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Duration 7 hours
Course Outline
1. Overview of Quality Core Tools
- Summary of Quality Core Tools within the automotive sector
- Objective and significance of Quality Core Tools
- Interconnection between Quality Core Tools and automotive quality benchmarks
- Summary of:
- Advanced Product Quality Planning (APQP)
- Production Part Approval Process (PPAP)
- Failure Mode and Effects Analysis (FMEA)
- Statistical Process Control (SPC)
- Measurement Systems Analysis (MSA)
- Mechanism by which Quality Core Tools facilitate prevention-oriented quality management
2. Advanced Product Quality Planning (APQP)
2.1 APQP Essentials
- Intent and targets of APQP
- Product and process development life cycle
- Customer specifications and quality expectations
- Interdisciplinary team methodology
2.2 APQP Stages
- Stage 1: Program planning and definition
- Stage 2: Product design and development
- Stage 3: Process design and development
- Stage 4: Product and process verification
- Stage 5: Feedback, evaluation, and corrective measures
2.3 Applied APQP Implementation
- Formulation of an APQP project plan
- Identification of critical milestones
- Risk mitigation during product development
- Alignment of APQP activities with customer specifications
3. Production Part Approval Process (PPAP)
3.1 PPAP Summary
- Intent of PPAP
- Criteria for PPAP requirement
- Customer approval standards
- PPAP tiers and submission obligations
3.2 PPAP Documentation
- Comprehension of PPAP components:
- Design records
- Engineering change documentation
- Process flow diagrams
- Control plans
- Measurement system studies
- Dimensional results
- Material and performance test outcomes
- Initial process studies
3.3 PPAP Execution
- Preparation of PPAP packages
- Evaluation of supplier submissions
- Frequent PPAP difficulties
- Sustaining PPAP adherence
4. Failure Mode and Effects Analysis (FMEA)
4.1 FMEA Essentials
- Intent of FMEA
- Preventive versus detective methodologies
- Categories of FMEA:
- Design FMEA (DFMEA)
- Process FMEA (PFMEA)
4.2 Conducting FMEA Evaluation
- Detection of potential failure modes
- Analysis of causes and consequences
- Assessment of:
- Severity
- Frequency
- Detection
- Risk prioritization
- Establishment of preventive and corrective measures
4.3 Applied FMEA Workshop
- Construction of a simplified FMEA case study
- Assessment of risks in manufacturing operations
- Formulation of improvement measures
5. Statistical Process Control (SPC)
5.1 SPC Essentials
- Intent of statistical process control
- Concepts of variation:
- Common cause variation
- Special cause variation
- Process stability and competence
5.2 SPC Instruments and Methods
- Control charts:
- X-bar and R charts
- Individual and moving range charts
- Attribute control charts
- Process competence analysis:
- Cp
- Cpk
- Interpretation of SPC data
5.3 SPC Application in Manufacturing
- Selection of process parameters for monitoring
- Establishment of control limits
- Response to out-of-control states
- Ongoing process optimization
6. Measurement Systems Analysis (MSA)
6.1 MSA Essentials
- Significance of measurement precision
- Origins of measurement variation
- Measurement system standards
6.2 Gauge Repeatability and Reproducibility (Gage R&R)
- Distinction between repeatability and reproducibility
- Execution of Gage R&R studies
- Interpretation of outcomes
- Optimization of measurement systems
6.3 Applied MSA Implementation
- Assessment of measurement instruments
- Detection of measurement defects
- Selection of suitable measurement techniques
7. Integration of Quality Core Tools into Quality Management Systems
- Alignment of Quality Core Tools with quality management procedures
- Fostering ongoing optimization
- Utilization of instruments throughout the product life cycle
- Interdisciplinary cooperation
- Supplier quality oversight
- Record-keeping and traceability
- Cultivation of a prevention-oriented quality culture
8. Practical Workshop and Conclusion
- Application of Quality Core Tools to a manufacturing case study
- Development of:
- APQP strategic plan
- Simplified PFMEA
- Control plan
- SPC evaluation
- MSA assessment
- Analysis of interconnections between instruments
- Frequent implementation barriers
- Inquiry and response session
- Future actions for quality specialists
Requirements
- Basic understanding of quality management systems
- Familiarity with manufacturing processes and environments
Audience
- Quality engineers
- Process engineers