A special process is a process whose output cannot be fully verified by measurement immediately after completion. Heat treatment, plating, welding, casting and soldering fall into this category.
In these processes, quality assurance cannot rely on product inspection; you must demonstrate that the process itself is under control. AIAG‘s CQI assessments audit exactly that.
Two different needs
If you run the process yourself: you are expected to perform an annual self-assessment and retain the records. We run the assessment together with you and support you in closing the findings.
If you buy the process: the responsibility for verifying your supplier’s conformity rests with you. We conduct the audit on your behalf.
The second case is frequently overlooked: if you outsource plating, that responsibility is yours even though you do no plating yourself.
Scope
Special process assessments: CQI-9 heat treatment, CQI-11 electroplating, CQI-12 coating and painting, CQI-15 welding, CQI-17 soldering and electronic assembly, CQI-23 moulding, CQI-27 casting, CQI-29 brazing, CQI-30 rubber processing, CQI-35 wire harness.
Service steps
- Scope definition: which process, which guideline, which lines
- Preliminary review and evaluation of the existing record structure
- Execution of the assessment
- Classification and reporting of findings
- Preparation of the action plan
- Corrective action follow-up and closure verification
Deliverables
- Assessment report
- Finding list and action plan
- Self-assessment record in a format ready to present to your customer
- Closure verification report
When is this service needed?
You have no competent staff to run the self-assessment. You must be able to demonstrate the assessor’s competence; a form filled in by an employee with no training record gets questioned in the audit.
Assessments are done but never produce findings. A self-assessment where every question got a favourable answer rarely survives an external look. A finding-free assessment is a sign that the assessment was not done seriously.
You cannot evaluate the file your supplier sends. Filing away a forty-page assessment package is not verification. It takes competence to read it and extract meaningful findings.
A customer audit is approaching. Special process records are among the most frequently requested documents in customer audits; an independent look in advance reduces the risk of surprises.
You have commissioned a new process. After a new line, a new furnace or a new bath, the assessment needs to be updated.
You run several processes. Each process requires its own assessment; one does not substitute for another. A facility running both plating and heat treatment must complete two separate self-assessments. Running them in combination saves both time and resources.
Who are special process audits for?
- Facilities performing heat treatment, plating, welding, casting or soldering
- Automotive suppliers outsourcing these processes
- Organizations with an annual self-assessment obligation
- Companies that have not yet built assessor competence
- Multi-line facilities running several special processes
- Organizations preparing for customer audits or IATF 16949 audits
How We Work
On site and remote: steps that require field work take place at your facility, while document and analysis work is carried out remotely.
Together with your team: the work is done with you, not on your behalf. The goal is not to finish a project but to leave you with a system you can sustain.
Transparent planning: a step-by-step plan with owners and dates is shared at the start, and progress is reported regularly.
Related Services and Training
- CQI Training Programmes — if you want to train your own assessors
- System Audit — supplier system audits
- IATF 16949 Training
- Process Audit
Frequently Asked Questions About Special Process Audits (CQI Assessments)
Which CQI assessment applies to us?
It depends on the processes you run or purchase and on your customer-specific requirements. We recommend checking your contracts and CSR documents; if you are unsure, we can determine it together in a short call.
Do you carry out the self-assessment for us?
We run it together. A self-assessment is, by definition, the organization’s own evaluation; we set up the method, guide the work and support the reporting.
How often should it be done?
Special process assessments are expected at least once a year. Your customer requirements may specify a more frequent cycle.
We purchase the process — is it still required?
Yes. The responsibility for verifying the supplier’s conformity rests with the buyer. We can conduct the audit on your behalf.
Do you provide the CQI guideline?
No. AIAG publications are copyright-protected. You need access to the current guideline for the assessment to be carried out.