CQI-12 Ver 3 Understanding and Implementation

Understanding & Implementation of CQI-12 ver.
3
Faculty :-
Mangesh Rajhansa
Mob: 9545223656 ; 9860317504
Email : mvrajhansa1@gmail.com
Email : sairajconsultant2016@gmail.com
LinkedIN: @Mangesh Rajhansa
SAIRAJ Consultant
13,“Samarth Residency“,Govind Nagar,
Nashik, Maharatstra state / INDIA
TopQM-Systems GmbH & Co. KG
Oberer Schafackerweg 1
+91 9545223656; +91 9860317504
74850 Schefflenz´/ Germany mvrajhansa1@gmail.com;
Phone +49 6293 9289 888 mangesh.rajhansa@topqm.de
Email: info@topqm.de
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Understanding & Implementation of CQI-12 ver. 3
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Who is the IATF ?

International Automotive Task Force
The IATF International Task Force is a global organization of large OEMs and their
automotive associations, mainly from Europe and America. The IATF is the
responsible publisher of the IATF 16949 based on the ISO 9001 (International
Organization for Standardization) The Headquarter is located in London / UK
Asian countries are so far not represented in the IATF

organization, such as, for example, Japan (Nissan,
Honda, Mazda, Toyota…….) and South Korea (Hyundai,
Kia, Renault-Samsung……..). The IATF 16949 is only
partly accepted, mostly their own OEM standards are
Source: www.iatfglobaloversight.org
assumed > like Toyota-TPS, 5STAR, SQ-Mark….etc current status 2019
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3 © TopQM-Systems GmbH & Co. KG , D-74850 Schefflenz
IATF – Members
Vehicle
manufacturers
IATF – Members
Automotive
Associations
USA France
Italy UK Germany
Source: www.iatfglobaloversight.org, current status 2019
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Who is the AIAG ?
The AIAG (Automotive Industry Action Group) is a federation of the north

American automobile industry. It was founded in 1982 by Chrysler, Ford
and General Motors with headquarters in Detroit, Michigan.
The AIAG is a globally-recognized organization, in which the OEMs and

their suppliers regulate their worldwide supply chains.
AIAG’s goal are to reduce cost, complexity through collaboration, improve

product quality, health, safety & environment and optimize speed to market
throughout the supply chain.
The AIAG is the publisher of CQI Special Processes

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Main Automotive Core Tools
QM-System
Automotive
www.iatfoversight.org
IATF IATF 16949 AIAG VDA QMC
VDA CQI •FMEA APQP
the old
PPAP SPC MSA QS9000 Core Tools
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What does CQI mean?

Continuous Quality Improvement
Products & Publications
Tools / Forms Guidelines White Papers Best Practice
Tools
Manuals Information
Forms Expert know-how
CQI-Standards Publications
Checklists
AIAG CQI Special Processes

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Overview of the AIAG CQI Special Processes
CQI-9 Heat Treatment System Assessment Ed.4
CQI-11 Plating System Assessment Ed.3
CQI-12 Coating System Assessment Ed.3
CQI-15 Welding System Assessment Ed.2
CQI-17 EAM-Soldering System Assessment Ed.2
CQI-23 Moulding System Assessment Ed.2
CQI-27 Casting System Assessment Ed.2
CQI-29 Brazing System Assessment Ed.1

this is our
training today
CQI-30 Rubber Processing System Assessment Ed.1
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What does CQI mean in terms of realization?

The CQI standards are guidelines
The requirements of the CQI standards are

complimentary to customer & product
requirements
The CQI standards form part of the customer-specific

requirements & are thus an inherent part of the IATF
16949 requirements
The CQI standards for “special processes“ are self assessments“
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Purpose of CQI- 12 version 3
The purpose of the guide is to provide

an understanding of the CQI-12 ver 3 standard,
& is aimed at both suppliers & end users in the
Coating industry.
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CQI- 12 version history
Sr. Version Release Month /

Validity last for…
No. Number Year
1 Version 1 August 2007 4 Year, 6 months
2 Version 2 February 2012 8 years, 5 months
3 Version 3 July 2020 Current Version in use
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What are Special Processes?
Special Processes are manufacturing procedures, where not all product

characteristics may be verified without the use of destructive testing.
The quality must therefore be validated by means of “robust process

management“ and adequate sampling and testing.
The AIAG thus founded the various “CQI-Working Groups“ for the special
processes responsible for developing the respective process tables.
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Who is representing CQI-12 Quality Steering committee?
Chairperson: 1.Brian Glowacki Atotech USA Inc.

