Prakash Bajariya

Principal Consultant
+91 9727484006
adviceconsultancy011@gmail.com
www.adviceconsultancy.in
Address :
UL-47, First Floor, Shreemad Bhavan, Opp. Kanta Stree
Vikash Gruh,Dhebar Road, Rajkot-360 002.

Core Tools (APQP, PPAP, FMEA, SPC & MSA)

ADVICE CONSULTANCY often organize 5 days workshop on Core Tools
which comprises of
APQP, PPAP, FMEA, SPC and MSA. These quality core tools are building
blocks to effectively create and manage an organizations quality
management system.
This training program addresses in depth, 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 consistent with the
requirements of ISO/TS 16949 and the FMEA Manual as well as the basic
concepts of Statistical Process Control (SPC) and Measurement Systems
Analysis (MSA).
Course Objectives:
Provide a basic understanding of the core tools used in New Product
Development for effective auditing programs.
Provide a hands-on approach to APQP 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.
Focus on 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 FMEAs 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.
People will have a firm understanding of statistical tools required for
auditing an organizations knowledge and use of statistical methods.
How to conduct SPC & MSA?

Who Can Attend?

Management Representatives
Internal Auditors
Supervisors, Engineers and Managers, actively involved in Process
Design &Development Production
Executives involved in Quality & Quality Management System
activities.
Potential Internal Auditors
Course Highlights:
This program incorporates the changes in Measurement Systems
Analysis MSA AIAG Manual Fourth edition 2010
The training program will have blend of interactive and learning
based sessions coupled with value addition.
The training will provide the participants a forum to freely interact
with Advice Consultancy having excellent competency in APQP, PPAP,
Control Plan & FMEA, SPC and MSA.
The faculty is equipped with efficiency in Core Tools and teaches the
peoples, logic and sense of auditing by protecting their objectivity,
being independent & impartial to audit.

Course Contents:
Production Part Approval Process (PPAP)

Day 01

Purpose
ISO/TS requirements
Example process flow chart for PPAP
Comparison of PPAP with traditional approach
Significant production run
Requirements for part approval
Situations when PPAP validation, customer notification & Submission
required.
PPAP submission levels

Advanced Product Quality Planning (APQP)

Product Quality Planning Cycle

Fundamentals of Product Quality Planning
Control Plan
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

Failure Mode and Effective Analysis (FMEA)

Day 03

FMEA Concept for understanding

FMEA definitions
Advantages of FMEA
Process FMEA
Design FMEA
FMEA requirement in ISO/TS 16949:2009
How to Develop a FMEA?
Understanding of Severity, Occurrence & Detection Rankings
Risk Priority Number (RPN)
Guideline on recommended actions

Statistical Process Control (SPC)

Day 02

Day 04

Basic Definitions
Process Control
Common & Special Cause
Process Control & Process Capability
Process Improvement Cycle
Effective use & benefit of control chart
SPC Requirement in ISO/TS 16949
Control Chart Basics
Elements and mechanics of control charts
Variable control charts, Attribute control charts
Process Capability Study
3

Measurement System Analysis (MSA)

Day 05

Basic concepts & definitions

MSA Requirement in ISO/TS 16949:2009
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

PPAP 18 Documentation
REQUIREMENTS FOR PART APPROVAL
1. Design Record
2. Engineering Change Documents, if any
3. Customer Engineering Approval, if required
4. Design FMEA
5. Process Flow Diagrams.
6. Process FMEA
7. Control Plan.
8. Measurement System Analysis Studies.
9. Dimensional Result
10. Records of Material / Performance Test results
11. Initial Process Studies
12. Qualified Laboratory Documentation
13. Appearance Approval Report (AAR)
14. Sample Production Parts
15. Master Sample
16. Checking Aids.
17. Customer-Specification Requirements
18. Part Submission Warrant (PSW)