ATQT 1050 - Quality Standards & Core Tools

Credit Hours: 2.00

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.

• Communication: The graduate can communicate effectively for the intended purpose and audience.
• Critical Thinking: The graduate can make informed decisions after analyzing information or evidence related to the issue.
• Global Literacy: The graduate can analyze human behavior or experiences through cultural, social, political, or economic perspectives.
• Information Literacy: The graduate can responsibly use information gathered from a variety of formats in order to complete a task.
• Quantitative Reasoning: The graduate can apply quantitative methods or evidence to solve problems or make judgments.
• Scientific Literacy: The graduate can produce or interpret scientific information presented in a variety of formats.

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