CQI-27 Special Process: Casting System Assessment (CSA) is a critical quality framework developed by the Automotive Industry Action Group (AIAG)
to ensure robust casting processes across the automotive supply chain. Currently in its 2nd Edition
(published March 2018), this standard provides a common set of requirements for foundry suppliers to minimize defects and reduce process variation. www.cqi-support.de Key Features of the CQI-27 2nd Edition
The updated edition introduces several enhancements designed for better usability and process coverage: Consolidated Tables:
Requirements with similar characteristics have been merged to streamline the assessment process. Expanded Process Scope:
New tables were added to cover a wider range of casting methods. Excel Integration: The official AIAG assessment includes an Excel (.xls) file
designed with unprotected columns and rows, allowing organizations to edit and customize the spreadsheet for their internal use. Customer Alignment:
There is a stronger emphasis on ensuring that any process deviations are explicitly authorized by customer Product Engineering. www.cqi-support.de Process Tables Overview
The assessment is structured around ten specific process tables (A through J), ensuring that the audit is tailored to the specific casting technology used: Sand Casting (Iron/Steel) Table B/C: Centrifugal Castings and Liners Investment Castings (Iron/Steel) Table E/F/G: Aluminum (Cylinder Heads, Sand Castings, Metal Mold) Table H/I/J: High Pressure Die Casting (Aluminum, Magnesium, Zinc) Assessment Requirements & Auditor Qualifications
To conduct a valid CQI-27 assessment, the following criteria must be met: Auditor Expertise: Assessors must have a minimum of 5 years of experience
in casting processes and be qualified QMS internal auditors (e.g., IATF 16949 or ISO 9001). Audit Scope:
The assessment typically covers the entire foundry or a specific product line, focusing on design software, finite element analysis (FEA), tooling maintenance, and traceability. Defect Prevention:
Similar to reducing Risk Priority Numbers (RPN) in a PFMEA, full compliance aims to eliminate root causes of common casting failures before they reach the customer. Official Resources and Downloads
The CQI-27 2nd Edition (including the downloadable Excel assessment) is available through authorized providers:
The CQI-27 Special Process: Casting System Assessment (CSA) is a comprehensive framework developed by the Automotive Industry Action Group (AIAG). Its primary goal is to provide a standardized approach to auditing casting processes, ensuring they meet the rigorous quality requirements of the automotive supply chain. The "xls upd" (Excel update) refers to the digitized assessment tool used by auditors to evaluate compliance and drive continuous improvement. The Purpose of CQI-27
Casting is a complex metallurgical process where minor deviations in temperature, chemistry, or cooling can lead to catastrophic structural failures. CQI-27 was designed to move beyond simple product inspections. Instead, it focuses on process control. By assessing the entire system—from raw material handling to final heat treatment—it ensures that quality is "baked in" rather than just checked at the end. Key Components of the Assessment
The CQI-27 assessment is typically structured into several critical sections within the Excel spreadsheet: cqi27 casting system assessment xls upd
Management Responsibility & Quality Planning: Evaluates if the leadership is committed to quality and if robust Advanced Product Quality Planning (APQP) is in place.
Floor and Material Handling: Checks how raw materials, returns (re-melt), and finished goods are stored and moved to prevent contamination or damage.
Equipment & Tooling: Audits the maintenance schedules and calibration of furnaces, molds, and diagnostic machinery.
Process Tables: These are the heart of the "xls" tool. They provide specific criteria for different casting methods, such as Sand Casting, Centrifugal Casting, Die Casting, and Investment Casting. The Role of the Excel (XLS) Update
The transition to updated Excel-based assessments has streamlined the auditing process. These files often include:
Automated Scoring: Instantly calculating the percentage of compliance.
Red-Flagging: Highlighting "non-conforming" areas that require immediate Corrective Action Plans (CAP).
