Understanding Core Tools: (APQP/PPAP, DFMEA & DVP&R, PFMEA/Control Plan, SPC and MSA)

Understanding Core Tools: (APQP/PPAP, DFMEA & DVP&R, PFMEA/Control Plan, SPC and MSA)

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Course Duration: 5 Days - 8 Hours/day

Collectively, this five-day series of seminars are intended to provide a basic understanding of the Advanced Product Quality Planning (APQP) Core Tools and their use in New Product Development to ensure a successful launch and capable serial production. These Core Tools play a significant role in the planning, development, and launch of new products and processes.

These Core Tools include the following:

  • The five phases of APQP itself
  • Production Part Approval Process (PPAP)
  • Design Failure Modes and Effects Analysis (DFMEA) and Design Verification Plan & Report (DVP&R)
  • Process Failure Mode Effects Analysis (PFMEA) and Control Plans
  • Statistical Process Control (SPC)
  • Measurement Systems Analysis (MSA)

Learning Objectives

  • Understand the five phases of APQP for New Product Development and its relationship to program management and the knowledge and skills needed to participate in an APQP team
  • Understand the PPAP protocol, elements, deliverables and submission/approval process
  • Understand how to develop and use DFMEA and DVP&R to identify and address design risk during the product development process and in support of the manufacturing process development process
  • Understand how to achieve robust and comprehensive process control, process standardization and process improvement using Process Flow Diagrams, PFMEA and Process Control Plans
  • Understand the use of SPC to monitor and measure variation in manufacturing processes ad to identify and correct problem where they arise
  • Understand MSA and the statistical tests employed to determine measurement variation and measurement uncertainty for the effective management of measurement systems

  • APQP
  • Production Part Approval Process (PPAP)
  • DFMEA/DVP&R
  • Process Flow
  • Process FMEA
  • Control Plans
  • Work Instructions
  • SPC
  • MSA

This seminar is designed for Internal Auditors, Management Representatives, ISO 9001 and IATF 16949 Implementation Teams, and others who would like to develop judgment and decision-making in ISO 9001, IATF 16949 and to learn how to effectively audit the New Product Development activities.

Each participant will receive a seminar manual. All concepts will be introduced using examples. Group exercises will make use of an example product and process.

Participants should possess a working knowledge of, as well as some experience in ISO-based quality management systems, as well as a firm understanding of basic quality tools.

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