ATQT 1050 - Quality Standards & Core Tools

Objectives: Upon successful completion of this course, the student will be able to:

1. Identify the appropriate standard for each circumstance or business.
2. Identify the organization issuing the standard or guideline.
3. Implement and/or apply the standard or guideline
4. Explain the requirements, tools, skills, and metrics to document compliance to the standard or guideline.

Outcome 2: Upon successful completion of this course, the student will be able to apply the requirements of the standards to a manufacturing related situation.

Objectives: Upon successful completion of this course, the student will be able to:

1. Perform Advanced Product Quality Planning (APQP) activities.
2. Perform a DFMEA.
3. Perform a PFMEA.
4. Complete a Process Flow Diagram.
5. Complete a Control Plan.

Outcome 3: Upon successful completion of this course, the student will be able to perform the requirement of and document compliance to the standards.

Objectives:

1. Apply the required and appropriate statistical process controls to a manufacturing situation.
2. Recognize, define, and quantify measurement system variation.
3. Perform a capability analysis and recognize if a process is statistically capable.

Outcome 4: Upon successful completion of this course, the student will be able to describe the requirements of the Production Part Approval Process (PPAP).

Objectives:

1. Compile the required components of a PPAP package.
2. Construct a “balloon” part drawing.
3. Compile a Dimensional Inspection Report.

Outcome 5: Upon successful completion of this course, the student will be able to explain the relationship between the different requirements and how they relate to the Internal Auditing process.

Objectives:

1. Describe compliance to the Core Tools relating to “audit trail” during an internal audit.
2. Audit for compliance to the standards and to the Core Tool requirements.

1. Introduction to the ISO9001 and ISO16949 Standards
   • History
   • General Requirements of both Standards
   • Difference between ISO9001 and ISO16949 Standards
   • Customer-Specific Requirements
   • Registration Process
2. Introduction to the supporting Core Tools of the TS16949 Standard
   • Internal Auditor training requirement
   • Why Internal Auditors need to be familiar with the Core Tools / Audit Trails
3. Advanced Product Quality Planning (APQP)
   • Introduction / Benefits of APQP
   • Progression of the process: Process Flow Diagram, DFMEA, PFMEA, the Control Plan.
   • Quiz #1 covering ISO9001 and TS16949 Standard and APQP
4. DFMEA (Design Failure Mode Effects and Analysis)
   • How to construct and interpret
   • Severity / Occurrence / Detection Ranking
5. Process Flow Diagrams (PFD)
   • Introduction and how to construct
   • A team effort - involve multiple departments and stakeholders
   • How the information on the Process Flow Charts feeds the PFMEA
6. PFMEA (Process Failure Mode Effects and Analysis)
   • Introduction
   • How to construct and interpret
   • Severity / Occurrence / Detection Rankings
7. PFMEA Lab / Case Study
   • Quiz #2 covering DFMEA, PFMEA, and Process Flow Diagrams
8. Control Plans
   • Introduction and how to construct
   • Linkage to the PFMEA and Process Flow Diagram
   • Process step numbering / numbers should match on the Process Flow Diagram, PFMEA, and Control Plan.
9. Introduction to Statistical Process Control (SPC)
   • Chance vs. Assignable Causes
   • Attribute vs. Variable Data
   • Specification Limits vs. Control Limits
   • Attribute and Variable Control Charts
10. Statistical Process Control - Capability Analysis
    • Histograms
    • CP and Cpk Calculation and analysis
11. Measurement System Analysis
    • Introduction
    • Attribute and Variable Gage Repeatability and Reproducibility Studies
    • Interpretation and Analysis
    • How to improve if necessary
    • Quiz #3 covering SPC and MSA
12. Production Part Approval Process
    • Introduction
    • Nineteen required components
    • Drawing Ballooning, Dimensional Inspection Report
    • Putting together a PPAP package
13. Production Part Approval Process Lab
14. PPAP Package Class Review and Evaluation
    • Quiz #4 covering PPAP
15. Applying the knowledge of the Core Tools to be a successful Internal Auditor
16. Final Exam