Standardization: Ensuring that whether a foundry is in Michigan or Mumbai, they are being measured against the exact same technical benchmarks. Benefits to the Industry
For OEMs (Original Equipment Manufacturers), CQI-27 provides peace of mind that their Tier 1 and Tier 2 suppliers are operating at a global standard. For the foundries themselves, the assessment serves as a roadmap for operational excellence. It reduces scrap rates, minimizes the risk of expensive recalls, and fosters a culture of technical discipline.
In conclusion, the CQI-27 Casting System Assessment is an essential tool for modern manufacturing. By utilizing the updated Excel frameworks, organizations can ensure their casting processes are reliable, repeatable, and capable of meeting the evolving demands of the global automotive market.
Even with the latest update, users make recurring mistakes. Avoid these:
Pitfall #1: Forgetting to Unprotect Sheets
Solution: The XLS upd comes with default password AIAG_CQI27. Go to Review > Unprotect Sheet before modifying dropdown options.
Pitfall #2: Using WPS Office or Google Sheets Solution: The macros and validation formulas only work 100% in Microsoft Excel 2019 or newer (Windows only). Mac users report broken conditional formatting.
Pitfall #3: Ignoring the "Plunger Speed" Verification Solution: The new update requires numerical entry of actual plunger velocity (m/s) compared to setpoint. Do not leave blank—use “N/A” only if not applicable.
AIAG has signaled that the 2025 edition may move away from Excel entirely toward a cloud-based Collaborative Assessment Platform (CAP). However, for 2024-2026, the cqi27 casting system assessment xls upd remains the official tool. Auditors are already being trained to spot outdated versions, so updating now is not optional—it is mandatory for IATF compliance.
Because CQI-27 is a copyrighted AIAG standard, you cannot legally download a free, fully functional XLS from random file-sharing sites. However, legitimate sources include: CQI-27 Special Process: Casting System Assessment (CSA) is
Warning: Be extremely cautious of free XLS files claiming to be "CQI-27 2025 updated." They may contain spreadsheet errors, missing sections, or viruses. Always cross-check with the official AIAG checklist.
The ultimate goal of the XLS upd is not just to pass an audit, but to drive continuous improvement. To integrate effectively:
The CQI-27 Casting System Assessment (XLS UPD) is not merely a checklist—it is a structured, data-driven tool for ensuring that casting processes are stable, capable, and compliant with automotive customer expectations. The Excel format enables automatic scoring, consistent data capture, and easy sharing with customers. Keeping the file UPD (updated) to the latest revision is critical for audit acceptance and for driving genuine continuous improvement in foundries.
Manufacturers who embed the CQI-27 assessment into their annual process audits report fewer casting defects (porosity, cold shuts, misruns) and stronger supply chain confidence.
References (Suggested for further reading):
Note: Always verify the specific revision required by your customer before using any CQI-27 Excel file.
Mastering the CQI-27 Casting System Assessment: A Guide to the Latest Updates
For automotive foundry suppliers, the CQI-27 Special Process: Casting System Assessment is the critical roadmap for meeting OEM quality expectations. Published by the Automotive Industry Action Group (AIAG), this assessment ensures your casting processes are robust enough to minimize defects and align with IATF 16949 standards.
Whether you are downloading the latest CQI-27 XLS template or preparing for your annual audit, here is what you need to know about the current version and its requirements. Key Highlights of the CQI-27 2nd Edition
The 2nd Edition (released in March 2018) remains the current benchmark, featuring significant "upd" (updates) over the original version to improve clarity and coverage:
Consolidated Process Tables: Similar requirements have been merged to streamline the assessment process.
Expanded Scope: New tables were added to cover a wider range of casting processes, including high-pressure die casting for aluminum, magnesium, and zinc.
Mandatory Focus: There is a much greater emphasis on content regarded as mandatory by OEMs, with a strict requirement that any deviations be authorized by customer Product Engineering.
