AIAG CQI-15 Special Process: Welding System Assessment Mabuchi Motor Mexico, S.A.De C.V

CQI-15
Special Process: Welding System Assessment

Version 2 Issued 10/2019
AIAG CQI-15 Special Process: Welding System Assessment
Company Name: MABUCHI MOTOR MEXICO,S.A.DE C.V Current

GREEN Job Audit Summary
Status
Street Address: Circuito Cerezos Oriente ＃105,Parque Industrial San Francisco IV GMAW Overall Not Completed
Country/City/State/ZIP Code: San Francisco de Los Romo,Ags.,Mexico C.P.20304 Weld System % GMAW CTQ No Critical
100.00%
Site Code: 449 478 3200 Compliance LBW Overall Not Completed
Parent Code: Job Audit % LBW CTQ No Critical
Current Quality Certification(s): IATF Compliance Not Completed Drawn Arc Overall Not Completed
Date of This Assessment: January 12, 2023 Overall Total of WSA and Drawn Arc CTQ No Critical
Job Audits 100.00%
Date of Initial Assessment: January 24, 2022 Resistance Overall Not Completed
Date of Re-Assessment (if necessary): February 17 2023 Resistance CTQ No Critical
Number of Welding Employees at this Facility: 3 Friction Overall Not Completed
Captive Weld Organization (Y/N): No Friction CTQ No Critical
Induction Overall Not Completed
Review Members Title Email Address Phone Induction CTQ No Critical
Luis Aldana Quality Engineer Supervisor Fastener Projection Not Completed
Victor Oliva Garcia Fastener Projection CTQ No Critical
MIAB Overall Not Completed
MIAB CTQ No Critical
CTQ= Critical to Quality Higher is Better
Site Responsible Person Title Email Address Phone
Supplier Contacts Title Email Address Phone
Weld Classifications: Ship To Locations Tier Level Contact Name Contact eMail
Welding Processes Used: A07
Welding Specifications Used:
Commodity: Chassis
Part Number(s) Assessed: Vehicle / Program Product Information Overall Summary Comments:
GD558RH/LH
LEGEND
Does NOT meet the requirements, needs immediate action.
Red Any RED Element
Process review indicates that there is a risk of non-conforming product.
Does NOT meet the requirements, containment is in place.
Yellow <100% GREEN -0- RED
Process review indicates that there is sufficient containment of non-conforming product.
Green 100% GREEN Meets all requirements
CQI-15
SUMMARY of RESPONSES
Welding System Assessment Section % Compliance of RED YELLOW GREEN
Possible
Rated Elements Elements
Section 1 Weld System Process Assessment (SPS Assessment) 100.00% 0 0 6 #VALUE!
Section 2 Documentation 100.00% 0 0 14 #VALUE!
Section 3 Preplanning / Quality Documentation 100.00% 0 0 19 #VALUE!
Section 4 Production Monitoring / Documentation 100.00% 0 0 9 #VALUE!
Section 5 Rework or Scrap Procedures and Reports Not Completed 0 0 0 #VALUE!
% of Items Completed #VALUE! Section 1-5 Total 100.00% 0 0 48
% Compliance of
WELDING JOB PROCESSES Section RED YELLOW GREEN Possible
Rated Elements Elements
GMAW Overall 1. PART PRINT Not Completed 0 0 0 #VALUE!

Not Completed 2. CONTROL PLAN Not Completed 0 0 0 #VALUE!
GMAW Critical to Quality 3. DESTRUCTIVE & NONDESTRUCTIVE TESTING DATA Not Completed 0 0 0 #VALUE!
No Critical 4. WELD QUALITY INSPECTION & REPORTS Not Completed 0 0 0 #VALUE!
% of Items Completed 5. REWORK PROCEDURE & REPORTS Not Completed 0 0 0 #VALUE!
#VALUE! 6. PARAMETER DOCUMENTATION Not Completed 0 0 0 #VALUE!
7. MAINTENANCE RECORDS Not Completed 0 0 0 #VALUE!
8. SUSTAINABILITY Not Completed 0 0 0 #VALUE!
9. EQUIPMENT & ROBOTIC PROCESSING REQUIREMENTS Not Completed 0 0 0 #VALUE!
LBW Overall 1. PART PRINT Not Completed 0 0 0 #VALUE!
LBW Critical to Quality 3. DESTRUCTIVE & NONDESTRUCTIVE TESTING DATA Not Completed 0 0 0 #VALUE!
Drawn Arc Overall 1. PART PRINT Not Completed 0 0 0 #VALUE!
Drawn Arc Critical to Quality 3. DESTRUCTIVE & NONDESTRUCTIVE TESTING DATA Not Completed 0 0 0 #VALUE!
Resistance Overall 1. PART PRINT Not Completed 0 0 0 #VALUE!
Resistance Critical to Quality 3. DESTRUCTIVE & NONDESTRUCTIVE TESTING DATA Not Completed 0 0 0 #VALUE!
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Friction Overall 1. PART PRINT Not Completed 0 0 0 #VALUE!
Friction Critical to Quality 3. DESTRUCTIVE & NONDESTRUCTIVE TESTING DATA Not Completed 0 0 0 #VALUE!
% of Items Completed 5. PARAMETER DOCUMENTATION Not Completed 0 0 0 #VALUE!
#VALUE! 6. MAINTENANCE RECORDS Not Completed 0 0 0 #VALUE!
Induction Overall 1. PART PRINT Not Completed 0 0 0 #VALUE!
Induction Critical to Quality 3. DESTRUCTIVE & NONDESTRUCTIVE TESTING DATA Not Completed 0 0 0 #VALUE!
Fastener Projection Overall 1. PART PRINT Not Completed 0 0 0 #VALUE!
Fastener Projection Critical to Quality 3. DESTRUCTIVE & NONDESTRUCTIVE TESTING DATA Not Completed 0 0 0 #VALUE!
MIAB Overall 1. PART PRINT Not Completed 0 0 0 #VALUE!
MIAB Critical to Quality 3. DESTRUCTIVE & NONDESTRUCTIVE TESTING DATA Not Completed 0 0 0 #VALUE!
Job Audit Total Not Completed 0 0 0
Overall Total 100.00% 0 0 48

CQI-15
Weld System Assessment
San Francisco de Los Romo,Ags.,Mexico

Assessor MABUCHI MOTOR MEXICO,S.A.DE C.V
C.P.20304
Date 12-Jan-23
(Name - Company) (Name - Location)
1/24/2022 1/12/2023
Initial Rating Current Status
Item No. Question Requirements and Guidance (R/Y/G) Evidence / Gap Identified (R/Y/G) Follow up Comments
Section 1 - Weld System Process Assessment
Are internal assessments being completed on an annual

