Objective
The participant will understand the fundamentals of the automotive Core Tools and will be able to apply them through practical examples following the AIAG latest guidelines.

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Participant’s Profile
Professionals in charge of the new products introduction process, quality engineers reponsible for the integration or revision of PPAPs, internal auditors and all those interested in the analysis, control and improvement of processes within the automotive industry.

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APQP – Advanced Product Quality Planning

• Introduction to APQP

• PDCA vs APQP

• Product quality planning cycle

+ Phase 1. Planning and program definition

+ Phase 2. Product design and development

+ Phase 3. Process design and development

+ Phase 4.Product and process validation

+ Phase 5. Feedback, assessment and corrective action

• Feasibility commitment

• Detailed View of Activities by Phase

• Deliverables by Phase

 

FMEA – Failure Mode and Effects Analysis

• 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

 

Control Plan

• Introduction to Control Plan

• Controlling vs monitoring

• Special product characteristics

• Special process characteristics

• Evaluation technique

• Sample size and frequency

• Control method

• Reaction plan

 

SPC – Statistical Process Control

• Introduction to SPC

• Measure of dispersion

• Process variation analysis

• Elements of control chart

• Common and special causes

• Statistical stability

• Control limits

• Sample size and frequency

• Variable control charts

 + X-R Chart

 + I-MR Chart

• Attributes control charts

 + p Chart

 + u Chart

• Process capability and performance (Cp, Cpk, Pp, Ppk)

• Sixpack – Capability analysis with Minitab

 

MSA – Measurement Systems Analysis

• Introduction to MSA

• Elements of a measurement system

• Resolution, bias, stability, linearity

• Repeatability and reproducibility

• Gage R&R study – Guidelines

• Range method vs ANOVA method

• ANOVA method

• Gage R&R practice

• Gage R&R results interpretation

• Attribute measurement system

 

PPAP – Production Part Approval Process

• Introduction to PPAP

• PPAP emission

• Responsibilities and authorities

• Significant production run

• 18 PPAP requirements

• PPAP levels

• PSW – Part Submission Warrant

• Customer notification

• Record retention