common pitfalls and how to avoid them