Core Tools (APQP, PPAP, FMEA, SPC & MSA)

QIMS often organize 5 days’ workshop on Core Tools which comprises of APQP, PPAP, FMEA, SPC and MSA. These quality core tools are building blocks to effectively create and manage an organization’s quality management system.

This training program addresses in depth, how process flows, Process Failure Modes and Effects Analysis (PFMEA), Control Plans and shop floor documentation are linked and used to achieve process standardization and improvement. It also focuses on PPAP and PSW consistent with the requirements of IATF 16949 and the FMEA Manual as well as the basic concepts of Statistical Process Control (SPC) and Measurement Systems Analysis (MSA).

Course Objectives:
  • Provide a basic understanding of the core tools used in New
  • Product Development for effective auditing programs.
  • Provide a hands-on approach to APQP and its relationship to Program Management to give the knowledge and skills needed to participate in a team that will introduce new products and processes smoothly.
  • Focus on the use of Process Management to achieve standardization and improvement using Process Flow Diagrams, Process FMEA and Process Control Plans.
  • Understand all major automotive industry approaches to FMEA’s and Control Plans and the variations in current use.
  • Develop the understanding and skills necessary to measure and monitor manufacturing processes and correct problems when they arise.
  • People will have a firm understanding of statistical tools required for auditing an organizations knowledge and use of statistical methods.
  • How to conduct SPC & MSA
Who Can Attend?
  • Management Representatives
  • Internal Auditors
  • Supervisors, Engineers and Managers, actively involved in Process Design & Development Production
  • Executives involved in Quality & Quality Management System activities.
  • Potential Internal Auditors
Course Highlights:
  • This program incorporates the changes in Measurement Systems Analysis MSA – AIAG Manual Fourth edition 2010
  • The training program will have blend of interactive and learning based sessions coupled with value addition.
  • The training will provide the participants a forum to freely interact with Advice Consultancy having excellent competency in APQP, PPAP, Control Plan & FMEA, SPC and MSA.
  • The faculty is equipped with efficiency in Core Tools and teaches the peoples, logic and sense of auditing by protecting their objectivity, being independent & impartial to audit.
    Course Contents:
    • Production Part Approval Process (PPAP)
      • Purpose
      • ISO/TS requirements
      • Example process flow chart for PPAP
      • Comparison of PPAP with traditional approach
      • Significant production run
      • Requirements for part approval • Situations when PPAP validation, customer notification & Submission required.
      • PPAP submission level
    • Advanced Product Quality Planning (APQP)
      • Product Quality Planning Cycle
      • Fundamentals of Product Quality Planning
      • Control Plan
      • Phases of APQP
      • Phase 1 – Plan & Define program
      • Phase 2 – Product Design & Development
      • Phase 3 – Process Design & Development
      • Phase 4 – Product & Process Validation
      • Phase 5 – Feedback, Assessment & Corrective action
      • Inputs & outputs of each phase
    • Failure Mode and Effective Analysis (FMEA)
      • FMEA Concept for understanding
      • FMEA definitions
      • Advantages of FMEA
      • Process FMEA
      • Design FMEA
      • FMEA requirement in ISO/TS 16949:2009
      • How to Develop a FMEA?
      • Understanding of Severity, Occurrence & Detection Rankings
      • Risk Priority Number (RPN)
      • Guideline on recommended actions
    • Statistical Process Control (SPC)
      • Basic Definitions
      • Process Control
      • Common & Special Cause
      • Process Control & Process Capability
      • Process Improvement Cycle
      • Effective use & benefit of control chart
      • SPC Requirement in ISO/TS 16949
      • Control Chart Basics
      • Elements and mechanics of control charts
      • Variable control charts, Attribute control charts
      • Process Capability Study
    • Measurement System Analysis (MSA)
      • Basic concepts & definitions
      • MSA Requirement in ISO/TS 16949:2009
      • Statistical properties of Measurement systems
      • Preparation for a Measurement Study
      • Bias Study
      • Linearity Study
      • Stability Study
      • Gauge Repeatability & Reproducibility Study (Gauge R&R)
      • Attribute MSA – Kappa Method

PPAP 18 Documentation

REQUIREMENTS FOR PART APPROVAL
  1. Design Record
  2. Engineering Change Documents, if any
  3. Customer Engineering Approval, if required
  4. Design FMEA
  5. Process Flow Diagrams.
  6. Process FMEA
  7. Control Plan.
  8. Measurement System Analysis Studies.
  9. Dimensional Result
  10. Records of Material / Performance Test results
  11. Initial Process Studies
  12. Qualified Laboratory Documentation
  13. Appearance Approval Report (AAR)
  14. Sample Production Parts
  15. Master Sample
  16. Checking Aids.
  17. Customer-Specification Requirements
  18. Part Submission Warrant (PSW)

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