MSA (Measurement Systems Analysis)

Objective

The participant will know the different studies carried out on variable data and attribute data measurement systems, will be able to apply statistical methods for its analysis and interpretation and will recognize the importance of having reliable measurement systems.


Participant’s Profile

Professionals from engineering, quality, metrology, and production areas, as well as all personnel involved in the use of measurement systems for decision making.


MSA – Measurement  System Analysis (4th Edition)

Introduction

• Importance of MSA

• Relation to IATF 16949:2016

• When MSA is required?

• Who is responsible for MSA?

Concepts and definitions

Basics Statistics

• Central tendency measures

• Measures of dispersion

Resolution

• Required resolution calculation

• Selection of the measuring instrument

Variation in measuremnt systems

• Effects on the measurement of products

• Effects on the measuremnts of processes

Accuracy vs Precision

Bias Study

• Practical exercise

• Minitab – BIAS Study

• Causes of excessive bias

Linearity Study

• Practical exercise

• Minitab – Linearity Study

• Causes for linearity error

Stability Study

• Practical exercise

• Minitab – Control Charts

• Causes of instability

Gage R&R Study – Repeatability and Reproducibility

• Practical exercise

• Average and range method

• ANOVA method

• Minitab – Crossed Gage R&R

• Results interpretation

• NDC – Number of Distinct Characteristics

• Corrective actions

Attribute Measurement Systems Study

• Practical exercise

• Kappa index

• Crosstabulation

• Effectiveness of the measurement system

• Miss rate, false alarm date

• Minitab – Attribute agreement analysis

• Corrective actions

SPC (Statistical Process Control)

Objective

The participant will understand the statistical principles necessary for process control, will be able to interpret any control chart and capacity study (Cp, Cpk), and will understand the importance of decision-making based on data.


Participant’s Profile

Professionals from engineering, quality control, incoming inspection, and production areas, as well as all personnel involved in process control, product characteristics control, or data analysis for decision making.


SPC – Statistical Process Control (2nd Edition)

Introduction

• Importance of SPC

• Relation to IATF 16949:2016

• When SPC is required?

Concepts and definitions

Basics Statistics

• Central tendency measures

• Measures of dispersion

Variation

• Variation sources

• Common and special causes

• Local actions vs System actions

• Continuous variable vs Attributes

Control Charts

• How do they work and what are they for?

• Elements of Control Charts

• Control limits vs Spec limits

• Strategy implementation

+ Rational subgrouping

+ Sampling plan

• Interpretation and reaction plan

• Control process vs Control specifications

• Rules to identify special causes

Variables Control Charts

• Variables for sugroups

+ X-R Chart – practical exercise

+ X-S Chart – practical exercise

+ Solving with Minitab

+ X-R Chart – practical exercise

+ Control Charts Variables for

   Subgroups

• Variables individuals

+ I-MR – practical exercise

+ Solving with Minitab

+ Control Charts Variables for

   Individuals

Attributes Control Charts

• Attributes for Nonconforming

+ p Chart – practical exercise

+ np Charts – practical exercise

+ Solving with Minitab

+ Attributes Charts

• Attributes for Nonconformities

+ u Charts – practical exercise

+ c Charts – practical exercise

+ Solving with Minitab

+ Attributes Charts

Process Capability

• Stability and Normality

• What is Process Capability?

• Calculation and interpretation of Cp, Cpk, Pp y Ppk

+ Preliminar Study – 30 consecutive parts

+ Complete study – 25 subgroups, sample size: 5

• Minitab

+ Quality tools

+ Capability analysis

• Minitab

+ Quality tools

+ Capability sixpack

PPAP (Production Part Approval Process)

Objective

The participant will know in detail the 18 requirements of a PPAP, will understand which changes should be notified to the client and will be able to identify when a PPAP is complete and meets the AIAG guidelines.


Participant’s Profile

Professionals from engineering, quality, and production areas, as well as all the personnel involved in the process validation of new products, review of PPAPs from suppliers, and submission of PPAPs to customers.


PPAP –  Production Part Approval Process (4th Edition)

Introduction

• Importance of PPAP

• Relation to IATF 16949:2016

• When a PPAP is required?

• Who is responsible for PPAP?

 

18 PPAP Requirements

• Significant production run

• Design records

+ IMDS – International Material Data System

+ Marking of polymeric parts

• Authorized engineering change documents

• Customer engineering approval

• Design FMEA

• Process flow diagram

• Process FMEA

• Control Plan

• MSA – Measurement System Analysis

• Dimensional results

• Records of material / performance test results

• Initial process studies (Cp, Cpk, Pp, Ppk)

• Qualified laboratory documentation

  Appearance Approval Report (AAR)

• Sample production parts

• Master sample

• Checking aids

• CSR – Customer Specific Requirements

• PSW – Part Submission Warrant

 

Customer notification

PPAP submission levels

PPAP disposition

Record retention

PFMEA AIAG-VDA (Process Failure Mode and Effects Analysis)

Objective

The participant will learn the FMEA Model applied to productive or administrative processes, will understand the different elements of a correct failure Modes Analysis and will be able to create effective control strategies that reduce risks.


Participant’s Profile

Professionals involved in the design of production lines, product engineering, processes, manufacturing, industrial, quality and production interested in the prevention / reduction of risks in their processes.


