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Training Course on Core Tools – Foundation Level (MSA, SPC, New AIAG VDA FMEA & APQP, PPAP)

Qualifying People - Developing Future

About the course

TÜV SÜD South Asia organize 4 days’ workshop on Core Tools which comprises of APQP, PPAP, New Harmonized FMEA (AIAG VDA), SPC and MSA. These quality core tools are building blocks to effectively create and manage an organization’s quality management system. This course will also help participant to achieve Internal or Second Party Auditor competence to meet IATF 16949:2016 requirement and comply with IATF 16949:2016 Certification requirement. 

This training program addresses in depth awareness and knowledge development on New Harmonized AIAG VDA FMEA, Basics of DFMEA & PFMEA, Changes with respect to Previous versions of FMEA, how process flows, Process Failure Modes and Effects Analysis (PFMEA), Control Plans and shop floor documentation are linked and used to achieve process standardization and improvement. It also focuses on PPAP and PSW consist with the requirements of IATF 16949 and the APQP Guideline for Project Management as well as the basic concepts of Statistical Process Control (SPC) and Measurement Systems Analysis (MSA). 


Your Benefits

Participants will be able to:

  • Gain knowledge on Automotive Core Tools (APQP, PPAP, MSA, SPC & New Harmonized FMEA)
  • Understand the concept and application of Core Tools as per IATF 16949:2016 requirement
  • Understand the importance and necessity of Advanced Product Quality Planning (APQP)
  • Conduct FMEA in their organization as per new harmonized AIAG VDA FMEA Handbook
  • Perform basic MSA & SPC studies in their organizations 
  • Learn PPAP requirements and submit PPAP documentation to their customer.
  • Fulfill their customer specific requirements for Core Tools implementation/compliance

  • COURSE CONTENT/OUTLINE

    Day 1: Measurement System Analysis (MSA)

    •  Basic concepts & definitions
    • MSA Requirement in IATF 16949:2016
    • Statistical properties of Measurement systems
    • Preparation for a Measurement Study
    • Bias Study
    • Linearity Study
    • Stability Study
    • Gauge Repeatability & Reproducibility Study (Gauge R&R)
    • Attribute MSA – Kappa Method

    Day 2: Statistical Process Control (SPC)

    • Basic Definitions
    • Process Control
    • Common & Special Cause
    • Process Control & Process Capability
    • Process Improvement Cycle
    • Effective use & benefit of control chart
    • SPC Requirement in IATF 16949
    • Control Chart Basics
    • Elements and mechanics of control charts
    • Variable control charts, Attribute control charts
    • Process Capability Study

    Day 3: New Harmonized AIAG VDA FMEA

    • FMEA Concept for understanding
    • FMEA Team Formation and Management Commitment, Scope of FMEA
    • New 7 Step Approach in FMEA
    • FMEA requirement in IATF 16949:2016
    • Understanding of Severity, Occurrence & Detection Rankings
    • Action Priority & Risk Optimization (AP table)
    • Risk Documentation
    • Process FMEA Example & Design FMEA Example.

    Day 4: Advanced Product Quality Planning (APQP)

    • Product Quality Planning Cycle
    • Fundamentals of Product Quality Planning
    • Phases of APQP
    • Phase 1 – Plan & Define program
    • Phase 2 – Product Design & Development
    • Phase 3 – Process Design & Development
    • Phase 4 – Product & Process Validation
    • Phase 5 – Feedback, Assessment & Corrective action
    • Inputs & outputs of each phase

    Production Part Approval Process (PPAP)

    •  Introduction of PPAP & Purpose
    • Significant production run
    • Requirements for part approval
    • Situations when PPAP validation, customer notification & Submission required.
    • PPAP submission levels

 

Who should attend?

Design Engineers, Process Engineers, New Product Development Team Member, Quality Assurance Engineers / Supervisors / In charge, IATF Internal or Second Party Auditors, Process Auditors, Supply Chain Personnel, Production Personnel, Quality Control, Laboratory & Quality Personnel.

Training Duration

4 days 

Prerequisites

Basic Knowledge of Quality Management System, New Product Development cycle, basic statistics

Exam Details

Pen Paper based written examination at the end of the course on Day 4 for 75 Minutes. Exam contains Objective questions of 50 Marks from APQP, PPAP, MSA, SPC, New Harmonized FMEA. Maximum Possible Marks: 50 
Minimum Passing marks: 30 (i.e. Passing criteria: 60% marks minimum)

Certification

Participants who scores 60% and above in the written examination, i.e. successful candidate, will be issued a TÜV SÜD South Asia’s certificate of successful completion of Core Tools Training Course – Foundation Level. Unsuccessful candidates will be issued a certificate of attendance.

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