Editable Excel Tool: The assessment document typically includes a downloadable Excel (.xls) file. In the latest version, unused columns and rows are no longer protected, allowing for easier common editing during the audit. Navigating the Process Tables
The heart of the CQI-27 XLS is the series of Process Tables (A through J), each tailored to specific materials and methods:
Tables A–D: Sand Casting, Centrifugal Castings, and Investment Castings (Iron/Steel). Even with the latest update, users make recurring mistakes
Tables E–G: Aluminum SPM Cylinder Heads, Sand Castings, and Metal Mold.
Tables H–J: High-Pressure Die Casting (Aluminum, Magnesium, Zinc). Best Practices for Your Annual Assessment
Annual Frequency: Assessments must be conducted at least once a year to ensure continued compliance.
Expert Auditors: The assessment should be performed by someone with technical expertise in casting, as the person doing the work is expected to be the "expert".
Root Cause Focus: Use the tool not just for compliance, but as a way to reduce RPN (Risk Priority Number) values on your PFMEA, effectively lowering the risk of sending non-conforming parts to customers.
Use Official Templates: Ensure you are using the official AIAG template. You can find the hardcopy with the downloadable assessment on the AIAG Store or through authorized distributors like Standards Media.
By staying current with the CQI-27 XLS updates, foundries can reduce waste, minimize variation, and ultimately increase customer satisfaction across the automotive supply chain.
The CQI-27 Special Process: Casting System Assessment (2nd Edition) is a critical quality standard developed by the Automotive Industry Action Group (AIAG) to create uniform process requirements for foundry suppliers. The "xls upd" refers to the updated Excel-based assessment tool released with the 2nd Edition, which significantly improved user flexibility and technical scope compared to the original version. Key Features of the CQI-27 2nd Edition XLS
The updated assessment tool introduces several functional and structural enhancements designed to align with IATF 16949 standards and reduce casting defects in automotive applications.
Unprotected Spreadsheet Editing: Unlike the 1st Edition, the 2nd Edition's Excel sheets leave unused columns, rows, and sheets unprotected. This allows auditors to perform common Excel editing to better customize the documentation for their specific foundry layout or customer requirements.
Consolidated Requirement Tables: To streamline the audit process, tables with overlapping or similar requirements were merged. This reduces redundancy and ensures that auditors can focus on the core "voice of the customer" requirements.
Expanded Process Coverage: The update includes 10 specific Process Tables (A through J) that cover a wider range of casting methods, including: Sand Casting (Iron/Steel and Aluminum). Centrifugal Castings and Centrifugal Liners. Investment Castings (Iron/Steel). High Pressure Die Cast (Aluminum, Magnesium, and Zinc).
Mandatory Content Emphasis: The updated XLS places greater weight on requirements that are considered mandatory by OEMs. It explicitly highlights that any deviations from these standards must be authorized by the customer's Product Engineering department.
Revised Technical Clarity: The wording for several requirements from the 1st Edition was rewritten to remove ambiguity, particularly regarding failure modes and root causes. Assessment Scope and Audit Areas
The CQI-27 Assessment Guide ensures that foundries maintain robust controls across the entire production lifecycle: 2nd Edition CQI-27: Casting System Assessment is ... - AIAG
In the world of automotive and heavy-duty manufacturing, CQI-27 (Casting System Assessment) is not just another compliance document—it is the gold standard for process control in foundries. Developed by the AIAG (Automotive Industry Action Group), this specialized audit ensures that high-pressure, low-pressure, and gravity casting operations meet rigorous quality and safety standards.
However, the landscape of casting quality shifted dramatically with the release of the latest CQI-27 assessment XLS upd. If you are a process engineer, quality auditor, or supply chain manager, relying on outdated Excel spreadsheets (XLS files) from 2018 or 2020 is a high-risk gamble. This article provides an in-depth analysis of the new cqi27 casting system assessment xls upd, breaking down what has changed, how to implement the new scoring system, and where to download the legitimate update.
Protect sections containing formulas and historical scores. Use Review → Protect Sheet to prevent accidental overwrites.