MODULE I STATISTICAL PROCESS CONTROL (AIAG SPC-2nd. ED.)
OBJECTIVE: to know the tools to carry out the selection, elaboration, interpretation and reaction to the behavior of a measurable variable or attributes of the product and the process.
- Type of process vs. application of a suitable statistical control tool to evaluate the stability of a process.
- Statistical control for continuous data.
- Variation, centering and stability of a process.
- Special causes and common causes of variation.
- Control limits vs. Specification limits.
- XR charts
- IMR charts
- Statistical control for discrete data (attributes).
- P charts
- C charts
- U charts
- Identification, analysis and interpretation of symptomatic trends of instability.
- PC Potential process capacity.
- Standard deviation between groups and total. Short term and long term.
- CPK Actual capacity or ability of the process. Short term.
- PPK Actual performance of the process. Long term.
- Off-centered processes vs. Processes with high variation.
- Calculation of probability of defect and PPMs.
MODULE II ANALYSIS OF THE MEASUREMENT SYSTEM (AIAG MSA-4th. ED.)
OBJECTIVE: To apply statistical techniques based on best practices, which allow to analyze, control and reduce the variation in the organization’s measurement systems, for the benefit of the client and the interested parties.
- Components of a measurement system and their variation.
- Statistical tests of hypotheses.
- Bias studies.
- Studies of Linearity and Stability.
- Appropriate resolution for a measuring instrument.
- The concepts of repeatability and reproducibility of a system.
- Repeatability and Reproducibility Studies (GRR) for measurement systems with continuous data.
- Attribute agreement studies for attribute measurement systems.
- Preparation and interpretation.
MODULE III ANALYSIS OF THE MODE AND EFFECT OF THE FAILURE (AIAG FMEA-4th. ED.)
OBJECTIVE: To train participants in the best practices to identify and manage the main non-quality risks in a production process of various kinds.
- General aspects of the FMEA.
- Multidisciplinary analysis teams.
- The detailed process flow diagram as main input.
- Process steps and key elements.
- Failure modes and effects (product).
- Causes (process) and failure chains.
- Analysis and application of AIAG tables of severity, occurrence and detection.
- Preventive (process) and corrective (product) controls.
- Improvement plans and projection of results.
- The FMEA as a living document.
- Review and exercises with the FMEA formats of the process.
MODULE IV PRODUCTION PARTS APPROVAL PROCESS (AIAG PPAP-4th. EDITION).
OBJECTIVE: To discuss and apply the established requirements for the production parts approval protocol (PPAP) know the content of the PPAP folder and the proper filling of its forms and records.
- Purpose, application and approach of the PPAP.
- GENERALITIES. Issuance of a PPAP.
- Significant production run.
- Requirements for the PPAP.
- Requirements for notification and issuance to customers.
- Issuance levels to customers.
- One-party Issuance Certificate (PSW).
- Status of issuance of parts.
- Retention of records and appendices.
- Exercises with the formats.
MODULE V ADVANCED PLANNING FOR PRODUCT QUALITY
(AIAG APQP-2nd. EDITION).
OBJECTIVE: To assimilate and apply the best practices for advanced planning for product quality and the methodology for the development of control plans, as a tool to ensure consistent compliance with customer requirements.
- Fundamentals of advanced product quality planning.
- Planning of the APQP Project (Times, quality, resources).
- Work team for each stage.
- The concept of manufacturability.
- Feasibility analysis.
- Product design and development.
- Process design and development.
- Product and process validation.
- Reaction, evaluation and corrective actions.
- Lessons learned from the APQP Project.
- Process control (6Ms) and product control in each step or station of the production process.
- Methodology and exercises of the control plans.
- Reaction plans.
MODULE VI PROCESS APPROACH AND RISK-BASED THINKING
OBJECTIVE: To update the knowledge of the participants in the principles and foundations of a cash management system, as the main element of management, planning and systematic assurance of all customer requirements. Mapping of the processes (Turtles) oriented to the client, in the support and in the managerial processes, as well as in the use of graphic indicators to monitor the objectives and goals of each process.
- Difference between non-conformities and continuous improvement.
- Corrective actions, preventive actions, and improvement actions.
- Principles of quality management.
- Mapping of the SIPOCs and Turtle processes.
- Structure of a process to ensure proper management.
- Procedures / Instructions / Formats and Records.
- Examples and exercises of the CPOs, SOPs and MOPs.
- The ISO 31000 2018 standard for risk management.
- Risk identification by process.
- Criteria to evaluate and prioritize risks.
- Risk analysis and evaluation.
- Treatment of priority risks.
- Indicators of Customer Satisfaction and operational performance.
MODULE VII KNOWLEDGE OF THE TECHNICAL SPECIFICATION, IATF 16949:2016
OBJECTIVE: Analysis and interpretation of the different regulatory requirements to implement an effective quality management system that ensures compliance with customer requirements and regulatory elements. In such a way that customer and stakeholder satisfaction objectives are met. To understand the relationship between the different requirements of the Standard and other manuals, standards, specific requirements, CQIs and other documents that make up an automotive quality management system.
- What is a Quality Management System.
- Principles of an effective System.
- Mandatory requirements.
- IATF Certification Rules.
- Context of the Organization.
- Support processes.
- Operation, planning and control.
- Performance evaluation.
- Exercises with Formats.
MODULE VIII ISO 19011:2018 AUDITS FOR QUALITY AND ENVIRONMENTAL SYSTEMS (ISO 19011 2018)
OBJECTIVE: The participant will know the audit process for the Environmental Quality Management Systems (EQMS), the competence of the auditors, as well as how to administer an internal audit system under the framework of guidelines and references indicated in the Standard, applying the process approach and the risk-based thinking.
- Introduction, terms and definitions of the ISO 19011:2018 Standard.
- Requirements of the ISO 19011:2018 Standard.
- Audits process and application to quality systems.
- Criteria for the qualification and competence of auditors.
- Audit principles.
- Audit Strategy.
- Audit programs management.
- Planning audits.
- Audit criteria.
- Evidence of non-conformities.
- Classification of non-conformities.
- Closure of non-conformities.
- Audit exercise to the quality and environmental system.