There are 3 different workshops with this series: Process Failure Modes Effects and Analysis, Advanced Product Quality Planning and Control Plan, and Production Part Approval Process.
Process Failure Modes Effects and Analysis (FMEA)
A process failure modes and effects analysis (FMEA) is a structured method for identifying potential problems throughout a manufacturing process. Using a simple manufactured part and documentation, participants work through a Process FMEA using Automotive Industry Action Group (AIAG) guidelines. Emphasis is placed on understanding the guidelines and FMEA form, maximizing organizational value, team determination of rankings, and linkage to other quality documents.
Advanced Product Quality Planning and Control Plan (APQP)
With APQP, the Automotive Industry Action Group (AIAG) provides a detailed description and a structured method to define and establish the steps needed to assure customer satisfaction with production parts. Discussion and activities covering this aspect of the workshop give participants a life cycle view of what activities should be planned and implemented during each of the five phases of product quality planning. Common tools to manage the APQP effort are also included.
Control Plans provide your customer a structured summary of the systems used to minimize variation of product and process characteristics. The methodology is covered in detail in the workshop. Your team will develop a control plan using a simple manufactured part and documentation.
Production Part Approval Process (PPAP)
A part approval process is a requirement of TS16949, and is requested by many customers. The intent is to provide the customer with assurance that the production parts will meet all requirements. This is provided as a package of documents which include the customer requirements; dimensional, material and functional test data; initial process and gage studies where needed; and product quality planning documents such as FMEAs and Control Plans. The Automotive Industry Action Group (AIAG)'s 4th Edition PPAP, plus some customer specific requirements, is covered in this workshop. You will assemble a PPAP, including all required elements, for a simple manufactured product. To enhance understanding, you will calculate process capability and complete a Gage R&R on a characteristic of our simple manufactured part.