Quality Management & Training


The Core Tools comprise a best practice methodology and a series of key tools and techniques for introducing new products and processes into production.  The Core Tools are used within a variety of industry sectors including automotive, aerospace, defence, medical and pharmaceutical.

Many of the elements are required to support quality management systems, industry expectations, and customer-specific requirements.

Although the Core Tools can be utilised individually, they are most effective when applied in a coordinated way, within a defined process for new product introduction.

The Core Tools Programme comprises the following key topics:

Advanced Product Quality Planning (APQP)

Failure Mode and Effects Analysis (FMEA)

Measurement Systems Analysis (MSA)

Statistical Process Control (SPC)

Production Part Approval Process (PPAP)

(The above topics can be delivered as individual courses if required.  The links above show the individual courses.)


5 days (either as 5 consecutive days, or a delivery pattern to suit the client).


  • Provides a structured and coordinated approach to new product introduction
  • Promotes communication amongst those involved in the project, both internal and external to the organisation
  • Emphasises defect prevention: Risks and concerns identified and addressed before serial production begins
  • Enables new products and processes to be introduced in a timely manner
  • Supports a risk-based approach and the requirements of quality management systems
  • Supports supply chain management and development activities
  • Enables an organisation to demonstrate they will be able to consistently meet customer requirements during serial production
  • Assists an organisation to satisfy stakeholder needs and expectations
  • Provides a framework for continual improvement


The core tools methodology requires a multidisciplinary approach; hence this programme is intended for all personnel who are involved with the introduction of new products and processes, including:

  • Project and engineering managers
  • Design and development engineers
  • Project engineers
  • Manufacturing engineers
  • Quality engineers
  • Supplier development personnel
  • Internal quality auditors
  • Sales engineers
  • Other personnel who need to understand the principles and terminology in order to communicate effectively with customers and suppliers


The delegates should understand:

  • The background to, and benefits of APQP
  • A model for successfully introducing new products and processes
  • How a variety of key tools and techniques are positioned and used within this model
  • The importance of a multi-disciplinary team: How inputs from various organisational functions contribute to the APQP process
  • How to create and interpret an FMEA
  • How to create a control plan
  • How to carry out an MSA study
  • How to use SPC and carry out a Process Capability study
  • The requirements for a typical PPAP record and submission document
  • Typical product and process validation requirements prior to the start of serial production

On completion of the course, delegates will be a QM&T validated and certificated Core Tools practitioner.


Day 1:   Advanced Product Quality Planning (APQP)

  • Phase 1: Plan and Define Programme
  • Phase 2: Product Design and Development
  • Phase 3: Process Design and Development
  • Phase 4: Product and Process Validation
  • Phase 5: Feedback and Corrective Action Assessment
  • Control plan methodology

Day 2:   Failure Mode & Effects Analysis (FMEA)

  • Defining functions
  • Identifying Failure Modes, Effects and Severity
  • Special Characteristics
  • Causes and Occurrence
  • Process Controls and Detection
  • Interpretation of Ratings, Risk Prioritisation, Improvement Actions

Day 3:   Measurement Systems Analysis (MSA)

  • Types of measurement system errors
  • Measurement system discrimination
  • Gauge Repeatability & Reproducibility (GRR) study
  • Evaluating the results of a GRR study:
    • Graphical analysis
    • Indices for GRR
  • Attribute Agreement study using kappa

Day 4:   Statistical Process Control (SPC)

  • Sources of variation in a process
  • Basic statistics
  • Collection and analysis of data
  • Understanding process variation through data
  • Control charts for variables
  • Calculating control limits charts
  • Common and special causes of variation
  • Decision rules, and interpretation of control charts
  • Process performance and capability (Cp; Cpk, Pp, Ppk)

Day 5:   Production Part Approval Process (PPAP)

  • PPAP Process Requirements
  • Customer Notification and Submission Requirements
  • Submission to Customer – Levels of Evidence
  • Part Submission Status
  • Record Retention
  • Customer Specific Requirements
  • Core Tools exam



See Training Courses for price list and order form.

The following shows Core Tools Methodology overview – This was recently presented as a webinar in collaboration with the Chartered Quality Institute (CQI).