CQI - Implementation

1. CQI-9: Heat Treat System Assessment (HTSA)

Purpose: Ensures proper control of heat treatment processes (e.g., hardening, annealing) to prevent defects in automotive components.

Key Requirements:

• Process Control: Temperature uniformity surveys (TUS), system accuracy tests (SAT).

• Equipment Maintenance: Regular calibration of furnaces, ovens, and quench systems.

• Personnel Training: Certified heat treat operators per AMS 2750 or equivalent.

• Record Keeping: Documentation of process parameters (time, temp, atmosphere).

Implementation Steps:

1. Conduct a gap assessment against CQI-9 requirements.

2. Perform TUS & SAT testing on all heat treat equipment.

3. Train personnel to AMS 2750/Nadcap standards.

4. Implement process monitoring & corrective actions.

5. Undergo 3rd-party or customer audits.

Used by: Tier 1/Tier 2 suppliers for transmission gears, bearings, shafts.

2. CQI-11: Plating System Assessment (PSA)

Purpose: Ensures consistent plating quality (e.g., zinc, nickel, chrome) for corrosion resistance.

Key Requirements:

• Chemical Control: Bath composition, pH, temperature monitoring.

• Adhesion Testing: Peel tests, porosity checks.

• Waste Management: Compliance with EPA/REACH regulations.

• Process Validation: PPAP (Production Part Approval Process) for new parts.

Implementation Steps:

1. Audit plating processes against CQI-11 checklist.

2. Validate chemical bath controls & rinse cycles.

3. Perform corrosion resistance tests (salt spray, ASTM B117).

4. Maintain waste treatment logs.

Used by: Fastener suppliers, electrical connectors, brake components.

3. CQI-12: Coating System Assessment (CSA)

Purpose: Covers painting, powder coating, e-coating for durability & appearance.

Key Requirements:

• Pretreatment: Cleaning, phosphating, passivation.

• Cure Monitoring: Infrared (IR) oven validation.

• Thickness Checks: Micrometer or eddy current testing.

• Color/Gloss Consistency: Spectrophotometer measurements.

Implementation Steps:

1. Verify pretreatment chemical concentrations.

2. Calibrate curing ovens & spray equipment.

3. Conduct cross-hatch adhesion tests (ASTM D3359).

4. Document coating thickness & appearance checks.

Used by: Body panels, wheels, chassis components.

4. CQI-15: Welding System Assessment (WSA)

Purpose: Ensures weld integrity (resistance, MIG, laser welding) in automotive assemblies.

Key Requirements:

• Weld Validation: Destructive & non-destructive testing (pull tests, X-ray).

• Parameter Control: Weld current, time, electrode force monitoring.

• Maintenance: Tip dressing schedules, weld gun calibration.

• Operator Training: AWS (American Welding Society) certification.

Implementation Steps:

1. Perform weld lobe studies to define optimal settings.

2. Implement real-time weld monitoring (e.g., Bosch PMS).

3. Conduct periodic weld strength tests.

4. Maintain welder certification records.

Used by: Body-in-white (BIW), exhaust systems, battery trays.

5. CQI-17: Soldering Technology Assessment

Purpose: Ensures reliability of soldered electronics (e.g., ECUs, sensors).

Key Requirements:

• Solder Paste Control: Viscosity, storage conditions.

• Reflow Profile: Temperature curve validation.

• Inspection: Automated optical inspection (AOI), X-ray for voids.

• IPC-A-610 Compliance: Acceptability of electronic assemblies.

Implementation Steps:

1. Validate reflow oven profiles per J-STD-020.

2. Perform solder joint inspections (IPC Class 2/3).

3. Monitor ESD controls in soldering areas.

Used by: PCB manufacturers, EV battery modules.

6. CQI-23: Molding System Assessment

Purpose: Controls injection molding for plastic parts (e.g., dashboards, connectors).

Key Requirements:

• Process Stability: Cavity pressure monitoring.

• Material Drying: Moisture content checks.

• Tool Maintenance: Mold cleaning & wear inspection.

• Dimensional Checks: CMM (Coordinate Measuring Machine) validation.

Implementation Steps:

1. Conduct DOE (Design of Experiments) for optimal molding parameters.

2. Implement scientific molding techniques.

3. Track part weight & dimensions statistically.

Used by: Interior trim, lighting, under-hood components.