2.Darrell Rydzewski Control Services Inc.
3.Justin Rydzewski Control Services Inc.
4.Walt Kacher Kurtis Metal Finishing Co.
5.Amy Zyski Dana Incorporated
6.Albert Gelles Doerken Corporation
7.Jeff Szotek FCA US LLC
8.Kimberley Tress FCA US LLC
9.Kenneth Glaza Ford Motor Company
10.Steven Kwong General Motor Company
11.Ron Doran Henkel Corporation
12.Jim Toth Jim Toth Solutions LLC
13.John Hess NOF Metal Coatings North America
14.Tina L. Noll Shape Corporation
15.Nick Herdzik Toyota Technical Centre
16.Karen Krutsch AIAG
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CQI-8 Layered Process Audit Guideline
CQI-9 Heat Treat System Assessment (HTSA )
CQI-11 Plating System Assessment (PSA )
CQI-12 Coating System Assessment (CSA )
CQI-14 Automotive Warrant Management Guideline
CQI-15 Welding System Assessment (WSA )
CQI-17 Electronic Assemebly Manufacturing - Soldering System Assessment (EAM-SSA )
CQI-18 Effective Error-Proofing
CQI-19 Sub-Tier Supplier Management Process Guideline
CQI-20 Effective Problem Solving Guide
CQI-22 Cost of Poor Quality Guide

AIAG CQI
CQI-23 Molding System Assessment Special Processes
CQI-24 Design Review Based on Failure Modes (DRBFM Reference Guide)
CQI-27 Casting System Assessment
CQI-28 Traceability Guideline
CQI-29 Brazing System Assessment (BSA )
CQI-30 Rubber Processing System Assessment – Mixing and Molding
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CQI- 12 Goal
CQI-12 was published by AIAG to serve as a uniform
Coating Management audit system that provides:
 Continual improvement,
 Prevent defects,
 Reduce variation and waste in the supply chain.
Coupled with internationally recognized QMS.
 Provide common approach to Coating Management
system for automotive production & service part
organizations.
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Purpose of CSA ?
 To assess an organization’s ability to meet :
 CQI-12 requirements,
 Customer requirements,
 Regulatory requirements and,
 Organization’s own requirements.
 It can be used between an organization and its

suppliers.
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Structure of CSA
Structure of the CQI-12 Standard
Contract,
Forms,
Checklists
Records
Process Tables
Job Audit
(kind of an Product Audit)
CQI-12 Cover sheet & Main-Questionnaire
(kind of a System & Process Audit)
AIAG CQI System Assessment
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Structure of CSA
The Layout of CQI-12 questions (Section 1-3) was restructured to more clearly
specifying detailed requirements
The questions from the Main Audit Questionnaier were divided into individual
questions, which are identical to the previously specified, Requirements &
Guidance in the main questions.
This means that the Auditor must increase the scope of the audit evidence to
accommodate the necessary details in the audit report
Number of Requirements from the Main Audit Questionnaire

from Section 1-3
Edition 2 : Edition 3:
30 Que. 113 Que.
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Assessment Process :
 To ensure continuous compliance with CSA,
Ongoing assessments shall be conducted once in 12 months,
or a new line is installed or equipment modification is done,
review of organization’s systems using CSA.
 Job audits as per section 4.0 shall be performed

for parts from different automotive component
manufacturers that required compliance to CSA document.
 Assessment shall use process approach to auditing as per

requirements of ISO 9001 / VDA 6.3 / IATF 16949
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Use of CQI-12 ,CSA & Process Tables :
 CQI-12, CSA & process tables address the most common

thermal processes employed by automotive industry.
 Due to variety of Coating processes being followed across

industries, it may be necessary to incorporate requirements
as per appropriate process tables provided.
 It is possible to employ requirements from multiple process

tables, for an element of any Coating process being assessed.
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Assessor Qualifications :
Assessor(s) shall have the following experience to
conduct Coating System Assessment.
1) Be an experienced Quality Management System(QMS)