The organization shall conduct internal assessments on an annual basis, at a minimum, unless otherwise specified by
1.1 basis, at a minimum, using AIAG Welding System
the customer, using the AIAG WSA. Concerns shall be addressed in a timely manner.
Green Green
Assessment (WSA)?
<==START HERE Annual audits are performed based on AIAG checklist.
To ensure readily available expertise, there shall be a dedicated, qualified and full time welding person on site. This
individual shall be one of the following:
1. Degreed Welding Engineer, or equivalent science degree.
Is there a dedicated and qualified technical welding person
1.2
on-site?
2. Certified Welding Inspector from approved internationally recognized organization. Green Green
3. A minimum of 5 years experience in welding operations or a combination of a minimum of 5 years of formal
metallurgical education and welding experience.
4. A qualified person agreed upon between customer and supplier with documentation approval.
The person in charge was trained in CQI 15
Facilities: could include but is not limited to, capabilities such as safety, environmental regulations/practices, air (sizing,
1.3 Are the facilities sufficient for the welding operation? filtering and cleanliness), gas mixing system (equipment and sizing), ventilation, and adequate lighting. Utilities: sufficient Green Green
incoming power (balance and loading) and water.
Facilities are enough for welding system
The power supply should be adequate for the manufacturing process with consideration not limited to output energy, duty
1.4 Are the power supplies sufficiently sized and protected? cycle, cooling, flow rates and grounding. Power supply grounding per OEM and regulatory specifications. Surge Green Green
protection and power fluctuation/regulation.
The power supply is adequate and energy variation protected Power supply variation protected on site
The welder’s loading system, in-process handling, and shipping process shall be assessed for risk of part damage or
Is the handling, storage and packaging adequate to
1.5 other quality concerns. Other practices such as stacking of overloaded containers can also increase the risk of part Welding products are not for our final products for customers but Welding products are not for our final products for customers but
preserve product quality?
damage.
one of the components, one of the components,
When leaving work every day workers clean production lines and
Plant cleanliness, housekeeping, environmental, and working conditions shall be conducive to quality. The welding equipment
Are plant cleanliness, housekeeping, environmental and organization shall evaluate such conditions and their effect on quality. A housekeeping policy shall be clearly defined and Equipment and production lines are regularly cleaned
1.6
working conditions conducive to quality? executed. The facility shall be reviewed for conditions that are detrimental to quality processing such as loose parts on
Green Green
floor, contaminants, oil, inadequate plant lighting, fumes, etc.
The quality management division conducts 5S audits on a regular
basis There is a cleaning rol and procedure
Is there a preventative maintenance program specific to the The organization shall have a documented preventative maintenance program for weld process equipment. The program
1.7 welding process? Is the maintenance data being utilized to shall track maintenance schedules. Maintenance data shall be collected and analyzed as part of a preventative Green Green
verify the effectiveness? maintenance program.
Conduct regular checking, initial revision check sheet By initial revision check sheet
Section 2 - Documentation
Is there a responsibility matrix to ensure that all key welding

