IATF CORE TOOLS TRAINING

ABOUT THE COURSE

This 2-day course on Core Tools comprises of APQP, PPAP, FMEA, SPC and MSA. These quality core tools are building blocks to effectively create and manage an organisation’s quality management system.

This training program addresses in-depth on how process flows, Process Failure Modes and Effects Analysis (PFMEA), Advanced Quality Control Plans and shop floor documentation that are linked and used to achieve process standardization and improvement. It also focuses on PPAP, Statistical Process Control (SPC) and Measurement Systems Analysis (MSA).

Duration: 2 - day course

WHAT WILL YOU LEARN FROM THE COURSE?

At the end of this course, participant will be able to:

• Gain basic understanding of the core tools used in New Product Development for effective auditing program
• Learn hands-on approach to AQP and its relationship to Program Management to give the knowledge and skills needed to participate in a team that will introduce new products and processes smoothly
• Understand the use of Process Management to achieve standardization and improvement using Process Flow Diagrams, Process FMEA and Process Control Plans
• Understand all major automotive industry approaches to FMEA’s and Control Plans and the variations in current use
• Develop the understanding and skills necessary to measure and monitor manufacturing processes and correct problems when they arise
• Gain understanding of statistical tools required for auditing an organizations knowledge and use of statistical methods; and
• Know how to conduct SPC & MSA

Course Outline

Day 1

Failure Modes and Effects Analysis (FMEA)

1. Introduction to FMEA
1.1 What is FMEA?
1.2 Compare and contrast the different types FMEA
1.3 Types and selection of key quality characteristics for use in a FMEA process 
1.4 Linkages between DFMEA, PFMEA and Control Plan

2. Overview of steps in developing and applying an Process FMEA

Measurement System Analysis (MSA)

1. Introduction to Measurement System 
1.1 Metrology and Terminology 
1.2 The Measurement Process and types of measurement errors

2.  Variable Measurement System Study
2.1 Stability Study
2.2 Bias Study and Linearity Study

3. Variable Measurement System Study
3.1 Repeatability and Reproducibility Study

Day 2

Statistical Process Control (SPC)

1. Basic Statistics for Quality Control, Assurance and Improvements
1.1 Understanding Variation
1.2 Population and Sample
1.3 Measure of Location
1.4 Measure of Dispersion

2. Statistics Process Control
2.1 Fundamental and Concept
2.2 Analysis and interpretation of Patterns (Trends)  in Control Chart
2.3 Steps in Control Chart Setup
2.4 Types of Variable Control Charts

3. Process Capability
3.1 Introduction to Process Capability and Benefits 
3.2 Steps involved in a capability study 
3.3 Interpreting Defective level from Process Capability

Advanced Product Quality Planning (APQP)

1. Fundamentals of APQP 
2. Plan and Define Phase
3. Product Design and Development Phase
4. Process Design and Development Phase
5. Product and Process Validation
6. Feedback, Assessment and Corrective Action
7. Control Plan and terminology

Production Part Approval Process (PPAP) 

1. Purpose and scope 
2. Submission Requirements
3. Submission Levels Requirements
4. Approval Status and Record

WHAT IS THE COURSE METHODOLOGY?

Participants will learn through lectures, case studies, group exercises and discussions.

WHO SHOULD TAKE THE COURSE?

This course is specially designed for:

• Management representatives
• Executives from organizations willing to implement, maintain and improve the Quality Management Systems
• Engineers and Managers (in middle and senior management) who are actively involved in the development, maintenance and internal auditing of existing / proposed Quality Management Systems

Prerequisite: None

WHO IS THE COURSE ADVISOR?

The course content and structure are designed by the domain experts from TÜV SÜD.

With immense experience and knowledge in the relevant standards, our team of product specialists and technical experts at TÜV SÜD, developed the course content based on current business landscape and market requirements.