Internal auditor ( for eg. IATF 16949; VDA 6.3, ISO 9001)
2 ) Shall possess Coating knowledge. Evidence shall

include a min. of 5 years experience in Coating process
or a combination of formal chemical education and
Coating experience totaling a minimum of 5 years.
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Assessor Qualifications :
 3) Assessor shall possess knowledge of and be familiar with
the application of automotive quality core tools including
• Statistical Process Control (SPC),
• Measurement System Analysis(MSA),
• Part Approval Process (PPAP),
• Failure Mode and Effect Analysis (FMEA), and
• Advanced Quality Planning(APQP).
 If more than one assessor is required to meet above

qualifications, the lead assessor shall be the person
meeting the requirements in item no. 1
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Scope of CSA
 CSA specifies process requirements for an organization or
its suppliers performing applicable Coating, who need to:
 Demonstrate ability to consistently provide product that

meets customer and regulatory requirements.
 Enhance customer satisfaction through the effective

application of the system, including processes for
continual improvement of the system.
 CSA is applicable to sites, where customer specified parts

for production / or services throughout the automotive supply
chain.
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Application of CSA:
 All requirements of CSA are generic and are intended
to be applicable to all organizations performing
Coating regardless of type, size and product.
 Eleven Process Tables ( A to K) have been developed &

appropriate table is to be referenced during assessment.
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Process Tables :
Process table A :- Pre-Treatment ( Aqueous )
Process table B :- Pre-Treatment ( Mechanical )
Process table C :- Conversion Coating
Process table D :- Powder Coating
Process table E :- Spray Coating.
Process table F :- Electro Coat
Process table G :- Dip Spin and Zn Flake
Process table H :- Auto Deposition
Process table I :- Cure
Process table J :- Anodizing and Hard coat Anodizing
Process table K :- Process control & Testing Equipment
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Following standards are referenced in this document :
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Coating System Assessment procedure :
• Obtain the latest copy of CQI 12 Special Processes – CSA 3 rd
Edition from AIAG. www.aiag.org (Enter username & password, Go to my account, )
• Identify all the processes in your Plant which applies to

CQI 12 – Special Processes.
• Record these Processes on the CSA Cover Sheet.
• Complete the CSA , Determine the Level of compliance,

• Minimum one Job Audit to be Performed during each assessment.
• Address each “ NON CONFORMING“ item & Determine the Corrective

action for it.
• Do the Root cause analysis & Record Implementation Date for the
Corrective Actions.
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Coating System Assessment procedure :
• The Corrective Actions Shall be Completed within 90 Days or
sooner.
• Record all Corrective actions, including the Verification of those

actions.
• Assessment shall be done once a year unless it is Specified by

the Customer.
• The organizations shall keep records as evidence of compliance

to the requirements identified in the CSA, as well as all
appropriate action plans to address any unsatisfactory ratings.
These records shall be readily available for review by any
customer requiring compliance to the requirements within this
document.
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Instructions for Completion of Cover Sheet:

Following Points should be covered while filling the Cover Sheet:
 Facility Name
 Address
 Phone No
 Fax No
 Email ID
 Captive Coater– Yes / No
 Commercial Coater– Yes / No
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Instructions for Completion of Cover Sheet:

Following Points should be covered while filling the Cover Sheet:
 Date of assessment
 Date of Previous Assessment
 Types of Coating Processing in this facility
 Assessors Details
 No of “Non conforming” Findings
 No of “Non conforming” Findings in Job Audit
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Meaning of words in CSA ?
 Shall:- A requirement for purpose of the self assessment.

