Core Quality Tools
“Quality is not an act, it is a habit”– Aristotle
Automotive Industry Action Group (AIAG) has developed the core tools to be used in conjunction with IATF-16949. Quality Core Tools are the foundation of automotive quality excellence.
Why do you need this training ?
- You will learn how to improve the quality, reliability and the safety of the products and processes;
- You will increase the customer satisfaction;
- You will learn how to identify and eliminate the potential errors from the system;
- You will be able to minimize the errors when implementing changes, and associated costs; You will be able to provide products in the right quantity and quality, with minimal costs; You will be able to build a clear and efficient communication process, to control specifications and relevant information’s within your project.
- You will be able to solve quicker the problems resulted from documented product history.
Training content APQP
General remarks: Definitions; Benefits; PDCA cycle; Team approach; APQP diagram;
Phase 1: Planning, defining new programs; Input + Output; Customer voice, Preliminary activities;
Phase 2: Product Design and Development; Inputs + outputs; Building a prototype control plan; Defining the specifications;
Phase 3: Process Design and Development; Inputs + outputs, Developing the product / process for pre launch (Packaging, Process Flow Chart, Layout, Pre-Launch Control Plan, Process Instructions, MSA plan and Preliminary Process Capability Study Plan);
Phase 4: Product and Process Validation; Inputs + outputs; Production Trial Run; Production Control Plan; Preliminary Process Capability Study; Production Part Approval; Validation Testing;
Phase 5: Feedback, Assessment and Corrective Actions; Inputs + outputs; Reduced Variation; Customer Satisfaction; Delivery and Service.
Training content FMEA (New FMEA AIAG-VDA First Edition)
General remarks Process problems approach (Reactive / Proactive methods); Applicability;
FMEA construction procedure The main steps; Team approach; Guaranty of the product; Confidentiality; System structure analysis; 7-Step Approach; 5T’s Process
Process FMEA Entry elements; Process flow diagrams;
PFMEA Worksheet Process Item System, Subsystem, Part Element or Name of Process; Process Work Element 4M Type; Options for documenting Function and Requirement/Product; New Rating Charts; Action Priority
Process risks Risk matrix (impact – probability); Action Priority
Corrective actions & Improvements FMEA review; Top risks; Selection of risk reduction actions (design change, error proofing device, training, procedures); Recommended Action split into Prevention/Detection; FMEA Report
Training content CP
Control Plan types Definition, Approach, CP utilization; Prototype, Pre-launch, Serial production;
Methodology for creating control plan Process flow; Failure mode analysis; Special characteristics;
Control plan elements Description; CP standard form and the info’s that has to be filled in this form;
Control plan utilization Written description of the methods used in order to decrease the process / product variation; Modifications, according to the customer’s requests, and internal system;
Corrective actions Monitoring the processes and control methods; Lessons learned.
Training content SPC
General remarks Statistic; Process; Control; Which are the SPC benefits? SPC approach (flow);
Data collection Recording data; Type of charts (Histograms, Graphs, Pictorial graphs, Pie charts);
Process variation Causes of variation; Variation control; Unstable process approach; Process distribution (Normal distribution, Standard deviation).
Process control Control chart; Control limits; Interpreting control charts; Out of control signals; Western Electric rules; AIAG rules.
Process capability What is a capability study?; Capability scope; Typical situations; Interpreting capability indicators (Cp Index,, Cpk Index.)
Process improvement Process improvement strategy.
Training content MSA
General remarks about Measuring System Analysis MSA scope and characteristics; MSA components, properties, process; Types of measurements;
Sources of errors in measurement systems Measurement system accuracy and precision; Main source of errors in measurement systems;
Sources of variation in measurement systems Part-to-part variation, measurement system variation; Normal and special cause variation description; Identify source of variation in the
Measurement System Analysis Bias factor; Linearity; Stability; Repeatability and Reproducibility;
Gage R&R analysis – Conducting a Variable Gage R & R Study ANOVA method; Average and range method (x & R); Gage acceptability criteria; Key to successful gage studies.
Gage R&R analysis – Conducting an Attribute Gage R & R Study Attribute MSA problems; Conducting an attribute gage R&R; Acceptability guidelines; Sources of variability;
Training content PPAP
General remarks Definitions, Specific terms; PPAP as part of the Quality Management System; Applicability;
Description of quality-oriented process Process block diagram; Critical elements;
PPAP Requirements Documents requested by the customer (Design Records, Engineering Change Documents, Engineering Approval, DFMEA, PFMEA, Process Flow Diagrams, Dimensional Results, Initial Process Studies, MSA, CP, PSW, Master sample, Customer-Specific Requirements); Case study;
Submission Levels: Customer PPAP Status (Full Approval, Interim Approval, Rejected); Parts Submission Warrant – case study;
Special situations When to inform/ not to inform the customer?; When is necessary / not necessary to have PPAP for approval?
Investments: 450 EUR / person (3 days)
Super Deal: 45% discount (249 Euro/person) – (sign up until 5th of October 2019)
Early bird: 30% discount (315 Euro/ person) (sign up until 12th of October 2019) + Group discount: 50% (157 Euro) discount for the third participant.
The specified amount includes lunch, three coffee break, all required materials and the EMC participation certificate.
The specified amount does not include VAT.