The matrix shall identify both primary and secondary (backup) personnel for the key functions (as defined by the
2.1 management and supervisory functions are performed by
organization). This matrix shall be readily available to management and customer at all times.
Green Green
qualified personnel?
Defined in the internal standards Q-MAB-D011 and Q-MAB-D024 Defined by procedure
Does the welding organization perform advanced quality A manufacturing feasibility study shall be performed and internally approved for each part. Similar parts can be grouped
2.2 Welding products are not for our final products for customers but
planning? into part families for this effort as defined by the organization.
one of the components,
Management shall review the weld process control systems along with reviewing the efforts to detect out-of-control QA department is monitoring process defective data and asking
Is management reviewing the weld control system at a
2.3
frequency determined by the control plan?
conditions or alarm conditions. The process of reviewing the control system shall be documented and recorded in the Green relevant departments for root cause analysis and countermeasures Green
process control plan.
in the case of any abnormal conditions By abnormal defect procedure
The organization shall incorporate the use of a documented Failure Mode and Effects Analysis (FMEA) procedure and
Are welding DFMEA's and PFMEA's up to date reflecting
2.4
the current weld processing?
ensure the FMEA's are updated to reflect current part quality status. The PFMEA shall be written in conjunction with the Green Green
DFMEA.
Process FMEA is maintained based on the latest process status FMEA is updated
Are all OEM and referenced welding standards current and The organization shall have all current customer specific welding standards and specifications. The organization shall Welding products are not for our final products for customers but
2.5
available? For example: SAE, ASTM, ASME, AWS, ISO. identify who is responsible for maintaining, distributing, and implementing the standards/specifications. one of the components,
The quality management system shall include a process for documenting, reviewing, and addressing customer weld
Does the Quality Department review, address, and
2.6
document customer and internal concerns?
concerns and any other concerns internal to the organization. A disciplined problem solving approach shall be used for Green Green
internal concerns and concerns identified by the customer.
How does the organization document and respond to Reaction plans are to be followed per the process control plan and PFMEA or, in the case of newly identified issues
2.7
quality spills, nonconformance, customer concerns? PFMEA and control plan shall be updated to reflect the new failure mode and reaction steps taken.
Green Green
The control of suspect welded product is required to prevent shipment of non-conforming product. Procedures shall exist
Are procedures adequate to prevent movement of non-
2.8
conforming product into the production system?
addressing proper disposition, product identification, and tracking of material flow in and out of the hold area. A non- Green Internal standard Q-MAB-C050 clarifies procedure for non- Green
conforming hold area shall be clearly designated to maintain segregation of such material.
conforming products By procedure
Does the Quality Manager or designee authorize the
2.9
disposition of material from a quarantine status?
The Quality Manager or designee authorizes the disposition of the quarantined material with supporting documentation. Green Green
Designated senior line leader By procedure
Have the necessary replacement parts and process The welding organization shall develop and maintain a critical spare parts list and shall ensure the availability of such
2.10
consumables been identified and made readily available? parts to minimize production disruptions. Critical parts may include high frequency occurrence or long lead time items.
Green Green
Critical spare parts for production are listed up Controlled by AS400
All welding employees, including backup and temporary, shall be trained specific to their job function. Documented
evidence shall be maintained showing the employees were trained; the evidence shall include an assessment of the
effectiveness of training, shall prove knowledge of the customer's specific requirements and internal standards.
Does the organization use only qualified welders Employee certification, such as for a manual welder, shall be documented.
2.11
(personnel) and how is welder certification maintained?
Required qualification maintenance. If the employee has a qualification lapse in the specific operation in a 6 month time
frame, the welder shall be requalified to that operation. Based on the welder's quality performance, it shall be established
when retraining and requalification of the individual shall be performed.
The welding is performed by a machine
There shall be procedures and work instructions available for welding personnel covering the welding process. These
Are there procedures and work instructions available? procedures and work instructions shall include methods of addressing potential emergencies such as power failure, start-
2.12
up, shut-down, product segregation (See 2.8), product inspection, safety, house-keeping, and general operating
Green Green
procedures. These procedures or work instructions shall be accessible and used to train shop floor personnel.
Describe processing method for irregular stop such as
instantaneous power failure etc. In F-MXM-00-027 By procedure
The welding organization shall have controlled written process specifications for all active processes and repair
Are there documented weld procedure specifications
2.13
(WPS)?
procedures which identify all steps of the process including operating parameters as defined by the relevant process Green Green
tables. The parameters shall be defined with operating tolerances.
The specifications are described in the condition table for production By production condition table
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Are the tooling components designed for the welding Fixturing/tooling was developed considering movement, reach, accessibility, tool center point, maintenance, and
2.14
process? ergonomics (manual, automatic, and robotics) to maintain weld process angles.
Green Green
Supplier shall have documentation of the fixture design, that are stored properly and accessible. Proper identification and
2.15 Is there a record of the design and set-up of the fixture? revision level on the fixture or related to the fixture. Documented fixture set-up (i.e., clamps, pins, locating devices, and Green Green
shim packs).
Is the weld cell set-up procedure compliant to the work Set-up shall be verified to be in compliance to the documented work instructions. (i.e., equipment parameters, clamping
2.16
instructions? sequence, weld sequence, direction of travel and any other process controls, testing of poke yoke or error prevention).
Green Green
Conduct regular checking, initial revision check sheet By initial revision check sheet
Changeover to different part model shall have a documented procedure and verification of weld quality prior to start of Conduct regular checking, initial revision check sheet also in
2.17 Is changeover procedure established?
production releasable components. Procedure to comply with 2.16.
Green Green
changeover By initial revision check sheet
Prior to PPAP, there shall be a documented procedure for reprocessing and repair that includes authorization from a
Is there a documented procedure in place to authorize
2.18 customer designated individual. The process shall describe product characteristics which are acceptable for reprocessing
reprocessing and repair?
or repair.
No rework nor repair process in welding process
Section 3 - Preplanning / Quality Documentation
The organization shall incorporate the use of a documented Process Control Plan (PCP) procedure and ensure the PCP
are updated to reflect current PFMEA. The PCP shall be written for each part or part family or they may be process-
Are welding process control plans up to date reflecting
3.1
current PFMEA? (severity and detections)?
specific and written for each process. Sample sizes, methods and frequencies for evaluation of process and product Green Green
characteristics shall also be addressed consistent with the minimum requirements listed in the appropriate Welding
Process Job Audit tab.
If there are to be changes in process or materials outside of the current control plan and last agreed upon process and
3.2 Are process deviation requirements known/available? parts sign off, the supplier shall know what the customer requirements are, have notified the customer and have Green Green
customer approval prior to making the change.
Specified in change management standard F-MXM-00-067 By procedure
Is manual part loading specified, documented and
3.3 The manual loading, crowding, and clamping sequence of weld fixtures shall be specified, documented, and controlled.
controlled? The part is loaded automatically
Is product clearly identified at each stage throughout the Non-welded, in-process, and finished product shall be properly segregated and identified. All material shall be staged in a Not necessary identification since our welding process is only one
3.4
welding operations? dedicated and clearly defined area. process
Is lot traceability and integrity maintained throughout all Out-going lot(s) shall be traceable to the incoming lot(s).
3.5
processes? Lots shall be identified and linked to all pertinent information.
Green Green
Part lot is traceable by part control card By procedure
Are parts free from contaminants that would be detrimental Parts shall be free from contaminants that are detrimental to the quality of the welding process. If applicable, pre-wash
3.6
to the quality of the welding process? and post-wash parameters shall be monitored and documented.
Green Green
Part appareance and condition is checked 100% at a prior process 100% appearance
Gas, air, sensors, control cables, etc. are adequately protected for the welding process environment. Examples include
3.7 Are the fixture components robust and protected? shielding, leather wraps, spatter guard(s), air knives, etc. Part contacting materials should be used that support the Green Green
welding process, such as: wear surfaces, material compatibility, magnetic permeability, heat sink, etc.
Has a welding fixture repeatability or capability study been Features that may be studied include: part location, gap analysis, tool location, scribe widths. Sequence should include
3.8
completed? load, clamp, and unload steps with multiple operators. (remove and replace parts each time)
Green Green
Identify the process control equipment necessary to monitor, control and provide feedback on all essential process
3.9 Does the welding operation include the following?
variables as listed below and in the applicable Welding Requirement Tab.
3.9.1 Logic has been established to effectively identify and address process or equipment faults codes with a reaction plan. Green Green
By control plan
3.9.2 Weld faults audible, visible and line shut down with supervisor reset. All overrides or resets shall be identified and logged. Green Green
Controlled by equipment
3.9.3 At weld cycle interrupt, part shall not be removed or passed until dispositioned by appropriate personnel. Green Green
3.9.4 Establish calibration frequencies of meters and system controls. Green Green
Visual inspection of parts, at minimum, has been established during loading or unloading prior to subsequent operations,
3.9.5
if applicable.
Green Green
100 % inspection
3.9.6 Secure backups of all programs and procedures (electronic preferred). Green Green
3.9.7 High/Low limit alarms established by actual data.
Process variables have been defined and developed using data and are operated within documented and validated
3.9.8
process operating windows.
Green Green
3.9.9 Process Data shall link to the traceability records of the part, if applicable. Green Green
All tooling and process adjustments are documented in a change log. Change log should be used for process
3.9.10
improvement.
Welding procedures for each weld ID number, joint type and weld position, and each process variable as defined in the
3.9.11
Welding Requirement Tab.
Green Green
By production condition table
The organization shall perform product repeatability or capability studies for the initial validation of each process, after
Has a valid product repeatability or capability study been
3.10
performed initially and after process changes?
relocation of any process equipment and after a major process change of any equipment or parameter. The organization Green Green
and customer shall define what constitutes a major process change.
Specified in change management standard F-MXM-00-067
3.10.1 Initial product repeatability or capability studies, per agreed upon customer weld specification and source package. Green Green
Specified in change management standard F-MXM-00-067
In the case of new technology or new use of technology, the organization shall establish acceptable ranges for measures
3.10.2
of repeatability or capability.
An action plan shall be agreed upon to address the steps to be followed in case repeatability or capability indices fall
3.10.3
outside customer requirements or established ranges.
Green Green
3.10.4 All welding process combinations in the flow of manufacturing shall have repeatability or capability studies performed.
Boundary sample conditions as defined by the tolerances in the control plan shall be run and meet all customer Describe processing method for irregular stop such as
3.10.5
requirements. Example, any combination of tolerances as defined by process tables.
Green Green
instantaneous power failure etc. In F-MXM-00-027 By procedure
Section 4 - Production Monitoring / Documentation
Are process equipment calibrations and/or verification The calibration and certification of the process equipment shall be checked at regular specified intervals. Refer to the
4.1
certified, documented, available, and current? applicable Welding Requirement Tab.
Green Green
Calibrated and recorded By procedure
Is there error/mistake proofing for part presence and A method to detect proper fixture and part position is required for each part, such as the use of proximity switches, optical
4.2
location in the fixture? How is this controlled? sensors, mechanical probes, part presence or poke yokes, etc.
Green Green
The loading of the part is automatically Controlled by machine
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The welding operation shall have a list of welding process and equipment fault/alarms. These alarms shall be individually
Are the process and equipment fault/alarm checks for error
4.3
prevention devices being tested?
tested at the required frequency as listed on the control plan, and after any maintenance or change. These checks shall Green Green
be documented.
By control plan
Has fixturing/tooling preventative maintenance program Supplier shall have a preventive maintenance program that is documented and implemented within defined frequencies.
4.4
been established? PM activities shall be documented as to work completed.
Green Green
Period revision check sheet
Changes shall be documented (i.e., log of shim moves, clamp changes) and maintained in a log. Changes shall be
Are parameters changes, tooling maintenance and tooling
4.5
changes documented in a log?
logged (change date, root cause for reason change, management sign-off). Frequent fixture/shim changes require a Green Green
management review to determine root cause and define solution.
By procedure
A critical tooling/fixturing components list shall exist and suitable spare/replacement components shall be available within
4.6 Are critical wear components in stock and readily available?
24 hours.
Green Green
Controlled by AS400
Are process control parameters monitored at established Process control parameters shall be monitored per frequencies established in the control plan. An appropriate person
4.7
frequencies? shall verify the process control parameters. Management review is required.
Green Green
Production control table
Does the organization review and react to out of Are there documented reaction plans with appropriate levels of containment for both out of control and out of tolerance
4.8
control/specification parameters? process parameters? Is there documented evidence that reaction plans are followed?
Green Green
conducting regular checking By control plan
Are In-Process and Final Tests performed at established In-Process and Final Tests shall be performed per frequencies in the control plan as agreed upon between the supplier
4.9
frequencies? and the customer.
Green Green
Are weld quality requirements clearly defined per customer Weld quality requirements per internal and/or customer specifications, such as but not limited to the following testing not applicable there are not requirements from customer for welding
4.10
specifications? methodology (enter Yes in Critical to Quality column if applicable): parts
4.10.1 Cut and etch

