Competitiveness and innovation are challenges for leading automotive suppliers to provide OEM and end users safety and comfort.
We must not forget about all the requirements related to the reduction of emissions and weight reduction of the vehicle. This was the task that was set for the publication of the second edition of the CQI-15 standard.
More and more suppliers are looking for solutions, opting for light and at the same time durable materials such as magnesium, aluminum or copper, which force them to search for optimal joining solutions, while maintaining high quality and strength of the connection, as well as the production price and quality control.
CQI-15 – what has actually changed?
The second edition of the CQI-15 manual covers the latest and most frequently used welding methods and techniques to ensure a consistent management system for welding processes in production facilities and services.
The cooperation of representatives of companies such as Nexteer Automotive, Ford Motor Comopany, Adient US LLC, Dana Incorporated, Delphi Technologies, FCA US LLC, General Motors Company, Gestamp Mason and Magna International resulted in the exchange of experiences and best practices to share knowledge and update process tables on new techniques. These include Fastener Projection Welding and Arc Butt (MIAB) Welding, among others.
CQI-15 – scope of changes
The major updates of the second version of the manual include changes to:
1. Cover page:
- Complete redesign and supplement with an automated grading system in implementation classes, i.e. “Fulfillment Grade” (R-Y-G)
- Adding of rating and special features such as “Special Features” CTQ (Critical to Quality)
- Adding product specific information such as details of the welding process, position information, location of the component on the vehicle, and customer data to which the produced component is provided.
2. Control Questions Main Catalog, in which five sub-elements were redesigned and the number of questions increased from 69 to 80.
3. Process tables and job audits, which have been combined into a common checklist, with the name change to “Job Audit Process Tables”.
4. Checklists for individual welding processes “Job Audit Process Tables” that have been reclassified into sub-question elements:
- Part drawing
- Control Plan
- Destructive / non-destructive testing
- Welding quality testing
- Processing
- Process parameter specifications
- Maintenance and prevention
- Sustainable development
- Automated welding systems (robotics)
5. “Welding Health Chart” implementation used for continuous monitoring of welding quality.
What are the challenges of Industry 4.0 in the new version of the CQI-15 standard?
In recent years, the automotive industry has focused strongly on the automation and robotization of special processes by replacing machine-man cooperation with machine-robot. Another challenge has been the digitization and digitization of analogue and paper processes, by transferring data to their digital counterparts.
Industry 4.0 focuses on system integration and networking through the flow of information vertically, i.e. between products and the IT department and back. As well as horizontally, i.e. between process machines and the company’s production system. This means that the data flow must be consistent and cover all stages of product production, from receipt to the warehouse to shipment of the final product to the customer.
Data integrity and product traceability are covered in the new version of the CQI-15 manual in Section 3 – Initial Planning and Quality Documentation through the analysis of production data and the application of continuous improvement techniques.
Backup and archiving of process parameters, data storage and protection will enable quick response to any disruptions in the process and repeated failures, 24h monitoring and production review will protect against possible customer complaints, market returns and recurring campaigns.
Katarzyna Adamczyk
