5 Core Tools Automotive (SPC, MSA, APQP, PPAP, Control Plan, FMEA)

Course Outline

1. Introduction to Automotive Quality Core Tools
   • Overview of IATF 16949 Requirements
   • Importance of the 5 Core Tools in Quality Management
   • Integration of Tools in the Product Life Cycle
2. Statistical Process Control (SPC)
   • Fundamentals of SPC
   • Types of Control Charts
   • Application in Manufacturing Processes
   • Interpreting Control Chart Signals
3. Measurement Systems Analysis (MSA)
   • Principles of Measurement System Variability
   • GR&R (Gauge Repeatability & Reproducibility)
   • Bias, Linearity, and Stability
   • Best Practices for Ensuring Data Integrity
4. Advanced Product Quality Planning (APQP)
   • Phases of APQP
   • Key Inputs, Outputs, and Deliverables
   • Linking APQP with DFMEA, PFMEA, and Control Plans
5. Production Part Approval Process (PPAP)
   • Purpose and Scope of PPAP
   • Elements of PPAP Submission
   • Managing Changes and Revalidations
6. Failure Mode and Effects Analysis (FMEA)
   • DFMEA and PFMEA: Structure and Process
   • Identifying Failure Modes, Effects, and Causes
   • Risk Priority Number (RPN) and Action Plans
   • AIAG-VDA FMEA Updates
7. Control Plan Development
   • Linking FMEA to Control Plans
   • Key Characteristics and Monitoring Methods
   • Continuous Improvement Through Effective Controls
8. Case Studies and Practical Exercises
   • Real-world Application of Each Tool
   • Hands-on Group Activities: Developing an FMEA, MSA Plan, and Control Plan
9. Assessment and Wrap-Up
   • Summary of Key Learnings
   • Individual and Group Assessments
   • Q&A Session

Course Objectives

By the end of this training, participants will:

• Understand the purpose and scope of each core tool.
• Learn how to apply the tools in alignment with IATF 16949 requirements.
• Gain the skills needed to interpret and analyze data from SPC and MSA.
• Develop proficiency in creating APQP, PPAP, FMEA, and Control Plans.
• Understand the interconnected nature of the 5 tools to enhance product and process quality.

Learning Outcomes

After completing this course, participants will be able to:

1. Implement SPC to monitor and improve process stability.
2. Conduct MSA to validate the reliability of measurement systems.
3. Lead the APQP process to ensure robust product development.
4. Prepare and submit a compliant PPAP package.
5. Develop effective FMEAs and link them to Control Plans.
6. Proactively identify and mitigate risks using these tools.

Methodology

1. Interactive Lectures
   • Concepts explained with visual aids and practical examples.
2. Hands-on Workshops
   • Step-by-step exercises for SPC, MSA, FMEA, and Control Plans.
3. Group Activities
   • Collaborative exercises to simulate real-world scenarios.
4. Case Studies
   • Analysis of automotive quality challenges and solutions.
5. Assessments
   • Knowledge checks, quizzes, and project-based evaluations.
6. Templates and Job Aids
   • Ready-to-use templates for PPAP, FMEA, Control Plans, and SPC charts.
7. Guided Discussions
   • Q&A and troubleshooting sessions for participants’ specific challenges.