not applicable
4.10.2 Part location, warping, gap, and dimensional requirements

not applicable
4.10.3 Correct number of welds

not applicable
4.10.4 Weld length/size

not applicable
4.10.5 Weld location

not applicable
4.10.6 Non Destructive Testing (NDT)

not applicable
4.10.7 Visual weld quality inspection

not applicable
4.10.8 Weld direction confirmation

not applicable
4.10.9 Destructive testing

not applicable
4.10.10 Additional testing

not applicable
Does the welding organization collect and analyze data The organization shall have a system to collect, analyze, and react to shifts in ongoing or historic trends in weld quality
4.11
over time, and react to shifts in this data? data This data should also support continuous improvement activities or problem resolution.
There shall be a defined process for continuous improvement identified. The continuous improvement process shall be
Is there a continuous improvement plan based on
designed to bring about improvements in quality and productivity. Identified actions shall be prioritized and shall include
4.12 quantitative data applicable to each process defined in the
timing (estimated completion dates). The organization shall show evidence of program effectiveness/sustainability and
scope of the assessment?
product conformance.
5. Rework or Scrap Procedures and Reports
Is the organization following the approved weld rework

5.1 Documented and approved weld rework procedures.
procedure? not applicable
Rework and scrap parts, whether in-line or off-line repair, shall be identified and traceable. Rework and scrap shall be
5.2 Is the organization controlling traceability and lot control?
tracked by fixture, weld number, and defect type. not applicable
5.3 Are visual aids for discontinuity available? Visual aids for each welding discontinuity are displayed within approved weld rework procedures.
not applicable
5.4 Are people responsible for weld rework qualified? Rework personnel shall undergo documented formal training and qualification.
not applicable
5.5 Does data drive continuous improvement? Weld issues show objective evidence of action plan to resolve top issues.
CQI-15
Gas Metal Arc Welding Job Audit

Assessor MABUCHI MOTOR MEXICO,S.A.DE C.V Welding Plant C.P.20304
Date 12-Jan-23
1/24/2022 1/12/2023
Critical to Initial Rating Current Status
Item No. Area Requirements Quality (R/Y/G) Evidence / Gap Identified (R/Y/G) Follow up Comments
1. PART PRINT
The latest revision of the welding specifications at the time of release shall be called out on the part print. Black
1. Welding Specifications box components shall follow industry or internal welding specifications. <== START HERE
2. Weld Identification Welds shall be numbered uniquely for consistent tracking.
3. Weld Symbol Callout The weld symbol shall contain the Joint type, weld ID number, welding classification, process, total weld length.
4. Weld Classification Each weld number shall be assigned a classification per severity level in the DFMEA.
5. Spatter Free Zones Spatter free zones shall be identified.
6. Weld Size Requirements Weld size shall be based off Governing Material Thickness (GMT)/Thinnest material (T1).
2. CONTROL PLAN
1. Inline Visual Inspection Welds shall be inspected for presence and appearance per visual acceptance criteria.
2. Weld Quality Inspection Presence, Appearance, Size, and Total Length per the welding specification and classification.
3. Cut and Etch Performed per the weld specification and weld classification.
4. Destructive Testing Performed based off of the weld classification.
Welding Special Characteristic Identification: Welds shall be identified by weld number in the control plan per the
5. Weld Identification in Control Plan Design Records/DFMEA/PFMEA.
6. Weld Lot Containment All weld validation testing shall be performed prior to shipping (Batch & Hold).
Control of Changes and Unplanned

7. Events An event matrix shall be followed for events not listed in the control plan OR if changes are made,
All welds follow prelaunch control plan based off of the welding safe launch plan, utilized from prelaunch to start
8. Prelaunch Control Plans of production.
9. Production Part Traceability Traceability to welding build date and weld fixture.
Identification and Control of

10. Nonconforming Parts Physical separation and containment of Good and Reject Parts.
11. Setup Part Identification Setup parts shall be marked for easy identification to prevent further processing or shipping.
3. DESTRUCTIVE & NONDESTRUCTIVE

TESTING DATA
1. Destructive Testing Data Destructive testing data retention shall have a defined time period as per customer/regulatory requirements.
2. Variable Data Variable data shall be available and retained for a defined time period.
3. Attribute Data Attribute data shall be available and retained for a defined time period (pass/fail or go/no go).
4. WELD QUALITY INSPECTION & REPORTS
Personnel involved in weld inspection shall be qualified by the supplier as receiving adequate formal training on
1. Lab Technician Training the recognition of weld defects, and measurement techniques.
Personnel designated as weld inspectors shall have their vision reviewed annually by the supplier for compliance
2. Vision Acuity with recognized corrected levels of vision.
Weld examination equipment shall provide adequate magnification to capture the entire cross section, showing
3. Weld Cross Section Examination the measurements of the features defined in the welding specification in one picture.
4. Weld Attribute Measurements Per the welding specification, including (Leg size, root penetration, depth of fusion, throat, undercut, gaps).
Cross section measurement technique shall be reviewed by weld area manager and approved and signed off by
5. Cross Section Analysis Technique product engineering and supplier quality.
Cut and Etch Measuring System Variable gauge R&R on cut and etch measurements on a gas metal arc weld to calibrate lab personnel.
6. Effectiveness Destructive test measurement equipment shall be calibrated.
Weld Cross Section Evaluation Software formulas shall be utilized to calculate/generate pass/fail such as using conditional formatting as in a
7. (Pass/Fail Determination) spreadsheet.
Warning limits shall be utilized for controlling the weld attributes. Warning limits to establish an alert prior to
8. Warning Limits failure to meet specifications.
9. Weld Quality Traceability Welds shall be tracked per stream/fixture/weld#.

