Core Tools

Introduction to Quality Core Tools (APQP/PPAP, SPC, MSA, FMEA) 2 days

This course will provide an overview to the Quality Core Tools, APQP/PPAP, SPC, FMEA, and MSA. The core tools are building blocks to effectively create and manage an organization’s quality management system. Companies seeking IATF 16949 must understand the core tools in order to provide continual improvement while emphasizing defect prevention and the reduction of variation and waste in the supply chain.


Quality Core Tools Training Series

Developed over 30 years ago by the Automotive Industry Action Group (AIAG) and domestic auto manufacturers, the Automotive Quality Core Tools are the building blocks of an effective quality management system. Knowledge and effective use of the automotive core tools is one of the most important mechanisms for an organization to develop and manage a robust quality management system. The Core Quality Tools Training Series provides an in-depth understanding and hands-on application of the core tools. The approaches in this course are consistent with the intent and guidelines in the APQP 2nd Edition, FMEA 4th Edition, and PPAP 4th Edition manuals issued by GM, Ford and Chrysler through the AIAG.


Advanced Product Quality Planning (APQP) and Production Part Approval Process (PPAP)

Complex products and supply chains present plenty of possibilities for failure, especially when new products are  launched. Advanced Product Quality Planning (APQP) is a structured process aimed at ensuring customer satisfaction with new products or processes. The focus of APQP is utilization of tools and methods for mitigating the risks associated with change in the new product or process. The APQP process begins with the creation of a Product Quality Plan (PQP).

This advanced two-day training session addresses all the elements of Advance Product Quality Planning (APQP) and defines it as a process in your organization. It provides an overview of the five phases of APQP and how it is managed as a process. It also details PPAP as the culmination of the APQP process and provides a detailed examination of Production Part Approval Process requirements.

Topics include:

  • APQP requirements and process
  • Correlation of the Plan Do Study Act (PDSA) model with the APQP cycle
  • Alignment with IATF 16949:2016
  • AIAG APQP Model
  • Five Phases of APQP
    • Inputs
    • Plan and Define
    • Product Design and Development Tools
    • Process Design and Development Tools
    • Product and Process Validation
    • Feedback Assessment and Continuous Improvement
  • PPAP Overview
  • PPAP Definitions, Scope and Purpose
  • Requirement of Submission
  • PPAP Process Requirements


Failure Modes Effect Analysis (FMEA)  

Failure Mode and Effects Analysis (FMEA) is a structured approach to discovering potential failures that may exist within the design of a product or process. FMEA is not a substitute for good engineering. Rather, it enhances good engineering by applying the knowledge and experience of a cross-functional team to review the design progress of a product or process by assessing its risk of failure.

This advanced, one-day course follows a step-by- step method for conducting FMEA. Participants will learn how to assess risk and determine the levels of risk that trigger mitigation actions. Action plans derived from FMEAs and methods to manage FMEA data for future use are also covered in detail.

Participants can expect team activities and relevant exercises in a workshop format.

Topics include:

  • Linking FMEA to APQP and PPAP
  • FMEA Process
  • Practical Application of FMEA with Hands on Exercises
  • Developing Risk Mitigation and Continuous Improvement Plan

Statistical Process Control (SPC)   

Statistical Process Control is about assessing variation in a process or product, collecting data, analyzing data, and making decisions to act on based on statistical output. SPC is used as a quality core tool to help companies practice process control and continuously reduce the variation of those processes.

This one-day course provides participants with an understanding of the importance of SPC in controlling and improving the production process and gives students a practical knowledge of using statistical methods in analyzing the production processes.

Topics include:

  • Basic Statistics
  • Variation
  • Process Control
  • Common Cause vs. Special Cause Variation
  • Out of control signals
  • Capability Analysis
  • Sampling Procedures
  • Process Capability Studies
  • Use of Statistical Process Control Charts


Measurement Systems Analysis (MSA) 

Product and process conformance are determined by the measurements taken by a measurement system. If the measuring process is changing over time, the ability to use the data gathered in making decisions is reduced. Measurement System Analysis is used to assess the statistical properties of process measurement systems.

This one-day introductory course provides participants with an understanding of the importance of MSA in controlling and improving the production process and provides a practical knowledge of using statistical methods in analyzing the measurement system. A basic understanding of applied statistics and a background in statistical process control are recommended as prerequisites.

Topics include:

  • What is a Measurement System?
  • Statistical Properties of Measurement Systems
  • Discrimination and Uncertainty
  • Bias, Linearity and Stability
  • Breakout Exercise: Bias
  • Breakout Exercise: Bias & Linearity
  • Breakout Exercise: Stability
  • GRR Studies
  • Advanced Analysis – Analysis of Variance (ANOVA)
  • Automated and Non-Replicable Systems
  • Non-Replicable Case Study
  • Attribute MSA
  • Measurement Planning