[Checklists] CQI for Welding and Painting under IATF 16949

internal audit matrix for Welding and Painting processes under IATF 16949, including checklists, required evidence, and automotive-specific examples:

1. Welding Process Audit Matrix

(Aligned with IATF 16949 + AWS D1.1/CQI-15 standards)

Audit Focus	Checklist Question	Evidence to Review	Automotive Example	Compliance
4.1 Process Validation	Is weld procedure qualification (WPQR) up-to-date?	WPQR records, welder certifications (AWS/ISO 9606).	Resistance spot weld validation for truck chassis.	✔/✖
7.1.5.1 MSA	Are weld nugget measurement tools calibrated (GR&R ≤10%)?	MSA reports, caliper calibration logs.	Ultrasonic weld tester GR&R study.	✔/✖
8.5.1 SPC	Are weld strength tests monitored via control charts?	X-bar R charts, destructive test reports.	Peel test results for door hinges (CpK ≥1.33).	✔/✖
8.5.2 Traceability	Can all welded joints be traced to operator/shift?	Weld logs with barcode/VIN, MES data.	Recall investigation of faulty roof welds.	✔/✖
8.7.1 Non-Conformity	Are cracked welds contained within 1 hour?	Containment reports, quarantine tags.	Laser weld cracks in battery trays.	✔/✖
9.1.2 PFMEA	Is weld spatter (Severity=7) addressed in PFMEA?	PFMEA updates, poka-yoke solutions (anti-spatter gel).	Robot weld gun maintenance logs.	✔/✖

2. Painting Process Audit Matrix

(Aligned with IATF 16949 + CQI-12/VDA 6.3)

Audit Focus	Checklist Question	Evidence to Review	Automotive Example	Compliance
4.2 Pretreatment	Is chemical bath concentration checked hourly?	Titration logs, pH/conductivity records.	Zinc phosphate coating weight checks.	✔/✖
7.1.5.1 MSA	Is paint thickness gauge GR&R ≤10%?	MSA reports, Elcometer calibration certs.	E-coat thickness measurements.	✔/✖
8.5.1 SPC	Are oven temperature profiles monitored (CpK ≥1.67)?	Control charts, IR sensor data.	Curing oven profile for hood panels.	✔/✖
8.6.1 Final Audit	Is color match verified per customer standards?	Spectrophotometer reports, customer approval samples.	BMW’s "Alpine White" color batch approval.	✔/✖
8.7.1 Defects	Are fisheyes (paint bubbles) documented with RCA?	8D reports, contamination control checklists.	Dust contamination in clearcoat.	✔/✖
10.2.1 CAPA	Are corrective actions implemented for adhesion failures?	Cross-cut test results, paint supplier corrective actions.	Peeling paint on fenders.	✔/✖

Key Evidence Examples for Welding & Painting

Welding

• WPQR (Weld Procedure Qualification Record): Approved parameters for materials/thicknesses.

• Destructive Test Samples: Photographs of peel/shear tests.

• Weld Seam Tracking: Laser-scanned weld profiles vs. CAD specs.

Painting

• Salt Spray Test Reports: 500+ hours corrosion resistance proof.

• Color Match Data: ΔE ≤1.0 (spectrophotometer readings).

• Paint Viscosity Logs: Adjusted per ambient humidity (ISO cup tests).

Automotive-Specific Requirements

1. Welding:

   • IATF 16949 Clause 8.5.1.1: Validate robotic weld programs annually.

   • Customer CSR: GM’s "Weld Quality Standard GMW14058" for nugget size.

2. Painting:

   • IATF 16949 Clause 8.6.2: First/last piece audits for color/gloss.

   • Customer CSR: Ford’s "Paint Appearance Manual" for orange peel tolerance.

Non-Conformance Examples

Process	NC Finding	IATF Clause	Corrective Action
Welding	No torque checks on weld gun electrodes.	7.1.5.1 (MSA)	Implement daily torque audits + digital wrench.
Painting	E-coat tank contamination (Zn²⁺超标).	8.5.2 (Traceability)	Filter replacement + batch quarantine.

Audit Tools & Templates

1. Welding:

   • CQI-15 Checklist: [Download Link]

   • Weld Defect Atlas: For visual standards (porosity, cracks).

2. Painting:

   • CQI-12 Checklist: [Download Link]

   • VDA 6.3 Process Audit Sheet: Focus on P6 (Process Control).

Pro Tips

• Use IoT: Monitor weld current/paint booth humidity in real-time.

• Layered Audits: Daily checks by supervisors + monthly deep dives.