Automotive Core Tools are essential for an effective quality management system in the automotive industry. They include Advanced Product Quality Planning (APQP), Control Plan (CP), Production Part Approval Process (PPAP), Failure Modes and Effects Analysis (FMEA), Statistical Process Control (SPC) and Measurement System Analysis (MSA).
This training module provides a basic understanding on the concepts and applications of Automotive Core Tools, based on the latest version of AIAG reference manuals, which support the requirements of IATF 16949.
Objectives:
- Understand the basic concepts of Automotive Core Tools.
- Understand the applications of Automotive Core Tools in an organisation.
- Comprehend Automotive Core Tools in quality management system.
Learning Outcome:
Upon completion of the training, delegates will have the basic knowledge and/or skill on:
- Define and explain the fundamental principles and components of Automotive Core Tools.
- Demonstrate the practical implementation of Automotive Core Tools in organizational processes.
- Integrate Automotive Core Tools into a quality management system to enhance and maintain quality standards.
Course Outline:
Day 1 (APQP, PPAP, CP):
| Estimated Time | Agenda |
| 9:00 AM – 9:15 AM | Opening and Introduction |
| 9:15 AM – 10:30 AM | Advanced Product Quality Planning (APQP) ✓ Objective and Applicability ✓ Product Quality Planning Cycle ✓ 5 Phases of APQP |
| 10:30 AM – 10:45 AM | Morning Break |
| 10:15 AM – 10:35 AM | APQP Implementation ✓ Define Scope and Team ✓ Risk Management and Sourcing ✓ Inputs and Outputs of Phases ✓ Gated Management |
| 1:00 PM – 2:00 PM | Lunch |
| 2:00 PM – 3:30 PM | Production Part Approval Process (PPAP) ✓ PPAP Requirements ✓ Significant Production Run ✓ Submission and Record |
| 3:30 PM – 3:45 PM | Afternoon Break |
| 3:45 PM – 4:45 PM | Control Plan (CP) ✓ Control Plan Methodology ✓ Requirements and Guidelines ✓ Control Plan Development |
| 4:45 PM – 5:00 PM | Summary and Q&A |
Day 2 (FMEA):
| Estimated Time | Agenda |
| 9:00 AM – 9:15 AM | Opening and Introduction |
| 9:15 AM – 10:30 AM | Failure Mode and Effect Analysis (FMEA)
✓ Overview and History ✓ Scope and Benefits ✓ 7-Step Approach |
| 10:30 AM – 10:45 AM | Morning Break |
| 10:45 AM – 1:00 PM | System Analysis
✓ 5T Method and Process Flow Diagram ✓ 3-Tier Structure ✓ Product and Process Characteristics |
| 1:00 PM – 2:00 PM | Lunch |
| 2:00 PM – 3:30 PM | Failure Analysis and Risk Mitigation
✓ Failure Chain ✓ Prevention and Detection Control ✓ SOD Ratings and Action Priority ✓ Optimization |
| 3:30 PM – 3:45 PM | Afternoon Break |
| 3:45 PM – 4:45 PM | Risk Communication
✓ Results Documentation ✓ Linkages to Control Plan |
| 4:45 PM – 5:00 PM | Summary and Q&A |
Day 3 (SPC):
| Estimated Time | Agenda |
| 9:00 AM – 9:15 AM | Opening and Introduction |
| 9:15 AM – 10:30 AM | Statistical Process Control (SPC)
✓ Process Stability and Capability ✓ Common Cause and Special Cause Variation |
| 10:30 AM – 10:45 AM | Morning Break |
| 10:45 AM – 1:00 PM | Data Collection Strategy
✓ Types of Data ✓ Sampling Plan Variable Control Charts ✓ Within and Between Subgroup Variation ✓ Xbar-R, Xbar-S, I-MR Charts |
| 1:00 PM – 2:00 PM | Lunch |
| 2:00 PM – 3:30 PM | Attribute Control Charts
✓ Defective Unit and Defect ✓ P, np, u, c Charts Control Chart Analysis ✓ Zone Analysis ✓ Pattern Analysis |
| 3:30 PM – 3:45 PM | Afternoon Break |
| 3:45 PM – 4:45 PM | Process Capability Analysis
✓ Yield, Rejection Rate, Defect Per Unit ✓ Cp, Cpk, Pp, Ppk |
| 4:45 PM – 5:00 PM | Summary and Q&A |
Day 4 (MSA):
| Estimated Time | Agenda |
| 9:00 AM – 9:15 AM | Opening and Introduction |
| 9:15 AM – 10:30 AM | Measurement System Analysis (MSA)
✓ Measurement System ✓ Application and Requirements |
| 10:30 AM – 10:45 AM | Morning Break |
| 10:45 AM – 1:00 PM | Measurement System Variation and Studies
✓ Measurement System Variation ✓ Bias, Linearity, Stability ✓ Repeatability, Reproducibility Stability Study ✓ Control Chart Method ✓ Results Interpretation |
| 1:00 PM – 2:00 PM | Lunch |
| 2:00 PM – 3:30 PM | Bias and Linearity Study
✓ Regression Method ✓ Results Interpretation |
| 3:30 PM – 3:45 PM | Afternoon Break |
| 3:45 PM – 4:45 PM | GR&R Study
✓ Variable GR&R Study – Average and Range Method ✓ Attribute GR&R Study – Agreement Method ✓ Results Interpretation |
| 4:45 PM – 5:00 PM | Summary and Q&A |
Who Should Attend This Course?
Those who need to be equipped with a practical understanding of the automotive core tools, especially those involved in its implementation, including:
- Managers
- Engineers
- Executives
- Supervisors
Pre-Requisites:
- It is recommended that delegates have prior knowledge on automotive core tool.
Duration:
- This is a four-day (4) course from 0900-1700 (Face to face or Remote Online Training is available upon arrangement).
Training With Sincera Means:
- Delegates will be trained by experienced tutors who are passionate to share their knowledge.
- Reliable and trusted experts with years of hands-on experience to enhance delegates’ learning curve.
Find Out More With Us:
If want to learn more, please contact us for following training courses:
- Quality Management Systems (ISO 9001) Interpretation
- Quality Management Systems (ISO 9001) Internal Auditor
- Exemplar Global Recognized Quality Management Systems (ISO 9001) Lead Auditor
- Kaizen
- Cost of Poor Quality