failure to meet the requirements results in an
assessment that is “Non Conforming”
 Should:- Indicates a recommendation.
 Such as:- Suggestion given for guidance only.
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Sections of CSA : -
• Section 1
– Management Responsibility & Quality Planning
• Section 2
– Floor & Material Handling Responsibility
• Section 3
– Pyrometry
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Instructions for completing the Job audit Section 4 :
 The organization shall complete a Job audit during the annual CSA.
 The scope of the job audit is intended to verify the overall effectiveness
of the Coating system.
 It shall be conducted on a specific lot that is in process or has been

recently processed, but not yet shipped.
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Instructions for completing the Job audit :
 In subsequent CSAs, different parts and Coating processes
shall be audited.
 An automotive manufacturer’s part shall be used in performing the job

audit, If an automotive manufacturer’s part is not available, the selected
part shall be another part processed in compliance with CQI-12.
 The job audit shall be performed when applicable parts are available.
 Successive job audits shall sample parts from different automotive

manufacturer’s that requires compliance to the CSA document.
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Instructions for completing the Job audit :
 Each processing steps shall be reviewed for proper production

records/compliance/ inspection. These steps can be compared to those
in the CSA for the actual job/Coating process being reviewed for
compliance. The Coating & Tank/furnace records for the actual time
frame /shift etc. that the job was processed shall also be audited
 Address each “NON CONFORMING” item immediately. Any NC item

shall result in the update of the corresponding CSA element ( See CSA
procedure )
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Thermocouples :
General :
Guidelines for recommend temperature ranges or upper limits should be taken from
ASTM E230 , IEC 60584-1 or other national standards.
Thermocouples should be traceable to national institutes.( e.g. NIST ,PTB etc. )

(National Institute of Standards & Technology) ; ( Physikalisch-Technische Bundesanstalt )
Calibration:
Calibration before first use in the working temperature range and at intervals no greater
O
than 150 C
Certificates should state actual temperature , nominal temperature, correction factor for
each point, provider of calibration data and calibration method. Interpolation between
test points is allowed, extrapolation outside test points is not.
External sources needs to be accredited to ISO/IEC 17025 or other national equivalent.

Internal sources needs to calibrate with the intent of ISO/IEC17025 or other national
equivalent. Records of training and qualifications needs to kept of internal personnel
performing calibrations.
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Thermocouples :
Document the date the thermocouple is placed in service.
Damaged thermocouples shall not be used.
Control, Monitoring and Recording Thermocouples :

 Accuracy required is +/- 1.1 O C ( +/-2.0 O F ) or +/- 0.4% Max.
Calibrated against a primary or secondary standard thermocouple.
 Replace every 4 years , if Noble metal (B,R,S & Platinum RTDs ) is used all
Ovens & Process Tanks. or Base Metal ( K,J,N,T ) used for Ovens .
 Replace every 2 years for base metals (K,J,N,T ) used for Process Tanks.
 Replace every 2 years for base metals (K,J,N,T ) used for Process Tanks.
Hydrogen Embrittlement Relief, Electroless Nickel Hardening &

other Oven systems with a process temperature control tolerance
of 20⁰C (30⁰F) or less
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For Coating process (CQI-12 ):-
Table P3.1.1 – Calibration and Replacement Requirements for Thermocouples Used for Control, Monitoring and Recording
INITIAL
CALIBRATION /
CALIBRATED CALIBRATION
THERMOCOUPLE TYPE (1) SYSTEM TYPE REPLACEMENT
AGAINST ACCURACY
INTERVAL
REQUIRED
± 1.1ºC (± 2.0ºF)
Oven systems with a process
Base Metal Types Calibrate before first use. Primary or Secondary or
temperature control tolerance
(K, J, N, T) Replace every two years (2,3) Standard ± 0.4% whichever is
of 20⁰C (30⁰F) or less.
greater
± 1.1ºC (± 2.0ºF)
Other Ovens
(K, J, N, T) Replace every four years (2,3) Standard ± 0.4% whichever is
greater
± 1.1ºC (± 2.0ºF)
Process Tanks
(K, J, N, T) Replace every two years (2,3) Standard ± 0.4% whichever is
greater
± 1.1ºC (± 2.0ºF)
Calibrate before first use.
Noble Metal Types Primary or Secondary or
All Ovens and Process Tanks Replace or recalibrate every four years
(B,R,S, Platinum RTD) Standard ± 0.4% whichever is
(2)
greater
1. Non-Expendable
2. Thermocouples shall be replaced whenever needed (e.g., failed SAT or damaged thermocouple); however,
thermocouples shall be replaced minimally as stated
above. Thermocouples may either be purchased calibrated or calibrated internally and shall meet requirements of
P3.1.
3. Base metal thermocouples shall not be recalibrated.
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Table P3.1.2 – Calibration and Replacement Requirements for Test Thermocouples Used for Temperature Uniformity Surveys (TUS) and
System Accuracy Tests (SAT)
CALIBRATION / CALIBRATION
THERMOCOUPLE CALIBRATED
THERMOCOUPLE USE REPLACEMENT ACCURACY
TYPE AGAINST
INTERVAL REQUIRED
± 1.1ºC (± 2.0ºF)
Base Metal Types TUS As per Table P3.1.3 Recalibration Primary or Secondary
Test Thermocouples or
(K, J, N, T) SAT prohibited (1) Standard
± 0.4% whichever is greater
1. Base metal thermocouples shall not be recalibrated.
Table P3.1.3 – Allowable Number of Uses for Thermocouples in Specific Applications
MAXIMUM
THERMOCOUPLE TYPE USE (1) OPERATING TEMPERATURE
PERMITTED USES
Expendable Base Metal Temperature Uniformity Surveys (TUS) /