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10. Visual Aids Visual aids shall be available for cross section attributes, defects, and common failures modes.
5. REWORK PROCEDURE & REPORTS
1. Repair Procedure (WPS) Rework or repair welding shall have a customer approved procedure.
Welding Procedure Specification (WPS), Procedure Qualification Record (PQR), and Welder Qualification
2. Repair Qualification Records Record (WQR) shall be utilized.
3. Inspection and Repair Visual Aids Visual aids for welding defects and display acceptable repairs shall be posted per PFMEA.
4. Repair Welder Training Repair welders shall undergo formal training and qualification.
5. First Time Through Data Collection Internal First Time Through shall be tracked by each operation. Including in line and off line repair.
6. Scrap Reports Scrap shall be tracked by fixture, weld number, and defect code.
7. Scrap Codes Scrap shall be tracked by codes for the failure modes listed in the PFMEA.
8. Rework Data Rework shall be tracked by fixture, weld number, and defect code.
9. Rework Part Traceability Rework parts shall be identified and traceable.
6. PARAMETER DOCUMENTATION
1. Process Parameter Documentation A controlled document (WPS) shall contain all welding key process input variables and submitted at PPAP.
Welding parameter changes shall be password protected or gatekeeper controlled (quality manager, welding
2. Welding Parameters Controls engineer).
Key Process Input Variables

3. Items below are examples Example - Record as Applicable
Amperage Mark Green if Monitored
Voltage
Current Type / Polarity
Wire feed speed
Pulse info/reference number
Contact tip to work distance
Electrode/wire type, classification, and

diameter
Travel Speed
Gas Composition and flow rate
Gas nozzle size and type
Arc start parameters
Arc end parameters
Wire burn back settings
Travel and work angle
Robot target location
All parameter changes within specification shall be documented, changes outside of limits shall follow customer
4. Parameter Changes managing change process.
5. Setup Items/Tools Setup tools shall be linked to tool ID number and start-up procedures.
7. MAINTENANCE RECORDS
Maintenance reports shall be detailed to include technician identification, date, time, corrective action, and
1. Unplanned Downtime Log revalidation per the event matrix.
Scheduled Preventative Maintenance Established a preventative maintenance weld equipment schedule that shall include the equipment
2. (PM) manufactures PM recommendations.
2.a Torch Inner Liner Torch inner liners shall changed before failure using defined pull test limit.
2.b Contact Tip Changes Contact tips shall be changed before failure based off of time/arc hours.
Preventative maintenance of torch reamer shall include inspection of the cutter blade and jaws for wear and
2.c Torch Reamer debris, and inspection of the robot programing to ensure torch is aligned with the reamer.
3 Validation of Tooling Details All details checked for looseness, all non-pinned details torque checked and match marked.
Part touching details, locating pins,

fixture locators and tooling mating
4. surfaces All mating surfaces shall be free of spatter and debris.
8. SUSTAINABILITY
Shall have demonstrated at last PPAP, or can prove through customer requirements for consecutive build shifts
1. Weld Sustainability of meeting the welding spec without adjustments. Note: See Health Chart Example.
CQI-15
1/24/2022 1/12/2023
2. Weld Effectiveness Weld percent effectiveness shall be used as a key metric (good welds/total welds).
9. EQUIPMENT & ROBOTIC PROCESSING

REQUIREMENTS
Weld Identification in Robot Teach

1. Pendant Part print ID, weld sequence, and weld length should be called out in the robot teach pendant.
2. Weld Process Mapping Repair weld ID numbers should be linked to robot programming and part print weld ID numbers.
Robotic Pick and Place into Rack (Auto-

3. Racking) Parts should be visually inspected and repaired prior to racking of parts.
(Weld edges) Mating surface to print by die buy off and controlled in control plan. Profile and Trim edge are
repeatable to allow for robust welding process. High severity trim edges shall be maintained and monitored for
4. Dimensional Control dimensional repeatability or capability.
5. Equipment Debug Establish minimum material runoff quantities for tool try out at integrator.
CQI-15
Laser Welding Job Audit

Date 12-Jan-23
1/24/2022 1/12/2023
Item No. Area Requirements Critical to Quality (R/Y/G) Evidence / Gap Identified (R/Y/G) Follow up Comments
1. PART PRINT
3. Weld Symbol Callout The weld symbol shall contain the Joint type, weld ID number, welding classification, process, weld length.
5. Spatter Free Zones Spatter free zones shall be identified.
6. Weld Size Requirements Weld size shall be based off Governing Material Thickness (GMT) / Thinnest material (T1).
2. CONTROL PLAN
2. Weld Quality Inspection Presence, Appearance, Size, and Total Length per the welding specification and classification.
3. Destructive Testing Performed based off of the weld specification.
5. Hardness Testing Transverse micro-hardness from parent material through weld checks shall be performed.
6. Cup Test Perform deformation test (for taylor welded blanks)

9. Events An event matrix shall be followed for events not listed in the control plan OR if changes are made.

13 Setup Part Identification Setup parts shall be marked for easy identification to prevent further processing or shipping.

TESTING DATA
4. WELD QUALITY INSPECTION &

REPORTS
the measurements of the features defined in the welding specification in one picture. Per the welding
3. Weld Cross Section Examination specification, including (Leg size, root penetration, depth of fusion, throat, undercut, gaps).
Cross section measurement technique shall be reviewed by qualified technicians and approved and signed off
4. Cross Section Analysis Technique by product engineering and supplier quality.
Cut and Etch Measuring System Variable gauge R&R on cut and etch measurements on a laser beam weld to calibrate lab personnel.
5. Effectiveness Destructive test measurement equipment shall be calibrated.
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1/24/2022 1/12/2023
8. Weld Quality Traceability Welds shall be tracked per stream/ fixture/ weld #.
Shall have an in-process system that will prevent parts produced during machine interruption (weld setup,
9. Part Containment maintenance intervention, power outage, etc.) from further processing or shipping.

Beam quality Mark Green if Monitored
Cross Jet / Laser knife
Beam configuration
Focal length
Beam spot size
Gas tube angle
Optics purge gas
Mirror / optic cleanliness
Chiller flow rate
Chiller temperature
Fiber diameter
Fiber length
Bend radius
Power loss
Mirror coating
Optic and mirror cooling
Travel speed
Cleaning (Laser Ablative or

mechanical)
Power output control
Power ramping
Power at work piece
Offset of beam to joint
Continuous or Pulse
Pulse parameters
Angle of incidence
Focal point
Weld direction
Beam quality
Plasma suppression
Preheat
Post weld heat treat
Electrode/wire type, classification,
and diameter
Wire Feed Speed

CQI-15
1/24/2022 1/12/2023
Leading/Trailing edge wire
placement
4 Weld Failure Investigation Checklists A welding failure investigation checklist (trouble shooting procedure) shall be used prior to adjusting parameters.
6. Setup Tools Setup tools shall be linked to tool ID number and start-up procedures.
2.a Cover Lenses Cover lenses shall be changed on established frequency.
2.b Beam Power Actual beam power at the work piece shall be checked.
2.c Beam Quality Actual beam quality shall be checked per OEM recommendations.
2.d Run Out Check of Fixture Rotators All fixtures verification to equipment OEM recommendations.
2.e Air Knife Air knife shall provide adequate flow to cover lenses and verified.
3. Validation of Tooling Details All details checked for looseness, all non-pinned details torque checked and match marked.