Introduction

• Purpose and description

• Objective and limits

• Integration of FMEA in the company

• Project planning

• PFMEA methodology

Execution of the Process FMEA (PFMEA)

• 1st STEP: Planning and Preparation

+ Project Identification and Boundaries

+ Project plan

+ Process FMEA Header

• 2nd STEP: Structure Analysis

+ Process Flow Diagram

+ Structure Tree

• 3rd STEP: Functional Analysis

+ Function

+ Requirement(s) (characteristics)

+ Visualization of functional relationships

• 4th STEP: Failure Analysis

+ Failure

+ The Failure Chain

+ Failure Effects

+ Failure Mode

+ Failure Cause

+ Failure Analysis

+ Relationship DFMEA – PFMEA

• 5th STEP: Risk Analysis

+ Current Prevention / Detection Controls

+ Evaluations

+ Severity

+ Occurrence

+ Detection

+ Action Priority (AP)

• 6th STEP: Optimization

+ Purpose

+ Assignment of Responsibilities

+ Status of Actions

+ Assessment of action Effectiveness

+ Continual Improvement

• 7th STEP: Results Documentation

+ Purpose

+ PFMEA Report

Sample FMEA Form Sheets

• Standard PFMEA Form

• Alternative Forms D / E / F / G

Practice – Conducting a PFMEA

APQP (Advanced Product Quality Planning)

Objective

The participant will know the different requirements for each phase of the APQP, will understand the importance of the advanced planning for failure prevention and will be able to create a basic plan that suits the needs of your organization.


Participant’s Profile

Professionals involved in quality planning, project management and new products introduction, including administrative areas.


APQP – Advanced Product Quality

Planning 2nd Edition)

Introduction

• Importance of APQP

• Relation to IATF 16949:2016

• PDCA cycle vs APQP

• Gantt Chart / Timing Chart

Phase 1 – Plan and define program

• Voice of the customer (VOC)

• Business plan

• Benchmark

• Product / Process assumptions

• Design goals

• Quality goals

• Reliability goals

Phase 2 – Product design and development

• Design FMEA

• IMDS – International Material Data System

• Design for Manufacturability and Assembly

• Prototype build

• DVP&R – Design Verification Plan & Report

• Design review

• Special product characteristics

• Technical specification

• Feasibility commitment

Phase 3 – Process design and development

• Packaging standards and specifications

• Product / Process quality system

• Process flow diagram

• Process FMEA

• Pre-launch Control Plan

• Process definition

• Process instructions

• Measurement systems definition

• Attribute master samples

• Checking aids

Phase 4 – Product and process validation

• Significant production run

• MSA – Measurement System Analysis

• Dimensional results

• Records of material / performance test results

• Initial process capability study

(Cp, Cpk, Pp, Ppk)

• Production Control Plan

• Qualified laboratory documentation

• Appearance Approval Report (AAR)

• Sample production parts

• Customer specific requirements

• PSW – Part Submission Warrant

Phase 5 – Feedback, Assessment and Corrective Action

• Improved customer satisfaction

• Improved delivery and service

• Lessons learned

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IATF 16949:2016

Objective

At the end of the course the participant will acquire the theoretical concepts required to audit the automotive quality management system IATF16949:2016, will understand the importance of preparation previous to the audit and will be able to write effective audit reports.


Participant’s profile

Professionals responsible for the planning, execution or follow-up of internal audits to the automotive Quality Management System.


Day 1 – IATF 16949:2016 Overview

Introduction to Quality Management System

• Terms and definitions

Quality management principles

• Process approach

• Risk-based thinking

Interpretative review IATF 16949:2016

• Interpretative exercises

• Application exercises

• Documentary audit

Competencies for Internal Auditor

• Knowledge required

• Skills required

Sector and Customer Specific Requirements

• AIAG handbook

• IATF website

• Customer handbook

Day 2 – ISO 19011:2018 Guidelines for Auditing Management System

• Terms and definitions

• Principles of auditing

• Audit programme

   + Risks and opportunities

   + Roles and responsibilities

• Audit preparation

• Audit plan

• Opening meeting

• Audit Implementation

• Audit methods

• Audit findings

• Audit report

• Closing meeting

• Internal auditor competence

Core Tools

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.


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.


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

 

ISO 9001:2015

Objective
At the end of the course the participant will acquire the theoretical concepts required to audit the automotive quality management system ISO9001:2015, will understand the importance of preparation previous to the audit and will be able to write effective audit reports.


Participant’s Profile
Professionals responsible for the planning, execution or follow up of internal audits to the Quality Management System.


Day 1 – ISO 9001:2015 Overview

Introduction to Quality Management System

• Terms and definitions

• Quality management principles

• Process approach

• Risk-based thinking

Interpretative Review ISO 9001:2015

• Interpretative exercises

• Application exercises

• Documentary audit

Competencies for Internal Auditor

• Knowledge required

• Skills required

Day 2 – Auditing Management Systems

• Terms and definitions

• Principles of auditing

• Audit program

– Risks and opportunities

– Roles and responsibilities

• Preparing audit activities

• Audit plan

• Opening meeting

• Audit implementation

• Audit methods

• Audit findings

• Audit report

• Closing meeting

• Auditor competence