≤ 430ºC (800ºF) 15 (2)
(K, J, N, T) System Accuracy Test (SAT)
Expendable Base Metal

Control ≤ 430ºC (800ºF) 1 (2)
(K, J, N, T)
Expendable Base Metal

Monitor/Record/Load Sensing ≤ 430ºC (800ºF) 30 (2)
(K, J, N, T)
Non-expendable Base Metal Temperature Uniformity Surveys (TUS) /

≤ 430ºC (800ºF) 2yrs maximum
(K, J, N, T) System Accuracy Test (SAT)
Non-expendable Base Metal

Load Sensing (part temperature) ≤ 430ºC (800ºF) 6 months
(K, J, N, T)
1. Thermocouples shall be dedicated to a specific, unalterable purpose (TUS, SAT, Load Sensing, Control,
Monitoring, or Recording). Thermocouples that have achieved their maximum permitted number of uses for
this assigned application shall not be repurposed for other CQI-12 compliance requirements.
2. Under no circumstance shall any expendable base metal thermocouple be used beyond six months from date of first use.
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New Thermocouple Calibration: New Thermocouple :

1. Thermocouple ID
2. Make, Model,& serial number
3. Details of calibration thermocouple used.( primary / secondary )
4. Method of calibration
5. Ambient temperature and Humidity.
6. Required accuracy
7. Initial and Final values at each calibration point
8. Statement of acceptance
9. Any limitations or restrictions of the calibration
10.Date the calibration was performed.
11.Due date of next calibration
12.Technician who performed the calibration with signature
13.Calibration company if not performed in-house.
14.Sign- off by responsible person in the heat treat organization.
15.Seal of NABL accreditation lab if performed from third party agency
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Instrumentation :
 Calibration is performed to ensure the process instruments are
providing a true reading ( within limits ) of the actual temperature
being measured.
 A Field Test Instrument calibrated to a higher level of accuracy

is used to inject signals into the process instrument to see if
any deviation is observed .
 For Process instruments this is usually performed at a minimum,

midpoint and maximum temperature of the operating range.
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Instrumentation :
Control, Monitor or Recording Calibration Accuracy
Every 3 months against Field Test Instrument
O
(Single or multipoint ) accuracy +/-2.0 C
Every 6 months against Primary standard,

O
Accuracy +/-2.0 C
Temperature for each control zone shall be recorded by a

recording instrument 5 minute interval maximum for analog
recorders & 2 minutes maximum for digital recorders.
Offsets are generally discouraged, if used , then this needs

O
to be fully documented and not exceed 5.0 C
The system shall create write once, read only electronic

records that can not be altered without detection.
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Instrumentation :
P3.2.2 Offsets: Although the use of offsets is generally discouraged, they are
allowed to specifically correct for calibration errors, SAT errors or to center
a TUS result.
Offset values applied are limited & shall not exceed 5⁰C for the correction of
instrument calibration error. An additional offset of 5⁰C is allowed for the
correction of an SAT error & another 5⁰C of offset for the purpose of centering a
TUS result.
When offsets are used a documented procedure shall exist which at a minimum
describes each of the following:
• When the use of offset is permitted