4. surfaces All mating surfaces shall be free of spatter and debris.
8. SUSTAINABILITY

REQUIREMENTS
LASER WELD MONITORING
Initial Validation shall be performed with a cause and effect study for the common welding failure modes,
1. Validation of Process Control Limits ongoing validation to be done with red rabbit testing.
Only performed when all equipment PM is completed. New limits validated though cut and etch as well as red
2. Re-referencing / Adjusting Limits rabbit testing.
CQI-15
Drawn Arc Welding Job Audit

Date 12-Jan-23
1/24/2022 1/12/2023
1. PART PRINT
3. Weld Symbol Callout The weld symbol shall contain the material stack up, weld ID number, welding classification.
5. Weld Grouping All weld groups shall be defined in the spot pattern layout.
2. CONTROL PLAN
Presence, appearance, location, burn through, expulsion, cracks, porosity per the welding specification and
2. Weld Quality Inspection classification.
3. Destructive Testing Performed based off of the Customer Requirements.
4. Weld Identification in Control Plan Design Records / DFMEA / PFMEA.

6. Events An event matrix should be followed for events not listed in the control plan or if changes are made.

9. Nonconforming Parts Physically separate and contain non-conforming parts from compliant parts.

TESTING DATA

REPORTS
1. Lab Technician Training the recognition of weld defects, their cause, and effect on the product.
Weld examination equipment shall allow for adequate inspection of the features defined in the welding
3. Weld Examination specification.
4. Weld Attribute Measurements Per the welding specification, including average load testing or cross sectional data
Variable gauge R&R on cut and etch measurements on a drawn arc weld to calibrate lab personnel.
5. Measuring System Effectiveness Destructive test measurement equipment shall be calibrated.
6. Control Limits Control limits shall be utilized for controlling minimum load requirements.
7. Weld Quality Traceability Welds shall be tracked per stream/ fixture/ weld #.
8. Visual Aids Visual aids shall be available for, location, defects, and common failures modes.
CQI-15
1/24/2022 1/12/2023
1. Process Parameter Documentation A controlled document shall contain all welding key process input variables and submitted at PPAP.

Mode (Force/Positional) Mark Green if Monitored
Drop time / Setdown time
Weld mode (Force or Positional)
Base metal material / Coating type
Fastener material type / Coating type

Stud seating position in collet
Pilot weld current
Pilot weld time
Main weld current
Main weld time
Lift height
Penetration reference
Stud tolerance
Stud length value
Protective gas
Protective gas flow time during weld
Protective gas flow time post weld

Cooling air blow time
Cleaning air blow time
Other (Specify)
2.a Maintenance Counters Maintenance counters shall be used with warning limits and faults when limits exceeded for consumable parts
Grounding Blocks and Cable checks shall be performed to insure Leads are in good condition. Fixture shall be
2.b Grounding Checks isolated from earth ground.
2.c Validation of Tooling Details All details checked for looseness, and wear at the part rest.

fixture locators and tooling mating All details checked for looseness, all non-pinned details torque checked and match marked. All mating surfaces
3. surfaces shall be free of expulsion and debris.
The Collet, Feed Tubes, Slides and Cylinder change frequency shall be set in the maintenance PM or Fault
counters based on manufactures recommendations. Change out Shall be poke yoked to ensure all Scheduled /
4. Weld Head Management Faulted Items are changed.
Part location relative to stud distance shall be maintained precisely during welding. Can be controlled with
5. Part location stability during process backing blocks, clamps or stand off finger on gun.
8. SUSTAINABILITY
CQI-15
1/24/2022 1/12/2023
Validation of Welding Equipment and

3. Parameters Tip dressers and/or current steppers/ gradual boost frequencies shall be verified/confirmed prior to launch.

REQUIREMENTS
1. Equipment Debug Establish minimum material runoff quantities for tool tryout at integrator.
CQI-15
Resistance Welding Job Audit

Date 12-Jan-23
1/24/2022 1/12/2023
1. PART PRINT
1. Welding Specifications box components shall follow industry or internal welding specifications.
5. Weld Grouping All weld groups shall be defined in the spot pattern layout.
2. CONTROL PLAN
Presence, appearance, location, size, indentation, expulsion, cracks, porosity per the welding specification and
2. Weld Quality Inspection classification.
4. Pry Bar Testing Performed based off of the welding specification and classification, if allowable.
5. Ultrasonic Testing Ultrasonic testing may be performed after a correlation has been established and approved by customer.



TESTING DATA
1. Destructive Testing Data Destructive testing data retention shall have a defined time period as per customer / regulatory requirements.

REPORTS
3. Weld Examination specification.
4. Weld Attribute Measurements Per the welding specification, including average weld size diameter, indentation.
Variable gauge R&R on cut and etch measurements to calibrate lab personnel. Destructive test measurement
5. Measuring System Effectiveness equipment shall be calibrated.
8. Weld Quality Traceability Welds shall be tracked per stream / fixture / weld #.
9. Visual Aids Visual aids shall be available for measurement technique, location, defects, and common failures modes.

CQI-15
1/24/2022 1/12/2023

Actual tip force Mark Green if Monitored
Actual secondary amperage
Voltage
Power
Frequency
Pulse
Squeeze time
Weld time (spot welding)
Weld speed (seam welding)
Hold time
Quench time
Temper time
Upslope
Downslope
Electrode type
Electrode shape
Electrode face diameter
Stepper rate
Electrode dressing frequency
Electrode change frequency
Water flow
Water temperature
2.a Electrode Force Actual tip force shall measured and recorded in PM.
2.b Secondary Amperage Actual secondary amperage shall be measured with an amp meter and documented in weld parameter sheet.
2.c Shunt Checks Shunt checks shall be performed to insure shunts are in good condition.
2.d Validation of Tooling Details All details checked for looseness, all non-pinned details torque checked.

3. surfaces All details checked for looseness, all non-pinned details torque checked and match marked.
The electrode change frequency, electrode handling, refinishing geometry, and setup height shall be controlled.
4. Electrode Management Electrode changes shall be poke yoked to ensure all electrodes are changed.
CQI-15
1/24/2022 1/12/2023

5. surfaces All mating surfaces shall be free of expulsion and debris.
8. SUSTAINABILITY
Validation of Welding Equipment and

3. Parameters Tip dressers and/or current steppers/ gradual boost frequencies shall be verified/confirmed prior to launch.

