In many manufacturing companies within the automotive industry that utilize special processes, compliance with the guidelines outlined in the CQI-12 manual is mandatory. Key customers such as Ford, General Motors, and Stellantis (formerly FCA) enforce this requirement.
Organizations face the challenge of assessing product quality through destructive testing, which can be costly for organizations when dealing with special processes. Due to this limitation, achieving 100% verification of compliance with quality requirements during production may not be feasible.
To ensure a reliable production process that meets product requirements, it is crucial to effectively implement the guidelines outlined in the CQI-12 manual. This enables continuous process improvement, reduction of variability, and waste, ultimately leading to cost reduction.
The CQI-12 manual comprises four main thematic sections and eleven process tables
The first section emphasizes staff responsibility and quality planning. The second section addresses transportation, area management, and material flow requirements. Both sections include audit questions and corresponding requirements, supplemented by supporting questions to enhance understanding. These requirements are primarily based on the guidelines outlined in the IATF 16949 standard.
During auditing, it is essential to not only assess whether the requirements are met, not met, or do not apply but also to document evidence supporting the assessment.
The third section introduces new requirements concerning the pyrometry of the coating application process, evaluated within designated process tables.
The fourth element, known as the Job Audit, involves conducting product audits, akin to those outlined in the VDA 6.3 manual. During this assessment, we should conduct at least one product audit, focusing on safety-related or critical components. If time permits, we can perform additional audits.
The process tables
The process tables, labeled A-K, consist of tables A to J for individual process types. Table K pertains to equipment for monitoring and measuring process and product parameters.
Each table follows a standardized format, detailing the process stages and parameters requiring monitoring. It also specifies the minimum requirements for control (e.g., automatic, manual, as per the Control Plan) and monitoring frequency.
Additionally, during the “Job Audit,” these tables include sections for assessing the actual type of control and monitoring frequency, where current parameter results are recorded.
Table K differs from the others as it focuses on control and measurement devices rather than process parameters. It outlines the calibration requirements and frequency for each device.
CQI-12 requirements implementation
Implementing the requirements outlined in the CQI-12 manual may initially require significant time and resources from an organization, potentially resulting in added costs. However, in the long run, the benefits are manifold. By adhering to these standards, organizations can deliver products that meet stringent requirements while minimizing error costs.
Most importantly, it fosters customer satisfaction, paving the way for continued collaboration on future projects.
Joanna Kucharska-Cichoń