• How manual (external) and electronic (internal) offsets are performed
• How the basis (calibration, SAT or TUS) for the offset is documented
• How offset is accounted for when performing calibrations
• How offset is considered when performing an SAT
• How to reintroduce any intentional offsets
• Who has the authority to approve the use of offsets
• How is this approval documented
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Instrumentation :
Table P3.2.1 – Instrument Calibration Requirements
MAXIMUM
CALIBRATION
INSTRUMENT CALIBRATION CALIBRATED
INSTRUMENT ACCURACY USE
TYPE PERIOD AGAINST
REQUIRED
(MONTHS)
Portable
Limited to controlling, monitoring,
potentiometer or
± 0.6ºC (± 1.0ºF) or or recording instrument calibration,
Field Test digital instrument, Primary or Secondary
12 ± 0.1% of reading, performance of system accuracy
Instrument electronic data standard
whichever is greater tests and temperature uniformity
recorder, or data
surveys.
acquisition system.
Control, Digital, Mechanical Field Test Instrument

Limited to measuring, recording,
Monitoring, (analog), Electro- (single-point or multi- ± 2.0ºC (± 4.0ºF)
12 and controlling the temperature of
or Recording mechanical, or point calibration)
thermal processing equipment.
Instruments Thermal element.
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Calibration Report detail required : P3.2.4.2 Instrumentation :
• Oven or unit identification number
• Make, model and serial number of instrument calibrated. PLC devices/modules not serialized
require unique identification.
* Each channel/input calibrated shall be identified
• Standard or test instrument used during calibration
• Method of calibration
• Ambient temperature and humidity
• Required accuracy (+/-2⁰C; +/-4⁰F)
• As-Found/As-Left temperature values at each calibration point (if no adjustment is made then
the final value will equal the As-Found value)
• As-Found/As-Left offset/bias values (if no adjustment is made then the corrected offset/bias
value will equal the As-Found value)
• Basis for offset/bias values indicated and clearly defined (Calibration, SAT, or TUS)
• Pass/Fail status
• Any limitations or restrictions of the calibration
• Date the calibration was performed
• Due date of next calibration
• Technician who performed the calibration
• Signature of the technician who performed the calibration
• Calibration company if not performed in-house
• Accreditation symbol (or equivalent) if not performed in-house
• Sign-off to include the name and title of person reviewing/approving calibration report
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System Accuracy Test ( SAT ): P3.3
 Oven & Dryer Control, Monitoring & Recording temperature systems
( Instrument, Lead wire ,Thermocouple/RTD) are verified by performing SAT.
This requirement includes load sensing thermocouples.
 The oven SAT frequency shall be every SIX months.
 Process tank control temperature system ( Instrument, Lead wire, Thermocouple

/ RTD) are verified by performing a temperature check as per applicable
process Table. Process tank temperature check satisfies the SAT
requirement. For maximum allowable temperature check difference
values, refer the applicable process tables.
 The process tank temperature check frequency shall be Daily.

( or as otherwise specified )
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 Oven SAT & Process Tank temperature checks shall be performed using a test
thermocouple ,conforming the requirements of thermocouples as per P3.1.2 ,
coupled with a test instrument meeting the requirements of instrumentation as
per P3.2.1
 A new oven SAT or process tank daily temperature checks shall be performed
after any maintenance that could affect the SAT or temperature check accuracy,
e.g. Replacement of lead wire, replacement of control thermocouple, or
replacement of control instrument
 For oven systems, the SAT shall be performed while the oven is operating at a
typical operating temperature using Probe Method A
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Probe Method A :
 It is a check between uncorrected reading of the oven control, monitoring
and recording temperature system ( instrument, lead wire, thermocouple / RTD) &
corrected reading of the test temperature system instrument ( test instrument
& test thermocouple )
 The tip (measuring junction) of the test thermocouple shall be no further than
50 mm from the tip (measuring junction) of the oven control, monitoring &
recording thermocouple/RTD.
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 Probe Method A :
 The difference between the temperature indication of the oven control,
monitoring & recording instrument connected to its respective
thermocouple / RTD & corrected temperature indication of the test
thermocouple on a test instrument shall be within the following
tolerances.
 After insertion of the test thermocouple, allow sufficient time to achieve

equilibrium between the test thermocouple & control ,monitoring &
recording instrument thermocouple /RTD.
System Maximum SAT difference allowed