REQUIREMENTS
CQI-15
Friction Welding Job Audit

Does not include Friction Stir Welding

Date 12-Jan-23
1/24/2022 1/12/2023
Initial Rating Current
Item No. Area Requirements Critical to Quality (R/Y/G) Evidence / Gap Identified Status (R/Y/G) Follow up Comments
1. PART PRINT
2. CONTROL PLAN
2. Weld Quality Inspection Gauging to ensure proper curl.
4. Microstructure Evaluation Microstructure evaluation documented.
5. Flow Lines Documented image depicting weld flow lines.
6. Weld Curl Weld curl shall not make contact with any tooling and fixturing during welding.
8. Twist or Deflection Testing Recommend twist, deflection or proof load testing shall be performed in line.
9. Ultrasonic / Magnetic Particle Testing Ultrasonic or magnetic particle testing shall be performed at an agreed upon frequency.
10. Hardness Testing Micro transverse hardness from parent material through weld checks shall be performed.
13. Control of Changes and Unplanned Events An event matrix shall be followed for events not listed in the control plan OR if changes are made.
Identification and Control of Nonconforming

16. Parts Physical separation and containment of Good and Reject Parts.
3. DESTRUCTIVE & NONDESTRUCTIVE TESTING

DATA
4. Weld Attribute Measurements Per the welding specification, including (weld curl).
Cut and Etch Measuring System

6. Effectiveness Variable gauge R&R on cut and etch measurements on a friction weld to calibrate lab personnel.
CQI-15
1/24/2022 1/12/2023
Weld Cross Section Evaluation (Pass/Fail Software formulas shall be utilized to calculate/generate pass/fail such as using conditional formatting as in a
7. Determination) spreadsheet.

Spindle speed Mark Green if Monitored
Spindle clamp pressure
Fixture clamp pressure
Part stickout
Preheat force
Preheat time/RPM
Preheat shortening
Weld force
Friction speed
Forging speed
Forging force
Forging time
Forging length
Forge delay
Upset distance
Shortening
Upset hold time
Upset rate
Brake setting
Brake force
Brake delay
Total shortening
Established a preventative maintenance weld equipment schedule that shall include the equipment
2. Scheduled Preventative Maintenance (PM) manufactures PM recommendations.
2.a Stopper/Chuck Condition Visually inspect for wear or damage. Replacement frequency specified in PM.
2.b Limit Verification Red rabbits shall be run to verify stroke limits pre and post weld.
Part touching details, clamps, locating pins,

4. fixture locators and tooling mating surfaces All mating surfaces shall be free of contaminants and debris.
7. SUSTAINABILITY

REQUIREMENTS
1.
CQI-15
Induction/High Frequency Tube Welding Job Audit

Date 12-Jan-23
1/24/2022 1/12/2023
1. PART PRINT
The latest revision of the welding specification, if available, at the time of release should be called out on the part
1. Welding Specifications print. Black box components should follow industry or internal welding specifications. <==START HERE
2. CONTROL PLAN
1. Weld Quality Inspection Gauging to ensure proper scarf height plus or minus tolerance.
3. Pre-launch Microstructure Evaluation Pre-launch Microstructure evaluation documented.
4. Grain Flow Lines Documented image depicting weld flow lines not to be parallel shall show grain flow at interface.
6. Eddy Current / Ultrasonic Testing Eddy Current or Ultrasonic testing shall be performed and used to trigger the paint marking system.

11. Production Part Traceability Traceability to welding build date and mill line.

TESTING DATA
Per the welding specification, for example including presence of ferrite band for 100% of thickness and flow line
4. Weld Attribute Measurements angles for ID & OD of tube.
Cross Section Analysis Standardized Cross section measurement technique shall be reviewed by weld area manager and approved and signed off by
5. Technique product engineering and supplier quality.

6. Effectiveness Variable gauge R&R on cut and etch measurements on an induction weld to calibrate lab personnel.
9. Weld Quality Traceability Welds shall be tracked per mill number, time, material heat and lot control.
CQI-15
1/24/2022 1/12/2023

Power (Secondary) Mark Green if Monitored
Frequency
Weld travel speed / mill speed
System cooling coil / transformers,

impeder, etc.
Coil change frequency
Tip/electrode/wheel/coil alignment
Electrode selection/type (material type

etc.)
Strip width sufficient to accommodate

upset
Induction coil geometry
Impeder / concentrator
Scarf tooling height
Weld force / Roll pressure
Scheduled Preventative Maintenance

2. (PM) Established weld equipment PM per manufacturers recommendations to include feeder, roll, weld coil, etc.
7. SUSTAINABILITY
Shall have demonstrated at last PPAP, or can prove through consecutive build shifts of meeting the welding
1. Weld Sustainability spec within the allowable adjustments. Note: See Health Chart Example.

REQUIREMENTS
1.
CQI-15
Fastener Projection Welding Job Audit

Date 12-Jan-23
1/24/2022 1/12/2023
1. PART PRINT
2. CONTROL PLAN
Fasteners shall be inspected inline for presence and appearance per acceptance criteria as defined by PFMEA
1. Inline Visual Inspection and Control Plan.
Presence, appearance, location, size, gap, expulsion, cracks, porosity per the welding specification and
2. Weld Quality Inspection classification as defined by PFMEA and Control Plan.
3. Destructive Testing Performed based off of the weld specification and weld classification.
Welding Special Characteristic Identification: Each weld fastener shall be identified by weld number in the control
4. Weld Identification in Control Plan plan per the Design Records/DFMEA/PFMEA.

All welds follow safe launch plan prelaunch control plan based off of the welding safe launch plan, utilized from
pre-launch to start of production. 100% Satisfactory button diameters at each projection is required for Pre
7. Prelaunch Control Plans builds.


TESTING DATA

REPORTS
1 Lab Technician Training the recognition of weld defects, their cause, and effect on the product.
2 Inspector Vision Acuity with recognized corrected levels of vision (minimum of 20/30 near and distance with corrective lenses).
3 Weld Examination specification.
4 Weld Attribute Measurements Per the welding specification including projection set-down and fused area of each projection.
5 Measuring System Effectiveness Destructive test measurement equipment shall be calibrated.
Push Off Force or Torque Evaluation

6 (Pass/Fail Determination) Software formulas shall be utilized to calculate/generate pass/fail.
Boundary limits shall be utilized for controlling push off force and/or torque to failure. A warning system is in
7 Boundary Limits place as the value approaches minimum requirement.
8 Weld Quality Traceability Fasteners shall be tracked per stream/fixture/weld #.
9 Visual Aids Visual aids shall be available for measurement technique, location, defects, and common failures modes.
The surface of the adjacent steel in the immediate weld area shall be sufficiently flat to permit uniform contact of
all projections of the weld nut with that surface. Any feature of a weld nut shall not interfere with any mating
10 Part Fit-up component, trimline or pilot hole.
The thread major diameter of the weld nut shall not be in interference with the clearance hole of the adjacent
11 Alignment part (winking). Weld nuts and studs shall be positioned accurately within the dimensional limits of the print.
CQI-15
1/24/2022 1/12/2023
The welded fastener shall not deform the weld thread causing excessive variations in the assembly driving
12 Thread Distortion torque values. A thread gage can be used to determine compliance.
Flash in the threads shall not affect the assembly driving torque values. A thread gage can be used to determine
13 Flash in Threads compliance.
Seated to within the specified percentage of the original height of the unwelded projection. A feeler gap gage
14 Set-down can be used to determine compliance.
1. Process Parameter Documentation A controlled document shall contain all welding key process input variables and submitted at PPAP.

