Core Tools represent a set of essential instruments and methods used in the automotive industry and other industrial sectors to ensure process quality and performance. These tools are fundamental for quality management, supporting employees in improving procedures and serving as the pillars of an efficient quality management system, in accordance with current international standards (IATF 16949).
Essential Information:
- Duration: 4 days
- Recommended participants: 5-10
- Level: Advanced / Industrial (Automotive)
Target Audience:
- Production technical staff involved in the operation, control, or coordination of the Quality Management System.
- Personnel involved in process management within the following departments: quality, process engineering, production, management.
- Personnel involved in internal system, process, or product audits.
- Entrepreneurs and Consultants.
- Employees interested in professional development in the automotive industry.
Learning Objectives
At the end of the training, participants will be able to:
- Understand the concepts of process location and variation.
- Learn techniques for constructing control charts based on the type of data.
- Understand process capability and methods for improvement through centering or variation reduction.
- Identify and understand where variations can originate within the measurement process.
- Understand the concepts of accuracy, precision, bias, linearity, stability, repeatability, or reproducibility.
- Acquire the skills to perform Gage R&R studies to determine the correctness of inspection decisions, using the MSA technique for both continuous and attribute data.
- Understand what an FMEA risk analysis is.
- Identify potential failure modes and then the causes that led to their occurrence.
- Evaluate severity, occurrence, and detection, as well as Action Priority, to decide on the development of prevention and/or detection actions.
- Be able to complete a PFMEA together with the team.
- Understand what APQP is.
- Understand the link between APQP and process improvement.
- Understand the APQP steps, including their inputs and outputs.
- Understand what checklists are and what they are used for.
- Identify and understand PPAP requirements in accordance with IATF 16949.
- Understand the relationships between PPAP documents and how approval documentation must be constructed.
- Understand what a Control Plan is and why it is developed.
- Identify the types of Control Plans and the inputs used to complete them.
- Be able to complete a Control Plan together with the team.
Course Structure
Module 1 (Days 1 and 2)
- Statistical Process Control (SPC): Introduction to SPC; Basic statistical concepts; Introduction to MINITAB; Control charts (continuous and discrete data); Process capability analysis; Using MINITAB for control charts and capability studies.
- Measurement System Analysis (MSA): Introduction to MSA; Understanding basic concepts: Discrimination, Accuracy versus Precision, Bias, Linearity, Stability, Repeatability, Reproducibility, Gage R&R; Performing and interpreting MSA for continuous data; Performing and interpreting MSA for attribute data (graphical and analytical interpretation); Using MINITAB for Gage R&R studies.
Module 2 (Days 3 and 4)
- Failure Mode and Effects Analysis (FMEA): Introduction to FMEA; Types of FMEA; The 7-step FMEA methodology from a practical perspective: Planning and Preparation, Structure Analysis, Functional Analysis, Failure Analysis, Risk Analysis, Optimization, Documentation of results.
- Advanced Product Quality Planning & Control Plan (APQP & CP): Introduction to APQP; Product quality planning phases; Control Plan.
- Production Part Approval Process (PPAP): Introduction to PPAP; PPAP requirements; PPAP levels; Documentation and its preparation.
Organizational Benefits
- Efficiency and Cost Reduction: Process optimization and waste reduction.
- Defect Prevention: Identifying risks before they become critical problems.
- Compliance: Adhering to rigorous automotive industry standards.
- Customer Confidence: Demonstrated capability to deliver reliable and high-quality products.
- Competitive Advantage: Superior capabilities compared to competitors through the use of globally standardized tools.
The course will conclude with a multiple-choice examination, and participation statements or graduation certificates will be issued, as applicable.
Contact
Please contact us for further information or personalized offers.
- 📧 Email: george@sanconsulting.ro
- 📞 Phone: +40 723093515
- 🌐 Web: sanconsulting.ro/contact