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Core Tools Audit Course

Fault Detection Techniques in Core Tools

Catalog Area: Quality

Duration: 16 Hrs.

Modality: online and Face-to-face modality

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OBJECTIVE:

Validate through audit techniques that Core Tools are effectively developed, implemented, maintained, and integrated, identifying gaps, inconsistencies, and risks in compliance with current AIAG / AIAG & VDA editions, IATF 16949:2016, and Customer Specific Requirements (CSR). Updated to current 2026 editions.

BASIC COURSE INFORMATION:

ADDRESSED TO:

Leaders, managers, supervisors, and department heads; personnel responsible for Quality, Engineering, Production, APQP, Supplier Quality, internal/second-party auditors, and staff preparing for this level.

Competencies to Develop: Core Tools auditing, risk analysis, traceability, fault/inconsistency detection, and results orientation.

SYLLABUS

Module 1. Audit Techniques Applied to Current Core Tools:

A. Process Flow Diagram and Traceability: Actual sequence, interfaces, process changes, and document consistency.
B. APQP 3rd Edition: Program management, gate reviews, risks, metrics, change management, sourcing, and traceability.
C. AIAG & VDA FMEA: 7-step approach, S-O-D evaluation, Action Priority (AP), and DFMEA/PFMEA coherence.
D. Control Plan 1st Edition: Linkage to PFMEA, special characteristics, Safe Launch Plan, and reaction plans.
E. MSA 4th Edition: Measurement system adequacy, Variable/Attribute Gage R&R, and objective evidence.
F. AIAG & VDA SPC 1st Edition: Stability, performance/capability, chart selection, and response to out-of-control signals.
G. PPAP 4th Edition: 18 requirements, notification/resubmission triggers, PSW, and cross-package consistency.
H. Supporting Problem-Solving Techniques: 8D and 5 Whys applied to finding analysis, root cause, and corrective action verification.

Module 2. Integration with IATF 16949:2016, CSR, and Cross-Functional Auditing:

A. Core Tools alignment with IATF 16949:2016 and Customer Specific Requirements (CSR).
B. Horizontal Coherence Auditing: Flowchart → PFMEA → Control Plan → MSA/SPC → PPAP.
C. Objective Evidence: Document review, interviews, sampling, and shop-floor execution verification.
D. Typical Fault Detection: Obsolete documentation, inconsistent special characteristics, unimplemented controls, unrepresentative MSA/SPC studies, and incomplete PPAP packages.

BENEFITS

Timely detection of implementation inconsistencies and faults.
Strengthen traceability and objective evidence.
Reduce rejections and quality risks.
Improve readiness for internal, customer, and IATF 16949 system audits.
Prerequisites: Prior knowledge of Core Tools is required.
Technical references: IATF 16949:2016, APQP 3rd Edition, Control Plan 1st Edition, AIAG & VDA FMEA, MSA 4th Edition, AIAG & VDA SPC 1st Edition, PPAP 4th Edition, applicable CSR.