Ovens ( All ) ±5°C
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Probe Method A :
 If the calculated SAT difference exceeds the value stated in table, the
appropriate corrective action shall be taken before commencing with
additional processing. Oven control, monitoring & recording
thermocouples/RTD failing to meet the requirements shall be replaced.
 A new SAT shall be conducted on the replaced thermocouple/RTD.

Actions shall be documented.
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System Accuracy Test ( SAT ): P3.3.5
Probe Method A :
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Temperature Uniformity Survey ( TUS): P3.4
 Temperature Uniformity characteristics, qualified work zones & operating
temperature ranges of curing & drying ovens are verified by performing
annual TUS in accordance with the requirements.
 TUS shall be performed using independent test instrumentation meeting

the requirements of table P3.2.1. Instrument calibration requirements &
independent test thermocouple meeting the requirements as per table
P3.1.2
 Compensation for known deviations in the test instrumentation shall be

made by electronic or mathematic corrections.
 Any oven modifications or repairs that could alter the temperature

Uniformity characteristics of the oven shall result in a TUS being
performed prior to the oven system being used for processing.
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 All oven modifications or repairs shall be documented and include the
determination made by the responsible authority within the organization as
to whether this modifications or repairs could alter the TUS characteristics
of the oven.
 If the operating temperature range of the ovens qualified work zone is less
than or equal to 170 Deg C, then only the max. operating temperature to
be surveyed / tested.
 If the operating temperature range of oven qualified work zone is greater

than 170 Deg C, the minimum and the maximum operating temperature of
the oven shall be tested.
 When performing the TUS, the oven system parameters during the test
shall replicate the oven system parameters during normal production. The
pre heating of the oven system is permissible if the oven is preheated in
normal production.
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 TUS shall be performed with a dense, full production load or simulated
production load which shall represent the maximum permissible load rate for the
oven during normal production.
 Time required to achieve the set temperature shall meet the most stringent
applicable customer or process specifications.
 Methods of TUS : There are TWO methods of TUS.

1) Volumetric method 2) Plane method.
General requirements of continuous furnaces :

 Continuous furnaces can be surveyed by volumetric method.
( pusher furnaces ) or plane method ( belt furnaces ).
 Test T/C’s should be traversed through the furnace at a typical speed

& representing all locations, data collection starts as soon as they enter furnace
& recorded at least every 30 seconds.
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 Manual data collection is not allowed.
 This data is then compared with the data from the process record.
( the soak time should be clearly shown ).
General requirement of batch type furnaces :

 Data collection starts when TUS thermocouples are loaded into the furnaces
 Recorded data needs to be automatically collected, at least one set of readings,

every 30 seconds
 Manual data collection is not allowed.
 When the furnace control normally cycles around set point, & the TUS
thermocouples have stabilized, continue the data collection for a minimum
of 30 minutes.
 This data is then compared with the data from the process record.
( the soak time should be clearly shown ).
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The TUS shall be acceptable if all previous requirements are met including
the following :
 All the readings of all TUS thermocouples and control thermocouples are within
+/-10 Deg C of the temperature controller set point or other more stringent
customer specifications.
 The time required to achieve target part temperature did not exceed the time
limit specified in customer specifications, process sheet or technical data sheet.
 The required time at temperature was achieved ( For continuous / semi

continuous oven only ).
 The upper tolerance was not exceeded at any time by any TUS thermocouple
or temperature controller thermocouple.
 The lower temperature tolerance was continuously maintained after reaching

the beginning of soak period.
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Reaction to TUS failures P3.4.8 : -
 If the TUS results are not within the established limits, the cause of the
deviation shall be determined and documented.
 The equipment shall not be used for additional processing until the cause
has been corrected and the TUS has been performed successfully.
TUS report P3.4.9 :
 The points listed below shall be included in the TUS report.
1. Oven identification name or number

