Cqi-27 Casting System Assessment Xls -

In the high-stakes world of automotive and heavy equipment manufacturing, casting defects are not merely a quality nuisance—they are a financial catastrophe. Porosity, cold shuts, and dimensional inaccuracies can lead to field failures, warranty claims, and even safety recalls. This is where the CQI-27 Casting System Assessment comes into play.

Developed by the AIAG (Automotive Industry Action Group), CQI-27 is a specialized auditing standard designed specifically for special processes: casting. Unlike general quality audits (ISO 9001 or IATF 16949), CQI-27 dives deep into process tables, metallurgical controls, and in-process verification.

For quality managers and process engineers, the most practical tool to execute these audits efficiently is the CQI-27 Casting System Assessment XLS—an Excel spreadsheet that structures the audit, calculates scores, and ensures compliance.

This article provides a comprehensive breakdown of CQI-27, a step-by-step guide to using the XLS assessment tool, and best practices for achieving a "Level A" rating.

A high-quality cqi-27 casting system assessment xls includes an automated scoring engine:

Company: Midwest Automotive Casting (MAC), 120 employees, die casting aluminum transmission housings.

Baseline CQI-27 XLS Score (January): 58% (Level C – Non-Compliant)

Top 3 Gaps identified via XLS:

Actions taken:

Follow-up XLS Score (July): 94% (Level A – Fully Compliant). Customer removed the “probationary supplier” status, saving MAC a $2M contract.

CQI-27 was updated in 2022 (CQI-27 3rd Edition). Older XLS files (2nd edition) are obsolete. Verify your XLS includes new requirements like:

The CQI-27 Special Process: Casting System Assessment (2nd Edition) is a common process requirement developed by the AIAG to ensure foundries consistently produce high-quality automotive castings. It is designed to evaluate a foundry's ability to meet customer requirements and is typically required for self-assessment at least once a year. Assessment Structure & Components

The assessment is structured around several key sections, typically provided in an Excel (XLS) format to facilitate documentation:

Management Systems: Evaluates overall quality management, including operator training, maintenance, and documentation effectiveness.

Process Controls: Focuses on critical parameters such as melting temperatures, pouring conditions, and solidification control.

Casting Design & Tooling: Covers requirements for design software, stress analysis (FEA), casting simulations, and tool maintenance. cqi-27 casting system assessment xls

Process Tables (A-J): Specific requirements tailored to different casting methods: Table A: Sand Casting (Iron/Steel) Table B/C: Centrifugal Castings & Liners Table D: Investment Casting (Iron/Steel) Table E: Aluminum Semi-Permanent Mold (Cylinder Heads) Table G: Aluminum Metal Mold Table H: Aluminum High-Pressure Die Casting Table J: Zinc High-Pressure Die Casting Scoring and Documentation Guidelines

When completing the XLS template, the following rules generally apply for each line item:

Conforming: Mark if requirements and customer-specific standards are met. Non-Conforming: Requires a detailed corrective action plan. Not Applicable (N/A):

Enter a score of "3" if the element is N/A and there is no current risk.

Enter a score of "2" if the element is N/A but has potential future risk.

Notes: Always provide supporting records or explanations for actual conditions, especially if minimum requirements are not met. How to Obtain the Assessment

Official copies and the accompanying Excel file are proprietary and must be purchased directly from the AIAG Store. Some foundries use third-party platforms like TopQM-Systems for specialized support and training. CQI-27 Casting System Assessment - TopQM-Systems

It sounds like you’re looking for an Excel (.xls) file related to the CQI-27 Casting System Assessment — likely a form, checklist, or audit worksheet used in the automotive or manufacturing industry for process audits of casting operations (e.g., die casting, permanent mold, sand casting).

However, I cannot directly provide or attach files. But I can help you in these ways:

Let me know which would be most useful to you.

Mastering the CQI-27 Casting System Assessment The CQI-27 Special Process: Casting System Assessment (CSA) is a critical tool for automotive suppliers to ensure their casting processes meet the high-quality standards set by the Automotive Industry Action Group (AIAG). Managing this assessment via an XLS (Excel) spreadsheet is the industry standard for tracking compliance, organizing audit data, and driving continuous improvement. What is the CQI-27 Assessment?

Part of the Continuous Quality Improvement (CQI) family, CQI-27 focuses specifically on foundry operations. It serves as a self-assessment that must be conducted at least once per year to evaluate the effectiveness of process controls, equipment maintenance, and operator training. Key Components of a CQI-27 XLS Tool

A comprehensive assessment spreadsheet typically includes several specialized sections:

Audit Header: Basic information about the facility, assessment date, and the specific casting processes being reviewed (e.g., Sand Casting, Die Casting, Investment Casting).

