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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

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