2. Method of TUS ( If volumetric or plane )
3. Survey test temperature ( temperature controller set point & required TUS
tolerance indicated.
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4. TUS thermocouple quantity & location identification including a detailed
diagram in three dimensional space or detailed description or photograph(s)
of any load, rack or set up.
5. Photograph showing placement of thermocouples into the load.
6. TUS thermocouple calibration report to include correction factors.
7. Survey test instrument identification number
8. Survey test instrument calibration report to include calibration data and
correction factors for each adjustable channel or input
9. Testing company identification if not performed inhouse
10. Accreditation symbol if not performed in house.
11. Name & signature of the technician performing the TUS.
12. Survey start / stop time and Start / Stop date.
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13. Corrected readings of all thermocouples at each survey temperatures.
14. Identify time to temperature for the test load.
15. Process time parameters ( Conveyor/ belt speed, index time ).
16. The data collection period or soak period.
17. Soak time required Vs Soak time achieved.
18. Control instrument tuning parameters ,eg. PID values.
19. Time & temp.profile data for all TUS thermocouples & temp. control thermocouples
for all zones tested. Control thermocouple data shall be generated by associated
process recorder/ process data acquisition system.
20. Pass / Fail status
21. Summary of the final plus and minus readings at each test temperature.
22. Sign off by coating organization to include the name and title of the person
reviewing the and approving the report.
Sai Raj Consultant

Thank You !!
Happy to take your

queries / doubts ..
Sai Raj Consultant

CQI-12 Ver 3 Understanding and Implementation

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Understanding & Implementation of CQI-12 ver.

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Who is the IATF ?

Asian countries are so far not represented in the IATF

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The AIAG (Automotive Industry Action Group) is a federation of the north

The AIAG is a globally-recognized organization, in which the OEMs and

AIAG’s goal are to reduce cost, complexity through collaboration, improve

The AIAG is the publisher of CQI Special Processes

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Main Automotive Core Tools

IATF IATF 16949 AIAG VDA QMC

VDA CQI •FMEA APQP

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What does CQI mean?

Products & Publications

Tools / Forms Guidelines White Papers Best Practice

AIAG CQI Special Processes

CQI-11 Plating System Assessment Ed.3

CQI-12 Coating System Assessment Ed.3

CQI-15 Welding System Assessment Ed.2

CQI-17 EAM-Soldering System Assessment Ed.2

CQI-23 Moulding System Assessment Ed.2

CQI-27 Casting System Assessment Ed.2

CQI-29 Brazing System Assessment Ed.1

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What does CQI mean in terms of realization?

The requirements of the CQI standards are

The CQI standards form part of the customer-specific

The CQI standards for “special processes“ are self assessments“

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The purpose of the guide is to provide

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Sr. Version Release Month /

1 Version 1 August 2007 4 Year, 6 months

2 Version 2 February 2012 8 years, 5 months

3 Version 3 July 2020 Current Version in use

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What are Special Processes?

Special Processes are manufacturing procedures, where not all product

The quality must therefore be validated by means of “robust process

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Chairperson: 1.Brian Glowacki Atotech USA Inc.

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CQI-9 Heat Treat System Assessment (HTSA )

CQI-11 Plating System Assessment (PSA )

CQI-12 Coating System Assessment (CSA )

CQI-14 Automotive Warrant Management Guideline

CQI-15 Welding System Assessment (WSA )

CQI-17 Electronic Assemebly Manufacturing - Soldering System Assessment (EAM-SSA )

CQI-18 Effective Error-Proofing

CQI-19 Sub-Tier Supplier Management Process Guideline

CQI-20 Effective Problem Solving Guide

CQI-22 Cost of Poor Quality Guide

CQI-27 Casting System Assessment

CQI-28 Traceability Guideline

CQI-29 Brazing System Assessment (BSA )

CQI-30 Rubber Processing System Assessment – Mixing and Molding

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