Actual tip force Mark Green if Monitored
Actual secondary amperage
Voltage
1 or 3 Phase Power
Incoming power frequency
Pulse
Squeeze time
Squeeze force
Weld force (Intensified)
Weld time
Hold time
Quench time
Temper time
Upslope
Downslope
Electrode classification
Stepper
Electrode face diameter > the

diameter of the collective
projections
Electrode dressing frequency
Electrode change frequency
Projection shapes and dimensions

to be coplanar within tolerance
Water flow
Water temperature
Dressing limits (maximum)
CQI-15
1/24/2022 1/12/2023
2.a Electrode Force Actual tip force shall measured and recorded in PM.
2.b Secondary Amperage Actual secondary amperage shall be measured with an amp meter and documented in weld parameter sheet.
2.c Shunt Checks Shunt checks shall be performed to insure shunts are in good condition.
The equipment shall ensure that the electrode maintains force throughout projection collapse, such as
2.d Fast Follow Up diaphragm, spring or servo.
All details checked for looseness, all non-pinned details torque checked and match marked. All mating surfaces
3. Validation of Tooling Details shall be free of spatter and debris.
The electrode change frequency, surface reconditioning, retractable pin wear/performance and setup parallelism
shall be controlled. Electrode maintenance shall be poke yoked to ensure all electrodes PM has been
4. Electrode Management completed.
8. SUSTAINABILITY

REQUIREMENTS
CQI-15
Magnetically Impelled Arc Butt (MIAB) Welding Job Audit

Date 12-Jan-23
1/24/2022 1/12/2023
1. PART PRINT
2. CONTROL PLAN
2. Runout Gauging Gauging to ensure joint alignment
4. Microstructure Evaluation Microstructure evaluation documented.
5. Weld Fusion Documented image depicting weld bond line and flash
6. Weld Flash Weld flash shall not make contact with any tooling and fixturing during welding.
7. Destructive Testing Performed based off of the weld specification and weld classification.
8. Ultrasonic Testing Ultrasonic testing shall be performed on every welded joint.

14. Production Part Traceability Traceability to welding build date, weld unit, and weld fixture.


TESTING DATA

REPORTS
Personnel involved in weld inspection shall receive adequate formal training on the recognition of weld defects,
1. Lab Technician Training and measurement techniques.

5. Effectiveness Gauge R&R on measuring technique performed and recorded.
Warning limits should be utilized for controlling the weld attributes. Warning limits to establish an alert prior to
CQI-15

Fixture clamp pressure Mark Green if Monitored
Gap distance/retract length
Weld current
Coil current
Weld time
Forging speed
Forging pressure
Forging time
Forging length
Forge hold delay
Upset distance
Upset hold time
Total shortening
2.a Stopper/Chuck Condition Visually inspect for wear or damage. Replacement and maintenance frequency specified in PM.
Part touching details, clamps,

locating pins, fixture locators and
4. tooling mating surfaces. All mating surfaces shall be free of contaminants and debris.
7. SUSTAINABILITY

REQUIREMENTS
1.
CQI-15
WELDING HEALTH CHART
Part #: GD558RH/LH (Y095-1) Cell # A07 P P=Pass N = No Sample NF = Fixture not used
Part name: PW motor Fixture F F=Fail F/P = Fail, Passed on retest
Fixture ID WELD # 12/1/23 12/1/23 12/1/23
1 p p p
2 p p p
3 p p p
4 p p p
5 p p p
6 p p p
7 p p p
8 p p p
Comments
Good Welds 8 8 8 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Failed Welds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Total Welds 8 8 8 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
% Effectiveness 100.00% 100.00% 100.00%
CQI-15
WELDING HEALTH CHART
Part #: Cell # 10 P P=Pass N = No Sample NF = Fixture not used

Part name: Fixture A1,B1 F F=Fail F/P = Fail, Passed on retest
Fixture ID WELD # 10/27/19 10/28/19 10/29/19 10/30/19 11/1/19 11/2/19 11/3/19 11/4/19 11/5/19 11/6/19 11/7/19 11/8/19
Fixture A1 1 P P F P
2 P P P P
3 P F F F
4 P P F P
5 P P P P
6 P F/P P NF
7 P P P P
8 P P P P
Comments
F/P
counted
as Pass
Part
Good Welds 8 7 5 6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Failed Welds 0 1 3 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Total Welds 8 8 8 7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
% Effectiveness 100.00% 87.50% 62.50% 85.71%
CQI-15
OPEN ITEMS LIST
Planned Current Status Actual

Tab Item
Unsatisfactory Finding Corrective Action(s) Responsibility Implementation (In process or Completion
Number
Date Complete) Date
1
2
3
4
5
6
7
8
9
10

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CQI-15

Special Process: Welding System Assessment

AIAG CQI-15 Special Process: Welding System Assessment

Company Name: MABUCHI MOTOR MEXICO,S.A.DE C.V Current

Site Responsible Person Title Email Address Phone

Supplier Contacts Title Email Address Phone

% of Items Completed #VALUE! Section 1-5 Total 100.00% 0 0 48

GMAW Overall 1. PART PRINT Not Completed 0 0 0 #VALUE!

Job Audit Total Not Completed 0 0 0

Overall Total 100.00% 0 0 48

Weld System Assessment

San Francisco de Los Romo,Ags.,Mexico

Are internal assessments being completed on an annual

Is there a responsibility matrix to ensure that all key welding

Section 3 - Preplanning / Quality Documentation

3.9.7 High/Low limit alarms established by actual data.

Section 4 - Production Monitoring / Documentation

4.10.1 Cut and etch

4.10.2 Part location, warping, gap, and dimensional requirements

4.10.3 Correct number of welds

4.10.4 Weld length/size

4.10.5 Weld location

4.10.6 Non Destructive Testing (NDT)

4.10.7 Visual weld quality inspection

4.10.8 Weld direction confirmation

4.10.9 Destructive testing

4.10.10 Additional testing

5. Rework or Scrap Procedures and Reports

Is the organization following the approved weld rework

Gas Metal Arc Welding Job Audit

San Francisco de Los Romo,Ags.,Mexico

2. Weld Identification Welds shall be numbered uniquely for consistent tracking.

5. Spatter Free Zones Spatter free zones shall be identified.

4. Destructive Testing Performed based off of the weld classification.

Control of Changes and Unplanned

Identification and Control of

3. DESTRUCTIVE & NONDESTRUCTIVE

4. WELD QUALITY INSPECTION & REPORTS

9. Weld Quality Traceability Welds shall be tracked per stream/fixture/weld#.

5. REWORK PROCEDURE & REPORTS

9. Rework Part Traceability Rework parts shall be identified and traceable.

Key Process Input Variables

Electrode/wire type, classification, and

Part touching details, locating pins,

9. EQUIPMENT & ROBOTIC PROCESSING

Weld Identification in Robot Teach

Robotic Pick and Place into Rack (Auto-

Laser Welding Job Audit

San Francisco de Los Romo,Ags.,Mexico

2. Weld Identification Welds shall be numbered uniquely for consistent tracking.

5. Spatter Free Zones Spatter free zones shall be identified.

3. Destructive Testing Performed based off of the weld specification.

6. Cup Test Perform deformation test (for taylor welded blanks)

Control of Changes and Unplanned

Identification and Control of

3. DESTRUCTIVE & NONDESTRUCTIVE

4. WELD QUALITY INSPECTION &

5. REWORK PROCEDURE & REPORTS