Course # 1 - Advanced Product Quality Planning (APQP) & PPAP– A Project

Management Approach

The activity-based course will provide an understanding of the APQP tools and links
between process flow charts, Failure Mode and Effect Analysis (FMEA), control
plans and Production Part Approval Process (PPAP). The goal of this course is to
show why APQP deliverables are important and how to implement them for a
successful program launch. Participants will be able to construct a mock APQP using
their own products from Phase 1 through Phase 5, with the intensive group activities.

Objective
This course is designed to enable participants to:
 Define the purpose of APQP
 Describe the relationship between key APQP deliverables
 Demonstrate why each of the key APQP deliverables are important
 Identify APQP processes and phases and the corresponding milestones
 Identify examples of required input for each phase and the corresponding
outputs
 Identify appropriate activities for each phase of APQP
 Explain the relationship of APQP and TS16949 elements

Duration
1 day

Course Outline
 Introduction to Advanced Product Quality Planning
 Introduction to Macro-Level Innovation “Pipe-Line” and 5-Levels of
Innovation Strategies
 The need of 5 core tools in IATF16949
 5 Core Tools – APQP, PPAP, SPC, MSA, FMEA
 1st Core Tool – Advanced Product Quality Planning
o Why do we need APQP?
o Phases of APQP
o Inputs and outputs and their relationships
o How to drive a successful APQP
o Phase 1 – Planning
o Phase 2 – Product Design and Development
o Phase 3 – Process Design and Development
o Phase 4 – Product and Process Validation
o Phase 5 – Corrective Action, Feedback and Improvement
o Linking Phase 4 output to 2nd Tool – Production Parts Approval
Process (PPAP)
o What is PPAP and why it is important?
o When to do PPAP?
o What to be submitted for PPAP?
 Control Plan – Prototype, Pre-Launch and Mass Production and Safe Launch
 What to do and how to maintain the control plan

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  Effective Control Plan development for process control

Who Should Attend?

Managers, supervisors, team leaders, and other professionals involved in planning,
design, or implementation of a system, product, or manufacturing process and want to
improve their ability to lead a proactive change and improvement to their operatio

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Course # 2 - Failure Mode and Effects Analysis (FMEA) Workshop

Course Description
FMEA is a systemized group of activities intended to recognize and evaluate the
potential failure of a product/process and its effect, identify actions, which could
eliminate or reduce the chance of the potential failure occurring and document the
process. It is complementary to the process of defining what a design or process must
do to satisfy the customer. FMEA is also a proactive ‘before-the-event’ way of
eliminating and improve on the daily operations.

Who Should Attend?

Managers, supervisors, team leaders, and other professionals involved in planning,
design, or implementation of a system, product, or manufacturing process and want to
improve their ability to lead a proactive change and improvement to their operations.

Duration
1 day

Objectives / Benefit from attending the program

 Improves the quality, reliability and safety of the evaluated products /
processes
 Reduces product / process redevelopment timing and cost
 Documents and tracks actions taken to reduce risk
 Aids in the development of robust control plans
 Aids in the development of robust design verification plans
 Helps prioritize and focus on eliminating product and process concerns and/or
helps prevent problems from occurring
 Improve customer/consumer satisfaction through proactive approach

Course Outline
 Type of FMEAs
 The need of FMEA 4th edition requirements
 Management responsible and team work matrix
 How to conduct a design and a process FMEA – linkage of Design and
Process FMEA
 Planning of FMEA
 Conducting FMEA
 Follow up and action plan FMEA
 The impact of conducting the right FMEA – through the analysis of Severity,
Occurrence and Detection
 Alternative method in FMEA risk analysis (SOD, S, SO, RPN method
comparison)
 How to perform action plans to mitigate risks through FMEA

Learning Process
Case studies, small group practical exercises, small group discussion, facilitator
presentations, skill practices, application planning and walk-through simulations.

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Course # 3 - Measurement System Analysis (MSA)

Course Description
Measurement data are used more often and in more ways that ever before. We used
them to make conclusions of the overcome of the products and processes. But the
major question is that can our measurement data be trusted ?
Measurement System Analysis is designed to help engineers and quality professionals
assess, monitor, and reduce measurement system variation. Topics include
measurement system linearity, stability, repeatability and reproducibility (GR&R),
and the management and calibration of measurement instruments.

Who should attend?

This course is recommended for engineers, managers who need a fundamental
knowledge of gaging, gage repeatability, reproducibility and the techniques used to
determine gage R&R

Duration
1 day

Course Outline
 Introduction to MSA : What it is?
 Calibration and MSA : What is the difference?
 Single vs Multiple Opportunity measurement process
 Process Variation & Product Variation
 The essence of Measurement System Analysis:
o Bias, Repeatability, Reproducibility, Stability and Linearity
o What is a MSA?
o Comparing MSA with Calibration
o Conducting Gage Reproducbility and Repeatability
o Others MSA aspects to be considered
o Linearity
o Stability
o Bias
 Attribute MSA
 Measurement System Analysis and Troubleshooting

Learning Process
Case studies, small group practical exercises, small group discussion, facilitator
presentations, skill practices, application planning and walk-through simulations.

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Course # 4 - Statistical Process Control

Course Description
The course introduces participants to the concept if variation and shows how to apply
this concept for continuous improvement. This course offers applications of the SPC
techniques that are an integral part of the corporate-wide quality control
reproducibility and repeatability. Various techniques for process analysis are
reviewed, including process capability and performance studies. How to construct
attribute and variable control charts is also emphasized in this course. Participants
look at sample size, and frequency and control chart interpretation. Topics cover
interpreting and making decisions based on control charts. The integration of
continuous improvement concepts and strategies into process control is discussed
throughout the course

Who should attend?

This course is recommended for engineers, managers who need a fundamental
knowledge of controlling their processes using Statistical tools

Duration
1 day

Objectives
This course is designed to enable participants to:
 Understand Basic Statistical Concepts
 Identify Variable and Attribute Data
 Introduction to Control Charts with Control Limits vs. Specification Limits
 Interpret Control Charts
 Introduction to Measurement System evaluation
 Conduct Process Capability Studies
 Problem Solving and Continuous Quality Improvement
Course Outline
 When to use SPC?
 Attribute and Variable data charts
 How to perform a simple SPC – Control Chart – Variable and Attribute
 How to select the types of control chart – matrix analysis
 Development of Control Charts in SPC – understand the basic of control
charts test
 Understand Process Capability for Process analysis as per required in TS –
Calculating Cp, and Cpk (and also Pp and Ppk)
 Interpreting SPC results and histogram analysis
 Cpm Taguchi Capability Index for non-centred specification
 Understand normal and non normal distribution

Learning Process
 Case studies, small group practical exercises, small group discussion,
facilitator presentations, skill practices, application planning and walk-through
simulations.

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