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:
(The above topics can be delivered as individual courses if required. The links above show the individual courses.)
DURATION OF COURSE
5 days (either as 5 consecutive days, or a delivery pattern to suit the client).
BUSINESS BENEFITS
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
WHO SHOULD ATTEND?
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
COURSE OBJECTIVES
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.
COURSE STRUCTURE
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)
The following shows Core Tools Methodology overview – This was recently presented as a webinar in collaboration with the Chartered Quality Institute (CQI).