Process Tables: These are the "heart" of the assessment. They list specific requirements for various casting steps. Most digital tools or XLS templates include form-building macros to help you customize sections for material flow and process-specific parameters. In the high-stakes world of automotive and heavy

Job Audit: A physical walk-through where auditors verify that the documented processes are actually being followed on the shop floor.

Corrective Action Plan (CAP): A tracker to document any "Not Satisfactory" findings and the steps taken to resolve them. Best Practices for Using an XLS Template

Use Form-Building Macros: If your template supports it, use the "form builder" tab to construct a layout that matches your specific material flow.

One Step at a Time: When inputting control parameters, add them one by one to avoid layout errors. If a mistake occurs in the spreadsheet's structure, it is often easier to clear the sheet and restart rather than cutting and pasting.

Cross-Reference IATF 16949: Ensure your assessment aligns with broader IATF 16949 quality standards, as CQI audits are a foundational part of automotive process control.

Version Control: Always ensure you are using the most current version of the CQI-27 manual (currently the 2nd Edition) to remain compliant with OEM requirements. Why It Matters

Successful completion of the CQI-27 assessment demonstrates to OEMs that a foundry is capable of producing reliable, high-quality castings while minimizing waste and risk. By maintaining a living XLS assessment tool, quality managers can transition from "checking a box" to fostering a culture of proactive process health. CQI-27 | Special Process: Casting System Assessment - AIAG

The CQI-27 Special Process: Casting System Assessment provides requirements for foundry suppliers of OEM automotive castings. AIAG

CQI-11 Video Series #5: How to fill out the process tables | AIAG

Feature: CQI-27 Casting System Assessment XLS

Description: The CQI-27 Casting System Assessment XLS is an Excel-based tool designed to support the automotive industry in assessing and improving the quality of casting systems. This feature enables users to evaluate and analyze casting system performance, identify areas for improvement, and implement corrective actions to enhance overall quality.

Key Benefits:

Key Features:

Target Audience:

System Requirements:

Support and Maintenance:

Since I cannot browse live local networks or upload specific external files directly in this chat, I cannot "review" a specific XLS file you currently possess.

However, I can provide a comprehensive review of the CQI-27 Casting System Assessment standard itself, which is the basis for any valid CQI-27 XLS spreadsheet.

Here is a detailed breakdown of what the CQI-27 assessment entails, how the Excel file is typically structured, and key areas to focus on during a review.

Your IATF 16949 control plan must exactly mirror the CQI-27 XLS rows. For example, if the XLS asks for “Die spray verification frequency,” your control plan must state “every shift” and the operator log must show signatures.

Let’s walk through a real-world scenario: You are a quality engineer auditing an aluminum die casting supplier. You have your CQI-27 Casting System Assessment XLS open on a laptop.

Step 1 – Scoping Go to the Dashboard. Select “High Pressure Die Casting” (Section 2). Enter audit scope: Melting, shot end, trimming, and X-ray inspection.

Step 2 – Document Review Use the XLS to tick through documents required by CQI-27. For Clause 2.1.4 (Material verification), you ask for melt logs. The supplier shows a spreadsheet. You record in the XLS: “Compliant – logs complete.”

Step 3 – Floor Walk Check Clause 2.3.6 (Shot speed and intensification pressure). The machine’s digital display shows parameters out of range. You mark “Non-Compliant” in the drop-down. The XLS auto-flags the finding in red. You type the evidence: “Shot speed setpoint drift; closed-loop control not functioning.”

Step 4 – Real-Time Scoring As you continue, the XLS’s summary dashboard updates automatically. You see current compliance at 82% (Yellow). You know you are borderline. Focus on critical process controls.

Step 5 – Close-Out Meeting Export the XLS to PDF. Present the summary to supplier management. The CAP sheet is already populated with non-conformances. Assign responsible parties and due dates immediately.

Step 6 – Follow-Up Save the master XLS. In 30 days, reopen it, go to the CAP sheet, verify each action, and update the status to “Closed.” The final report is audit-ready for your customer (e.g., Ford or GM).

This is the heart of the XLS. For each CQI-27 clause, you need columns such as:

| Clause ID | Process Step | Requirement (from AIAG) | Finding / Observation | Compliance (Drop-down) | Evidence Reference | Action Required | Due Date | |-----------|--------------|-------------------------|----------------------|----------------|--------------------|------------------|-----------| | 2.1.1 | Melting | Furnace temperature uniformity ±15°C | Thermocouple calibration overdue | Non-Compliant | Cal log p.42 | Calibrate by 6/15 | 6/15/2025 | | 2.2.3 | Pouring | Tundish preheat temp logged daily | No log for shift 2 | Requires Action | Shift reports missing | Implement log sheet | 6/10/2025 |

Important: The XLS must mirror the latest version of CQI-27 (currently 3rd edition, 2022). Outdated templates referencing obsolete clauses will fail a customer audit. A high-quality cqi-27 casting system assessment xls includes