Module 1. Statistical Process Control (AIAG & VDA SPC · 1st Edition)

• Process variation: common/special causes and stability conditions.

• Statistical fundamentals, data distribution, and non-normal data handling.

• Machine performance, preliminary process performance, and ongoing capability.

• Pp/Ppk and Cp/Cpk indices: differences, application, and interpretation.

• Control chart selection for variables and attributes based on monitoring goals.

• Rational subgrouping, sampling frequency, and SPC strategy sensitivity.

• Time-dependent processes, OCAP (Out-of-Control Action Plan), and process logs for reaction and improvement.

Module 2. Measurement Systems Analysis (MSA · 4th Edition)

• Measurement system, sources of variation, and resolution/discrimination.

• Study planning and selection of process-representative parts.

• Stability, bias, and linearity.

• Variable Gage R&R: X̄-R method, ANOVA, and number of distinct categories (ndc).

• Attribute systems: agreement, false acceptances/rejections, and Kappa when applicable.

• Non-replicable systems and destructive testing: alternative designs and nested studies.

• Measurement system improvement and integration with MSA–Control Plan–SPC–PPAP.

• Criteria for repeating studies upon process changes, repairs, relocation, or performance issues.

Module 3. PFMEA – Process Failure Mode and Effects Analysis (AIAG & VDA FMEA · 1st Ed., 2nd Printing)

A. Fundamentals and evolution versus AIAG FMEA 4th Edition; Action Priority (AP) versus traditional RPN usage.

B. Step 1 – Planning and Preparation: 5Ts, scope, cross-functional team, Focus Element, CSR, and lessons learned.

C. Step 2 – Structure Analysis: Process Item, Process Step/Station, and Process Work Element.

D. Step 3 – Function Analysis: Functions, requirements, characteristics, and performance criteria.

E. Step 4 – Failure Analysis: Failure Effect (FE), Failure Mode (FM), Failure Cause (FC), and failure chains.

F. Step 5 – Risk Analysis: S-O-D, current controls, special characteristics, and Action Priority (AP).

G. Step 6 – Optimization: Actions, action owners, target dates, re-evaluation, and residual risk.

H. Step 7 – Results Documentation and Communication.

I. Integration: Flowchart → PFMEA → Special Characteristics → Control Plan and Work Instructions.

J. Foundation/Family FMEA, responsible reuse, changes, and updating as a living document.

Module 4. Production Part Approval Process (PPAP · 4th Edition, 2nd Printing)

A. Purpose of PPAP, relationship with IATF 16949, current Core Tools, and Customer Specific Requirements (CSR).

B. When PPAP is required: initial submission, customer notification, changes, and resubmission.

C. Significant production run: actual conditions, traceability, and evidence planning.

D. The 18 PPAP Requirements:

• 1–6: Design record, authorized changes, engineering approval, DFMEA, Flowchart, PFMEA.

• 7–12: Control Plan, MSA, dimensional results, material/performance test results, initial process studies, qualified laboratory documentation.

• 13–18: AAR (Appearance Approval Report), sample production parts, master sample, checking aids, CSR compliance, Part Submission Warrant (PSW).

  E. Submission Levels 1–5, PSW, approval status, and record/sample retention.

  F. Internal package review and consistency across Drawing/Spec ↔ FMEA ↔ Control Plan ↔ MSA/SPC ↔ PPAP.

Module 5. Advanced Product Quality Planning (APQP · 3rd Edition)

A. Evolution from APQP 2nd to 3rd Edition and formal separation of Control Plan into a standalone manual.

B. APQP program management: cross-functional team, scope, timing, milestones, and deliverables.

C. Gated Management, risk assessment/mitigation, sourcing, and program metrics.

D. Change management, part traceability, and lessons learned.

E. Phase 1 – Plan and Define Program: Voice of Customer, CSR, goals, and feasibility.

F. Phase 2 – Product Design and Development: DFMEA, DVP&R, special characteristics, and design validation.

G. Phase 3 – Process Design and Development: Process flow, PFMEA, MSA/SPC, equipment, capacity, and control strategy.

H. Phase 4 – Product and Process Validation: Production run, initial studies, and PPAP readiness.

I. Phase 5 – Feedback, Assessment, and Corrective Action: Launch performance, changes, and Core Tools updates.

J. Integration: APQP → FMEA → Control Plan → MSA/SPC → PPAP.

Module 6. Control Plan for Product and Process (Control Plan · 1st Edition)

A. Standalone manual fundamentals and relationship with APQP, PFMEA, PPAP, IATF 16949, and CSR.

B. Inputs: Process Flow Diagram, PFMEA, drawings/specs, special characteristics, MSA, SPC, and lessons learned.

C. Control Plan construction: Operation, characteristic, specification, measurement method, sample size/frequency, control method, and reaction plan.

D. Control Plan phases: Prototype, Pre-Launch, Production, and Safe Launch.

E. Control selection and reaction plans based on risk, stability, capability, and customer requirements.

F. Control Plan for highly automated manufacturing: Sensors, vision systems, interlocks, poka-yokes, and contingencies.

G. Digital management, version control, changes, approvals, and document updates.

H. Shop-floor verification of coherence: Flowchart → PFMEA → Control Plan → Work Instructions → Evidence.

Module 7. Practical Exercises and Assessment

A. Integrative Case Study: Customer requirements → APQP → PFMEA → Control Plan → MSA/SPC → PPAP; consistency review, gap analysis, and decision-making.