Competitiveness and innovation are key challenges for leading automotive suppliers in providing OEMs and end users with safety and comfort. We must not overlook the growing requirements related to emission reduction and vehicle weight optimization. Addressing these demands was one of the primary goals behind the publication of the second edition of the CQI-15 standard.
An increasing number of suppliers are seeking innovative solutions, opting for lightweight yet durable materials such as magnesium, aluminum, and copper. This trend drives the need for optimal joining technologies that ensure high connection strength and quality while maintaining cost efficiency and robust quality control.
CQI-15 – What has actually changed?
The second edition of the CQI-15 manual introduces updates to the latest and most widely used welding methods and techniques, ensuring a consistent management system for welding processes in production facilities and services.
This publication is the result of collaboration among industry leaders, including representatives from Nexteer Automotive, Ford Motor Company, Adient US LLC, Dana Incorporated, Delphi Technologies, Stellantis, General Motors Company, Gestamp Mason, and Magna International.
Their cooperation facilitated the exchange of experiences and best practices, leading to updated process tables that incorporate new techniques such as Fastener Projection Welding and Arc Butt (MIAB) Welding, among others.
CQI-15 – Scope of Changes
The key updates in the second version of the manual include:
1. Cover Page
- Complete redesign, now supplemented with an automated grading system for implementation classes, e.g., “Fulfillment Grade” (R-Y-G).
- Inclusion of rating and special features such as “Special Features” CTQ (Critical to Quality).
- Addition of product-specific information, including welding process details, component position and location on the vehicle, and customer data.
2. Control Questions Main Catalog
Five sub-elements have been redesigned, and the total number of questions has increased from 69 to 80.
3. Process Tables and Job Audits
These elements have been merged into a unified checklist, now renamed “Job Audit Process Tables”.
4. Checklists for Individual Welding Processes (Job Audit Process Tables)
Reclassified into sub-question elements, including:
- 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
Introduced for continuous monitoring of welding quality.
What are the challenges of Industry 4.0 in the new version of the standard?
In recent years, the automotive industry has placed significant focus on automation and robotization of special processes, transitioning from machine-man cooperation to machine-robot integration. Another key challenge has been the digitalization of analog and paper processes, enabling seamless data transfer to digital systems.
Industry 4.0 emphasizes system integration and networking through the flow of information:
- Vertically: between products and IT systems, and back.
- Horizontally: between process machines and the company’s production system.
This approach requires consistent data flow across all stages of production, from warehouse receipt to final product shipment.
The second edition of the CQI-15 manual addresses data integrity and product traceability in Section 3 – Initial Planning and Quality Documentation. This includes production data analysis and the application of continuous improvement techniques.
Furthermore, backup and archiving of process parameters, data storage, and data protection are crucial for quick responses to process disruptions and recurring failures. Features such as 24-hour monitoring and production reviews safeguard against customer complaints, product returns, and recurring market issues.
Katarzyna Adamczyk
