In the world of manufacturing, where quality is a key element, the welding process is becoming one of the most crucial aspects of production. The proper assessment of the welding system not only determines the durability and functionality of products but also significantly influences safety, efficiency, and customer satisfaction.
In the automotive industry, the CQI-15 manual embodies this, created in collaboration with the AIAG organization. It’s essential to recognize that this is more than just a standard; it’s a guiding principle that enables companies not only to meet expectations but also to continuously enhance their processes.
How does the Welding System Assessment relate to the IATF standard?
CQI-15 serves as an annex to the IATF standard and can be found in section 4.3.2. This standard is applicable to all automotive suppliers who have entered into purchase, delivery, and quality agreements.
When discussing automotive suppliers, it’s important to distinguish between first-tier suppliers, commonly known as Tier 1 suppliers, who directly supply OEMs (Original Equipment Manufacturers) in the automotive industry, and sub-suppliers, representing the entire supply chain where these processes are applied.
How frequently should an audit be conducted according to CQI-15 requirements?
At least once a year. Completing the audit within a period not exceeding 12 months of the last assessment is crucial. Plan it well in advance and include it in the annual audit schedule. It’s important to note that knowing the audit date from the previous year is necessary for proper planning and presentation to the client.
Can the Welding System Assessment also be conducted more frequently?
Certainly! For example, if an audit reveals non-compliance, the audited unit must immediately stop the process and implement protective measures if this non-compliance directly impacts the product’s quality and safety or if there is any unauthorized change in the process or process parameters without informing the customer.
The organization should rectify such non-compliance, introduce corrective actions within a period not exceeding 90 days, and then re-evaluate the system, thereby ensuring compliance with the requirements of the standards.
Is the organization with a welding process obligated to provide the client with audit results?
The organization must conduct and share the results of the self-assessment upon the customer’s request or confirm its completion through a system that allows direct communication with the customer.
Upon purchasing the manual, an XLS form will also be provided. The process of initiating the assessment involves identifying the relevant process. If the process applies to multiple OEMs, you can choose to focus on a specific product where a particular welding operation is employed and then conduct the audit using the provided form.
Our primary emphasis is on reviewing the main catalog questions, but we also pay attention to process tables. The new edition integrates these with job audits. This is the procedure for conducting the assessment.
Internal Auditor Competencies for CQI-15
The auditor must have completed training and obtained qualifications confirmed by the author of the quality management system, consistent with the requirements of IATF or ISO9001.
Welding knowledge is of utmost importance in this context. Candidates must present evidence of a minimum of five years’ experience in the field of welding or a combination of formal education and practical experience.
The auditor of special processes must possess basic knowledge of quality tools used in the automotive industry.Our primary focus includes:
- Statistical Process Control (SPC)
- Measurement Systems Analysis (MSA)
- Production Parts Approval Process(PPAP)
- Advanced Product Quality Planning (APQP)
- Analysis of the causes and effects of defects
What are the main changes in this second edition?
The updates in the new edition of CQI-15 result from the exchange of best practice experiences, covering the latest and most frequently used welding technology methods.
The goal is to establish a coherent system for managing welding processes in production facilities and services. This is crucial as the focus extends beyond suppliers and sub-suppliers to include services where these welding processes may also be implemented.
In addition, the second edition features a complete redesign of the questionnaire, encompassing six main changes that have occurred in this updated version:
The title page features an automated grading system providing information on the assessment of individual sections of the worksheet. Additionally, it presents the final assessment obtained after the entire audit.
Identification of special functions involves critical questions from a quality perspective.
Product-focused details cover the welding process, including the location of the component undergoing the process. Furthermore, we consider customer data to whom we deliver the part after the welding process.
The questions catalog has expanded from 69 to 80.
A significant change in the second edition is the integration of the process table with a job audit, providing insights into both the process and real-world occurrences. This marks a noteworthy shift in the audit itself and the auditor’s responsibilities.
Reclassification of sub-questions includes:
- Part drawing
- Control plans
- Destructive and non-destructive testing
- Welding quality testing
- Modifications
- Specification of process parameters
- Maintenance and prevention (i.e., all activities on machines and processes)
- Sustainable development
The implementation of automated welding systems is currently a priority. Why? Looking to the future, we are moving towards total automation and Industry 4.0. Therefore, the second manual adapts to the current production requirements in the automotive industry.
Assessment of the Welding System in Relation to Cooperation with Customers
First and foremost, it is impossible not to mention Ford, which is essentially the founder and cornerstone of the entire CQI-15 standard. Other notable contributors include suppliers such as Magna and Faurecia.
However, when uncertainty arises about the obligation to send audit results, our focus typically shifts to the client’s CSR. Here, a thorough analysis helps determine the necessity of transferring or presenting the audit results.
Guidance for Auditors
Crucial for every auditor is a basic understanding of the welding or welding process under audit. You don’t always need extensive knowledge. Why? Because, with the questions from the form, we can pinpoint the key aspects.
Equally important is the search for confirmation of compliance and specific evidence.
Let’s also bear in mind that people conduct audits. Our aim is to ensure that each audit provides an opportunity for enhancing quality, processes, and overall improvement.
Katarzyna Adamczyk & Dariusz Kowalczyk
