[2 WS -Welding & Torque]

CQI (Continuous Quality Improvement) for Press Operations,

1. Relevant CQI Standards for Press Operations

• CQI-9 (Special Process: Heat Treat System Assessment)

  • While focused on heat treatment, its process-control principles can be adapted for press operations (e.g., temperature, force monitoring).

• CQI-15 (Welding System Assessment)

  • Useful for welded stampings; emphasizes process validation and operator competency.

• CQI-23 (Molding System Assessment)

  • For plastic/composite presses; aligns with press control plans.

• CQI-24 (Casting System Assessment)

  • Relevant for die-casting presses (e.g., aluminum, zinc).

Note: No dedicated CQI standard exists for metal stamping/press operations, but the above can be tailored.

2. Press-Specific Quality Assessment Framework

(Modeled after CQI-11/CQI-9 Structure)

A. Process Control & Monitoring

• Tooling Maintenance: Dies/molds must be inspected, cleaned, and documented.

• Press Parameters: Monitor tonnage, speed, shut height, and alignment (SPC recommended).

• Material Verification: Confirm material grade, thickness, and coating pre-pressing.

B. Equipment & Calibration

• Preventive Maintenance: Scheduled checks for hydraulic systems, clutches, and sensors.

• Calibration: Load cells, pressure gauges, and laser micrometers must be calibrated.

C. Personnel Training

• Operator Certification: Training on press setup, safety, and defect detection (e.g., cracks, wrinkles).

• Die Changeover: SMED (Single-Minute Exchange of Dies) competency.

D. Nonconformance Management

• Root Cause Analysis: Use 5Why/8D for press-related defects (e.g., galling, mis-strokes).

• Containment: Quarantine nonconforming parts and verify corrective actions.

E. Safety & Compliance

• OSHA/ANSI Standards: Guarding, lockout/tagout (LOTO), and noise control.

• Environmental: Scrap/recycling procedures for metal waste.

  
  

3. Press Process Audit Checklist (CQI-Inspired)

4. Continuous Improvement for Press Operations

• Kaizen: Regular workshops to reduce setup time/scrap.

• Automation: Implement sensors for real-time defect detection.

• Benchmarking: Compare OEE (Overall Equipment Effectiveness) with industry standards.

5. Integration with IATF 16949

• Risk-Based Thinking: Include press risks in PFMEAs.

• Customer-Specific Requirements (CSRs): Follow OEM stamping standards (e.g., Ford’s Stamping Process Standards).

Recommendations

1. Develop a Press-Specific CQI Checklist using CQI-9/CQI-11 as a template.

2. Adopt IATF 16949 Core Tools (APQP, PPAP, MSA) for press processes.

3. Leverage Digital Tools: Press monitoring software (e.g., Press Dashboard by 4DSPC).

Would you like a customizable press audit template or guidance on press-specific PFMEAs?

CQI for Welding & Tightening Torque

Here’s a structured breakdown of CQI (Continuous Quality Improvement) for Welding & Torque Tightening, incorporating AIAG standards, best practices, and audit frameworks:

1. Relevant CQI Standards

A. Welding (CQI-15: Welding System Assessment)

• Scope: Covers resistance welding (spot/stud), arc welding (MIG/TIG), laser welding, and brazing.

• Key Requirements:

  • Process Validation: WPS (Welding Procedure Specifications) and PQR (Procedure Qualification Records).

  • Operator Qualification: AWS/ISO 9606 certification for welders.

  • Equipment Calibration: Regular checks of weld timers, current/voltage sensors.

  • Destructive/Non-Destructive Testing (NDT): Peel tests, X-ray, ultrasonic inspection.

B. Torque Tightening (No dedicated CQI standard, but aligned with IATF 16949)

• Key Requirements:

  • Tool Calibration: Regular calibration of torque wrenches, screwdrivers, and sensors.

  • Process Control: Torque-angle monitoring, SPC for critical joints.

  • Operator Training: Certified training on torque tools and error-proofing (e.g., Poka-Yoke).

2. Audit Frameworks

A. Welding (CQI-15 Based)

B. Torque Tightening (Custom Framework)

3. Process Controls

Welding

• Critical Parameters: Current, voltage, weld time, electrode force (for resistance welding).

• Monitoring: Real-time data logging (e.g., Weld Logger systems).

• Testing: Regular destructive tests (e.g., peel tests for spot welds).

Torque Tightening

• Critical Parameters: Torque value, angle, sequence, lubrication effects.

• Monitoring: Electronic torque controllers (e.g., Nexen Torque Systems).

• Verification: Audit joints using ultrasonic torque measurement.

4. Continuous Improvement

• Welding:

  • Implement weld data analytics to predict electrode wear.

  • Use AI-based vision systems for weld seam inspection.

• Torque:

  • Adopt Industry 4.0 tools (e.g., IoT-enabled torque tools with cloud tracking).

  • Benchmark against automotive OEM standards (e.g., GM Global Fastener Standards).

5. Integration with IATF 16949

• Risk Management: Include welding/torque risks in PFMEA.

• Customer Requirements: Follow OEM specs (e.g., Ford Weld Quality Standards, VW TL 23200 for torque).

• Core Tools: Use MSA for torque tool repeatability studies, SPC for weld nugget diameter.

6. Templates & Tools

• Welding Audit Checklist: Downloadable CQI-15 template.

• Torque Tightening Log: Customizable Excel tracker for torque values/angles.

Recommendations

1. For Welding:

   • Conduct CQI-15 gap assessments annually.

   • Invest in automated weld monitoring for critical joints.

2. For Torque:

   • Upgrade to digital torque systems with traceability.

   • Align with ISO 5393 (torque tool testing standards).

     
     

More ... Need a customized audit checklist or PFMEA for specific welding/torque processes.