Objective
The participants will learn how to apply the Core Tools within real situations in their organizations. They will be able to understand the importance of advance planning in product quality and regulation compliance.
Participant’s profile
• Basic knowledge of IATF 16949:2016 (preferred)
• Working experience in manufacturing environments
• Basic knowledge of statistics
Day 1: APQP – Advanced Product Quality Planning
• Introduction to APQP
• APQP tool correlation with IATF 16949:2016
• PDCA vs APQP cycle
• Quality Planning Cycle Product
+ Phase 1: Planning and defining the product
+ Phase 2: Design and development of the product
+ Phase 3: Design and development of the process
+ Phase 4: Product and process
+ Phase 5: Feedback, evaluation and corrective actions
• Feasibility commitment
• Detailed review of phase activities
• Phase by phase deliverables
Day 2: PFMEA AIAG-VDA 2019 1st Edition
• Introduction to FMEA 2019 (AIAG-VDA)
• FMEA tool correlation with IATF 16949:2016
• Purpose and description
• Objective and limits
• Integration of FMEA in the company
• Project Planning
• PFMEA Methodology
• 1st STEP: Planning and Preparation
• 2nd STEP: Structure Analysis
• 3rd STEP: Functional Analysis
• 4th STEP: Failure Analysis
• 5th STEP: Risk Analysis
• 6th STEP: Optimization
• 7th STEP: Results Documentation
• Practice – Conducting a PFMEA
Day 3: SPC – Statistical Process Control
• Introduction to Statistical Control
• SPC tool correlation with IATF 16949:2016
• Dispersion Measurement Exercises
• Process Variation Analysis
• Control Chart Elements
• Normal and Special Causes
• Statistical stability
• Calculation of Control Limits
• Sample Size and Frequency
• Variable Data Control Graphs
+ X-R Graphic – Case Study
+ I-MR Chart – Case Study
• Attribute Control Charts
+ Graph p – Case Study
+ Graphic u – Case Study
• Capability Analysis (Cp, Cpk, Pp, Ppk)
• Preliminary study vs full study
• Sixpack – Capability Analysis in Minitab
Day 4: MSA – Measurement Systems Analysis
• Introduction to measurement systems
• MSA tool correlation with IATF 16949:2016
• Elements of a measurement system
• Resolution, bias, stability, linearity
• Repeatability and Reproducibility
• Studio of Gage R&R – Design and execution
• Range Method vs ANOVA Method
• Gage R&R case study with Minitab
• Interpretation of Gage R&R results
• Attribute measurement systems
• Index calculation case study Kappa
• Attribute Agreement Analysis in Minitab
• Interpretation of analysis by attributes
Day 5: Control Plan
• Introduction to the Control Plan
• Control Plan tool correlation with IATF 16949:2016
• Control vs Measurement
• Critical Product Features
• Critical Process Features
• Evaluation techniques
• Sample Size and Frequency
• Control Methods
• Reaction Plan
Day 5: PPAP – Production Part Approval Process
• Introduction to PPAP
• PPAP tool correlation with IATF 16949:2016
• Issuance of a PPAP
• Responsibilities and authorities
• Significant production run
• The 18 requirements of the PPAP in detail
• PPAP levels
• PSW – Part Submission Warrant
• Customer notifications
• Records retention