Exegens® has a consistent experience in using “Automotive Core Tools” methodologies to support process improvement and implementation of quality management systems.

Automotive Core Tools Training

APQP (Advanced Product Quality Planning) and Control Plan: in house, 1 day

Through this APQP (Advanced Product Quality Planning) and Control Plan training, EXEGENS® offers participants an opportunity to understand the importance of the following elements: APQP language, formulating strategies consistent with APQP, evaluation of special features, especially how to make able and robust processes for special features in APQP.

All standards of Advanced Product Quality Planning provide structured methods for defining and establishing the necessary steps to ensure that the product meets the requirements of the customers. The Control Plans help products′ quality  being consistent with customer requirements and apriori standards. The Control Plans provide the  structural approach for design, selection and implementation of control methods for the added value in the whole system. A company that targets a high level of quality must use FMEA in the Advanced Quality Planning Processes and in the development of their control plans.

Summary of the training session:

  • Introduction in APQP and in Quality System working mode;
  • Fundamentals of Quality Planning;
  • Product Quality Planning Cycle: Deming’s cycle (P-D-C-A);
  • Presentation of the 5 APQP phases:
  1. Phase 1: Plan and Define (concept);
  2. Phase 2: Design and Development of the Product;
  3. Phase 3: Design and Development of the Process;
  4. Phase 4: Product and Process Validation;
  5. Phase 5: Feedback Assessments and Corrective Action;
  • APQP elements: FMEA positionning and goals, Control Plans, SPC, MSA and PPAP in APQP;
  • Control Plan: defining Control Plan; areas where improving Control and Reaction Plans;
  • Control Plan: important links to other documents; types of Control Plans; approaching common mistakes;
  • Control Plan: Control Plan in 26 steps – description of each step. Example;
  • Review. Conclusions. Free discussions.

Who should attend: quality engineers, maintenance engineers, industrial engineers, process engineers, department managers, operators.

FMEA (Failure Mode and Effect Analysis): in house, 2 days

Through this FMEA – Failure Mode and Effect Analysis training, EXEGENS® offers participants an opportunity to understand the importance of FMEA in making designs and capable and robust processes by increasing the effectiveness and the efficiency of their work. The main objective is to present P-FMEA and approaches to failures/ breakdowns in the system before starting the manufacturing process.

The main objective of this FMEA training is approaching ways in which a product or a process could “fail”. A “failure” of a product or a process is when this can not work as default. In the real life of the companies there are a multitude of “opportunities” for the system to “fail”.

FMEA is a group of activities designed to:
– Recognize and assess the potential “failure” of the products or processes and its effects;
– Identify actions that could eliminate or reduce potential “failure”;
– Document the processes.

Summary of the training session:

Day I

  1. What is FMEA? Origin. Purpose of FMEA. Connexions. FMEA Worksheet.  Types of FMEA. Advantages and disadvantages of FMEA. FMEA team. FMEA in 10 generic steps.
  2. Design FMEA (D-FMEA). Purpose of DFMEA (Boundary Diagram, Interface Matrix, P-diagram). D-FMEA Function. D-FMEA failure modes. Severity. Analysis of DFMEA failure causes. DFMEA Occurrence. DFMEA Control. Risk Priority Number (RPN).
  3. Process FMEA (P-FMEA). Process FMEA Form. Purpose of P-FMEA (MACRO & MICRO Process flow). Characteristic Matrix (connexion between D-FMEA and P-FMEA). P-FMEA Function (identifying process functions/ needs, examples). P-FMEA Failure modes (identify the failure modes, the list of effects).

Day II

  1. P-FMEA – continuing: Severity(Ranking table, classification, actions). Analysis of the P-FMEA failure modes (Root Cause Analysis Process, Ishikawa diagram, Why questions, Brainstorming, examples). P-FMEA Occurrence (how to identify, ranking table, classification, actions). P-FMEA Control (prevention/ detection, ranking tables, classification, actions).
  2. P-FMEA – continuing: Risk Priority Number (RPN) and identify actions to be taken. P-FMEA outputs. Case studies.
  3. Mistake Proofing – Poka Yoke.  Definition. Goal and connexion with P-FMEA. Poka Yoke phases and steps. Two practical examples (Poka Yoke detective; Poka Yoke prevention).
  4. Video Demonstrations: P-FMEA and Poka Yoke.
  5. Review. Conclusions. Free discussions.

Who should attend: quality engineers, maintenance engineers, industrial engineers, process engineers, department managers, operators.

SPC (Statistical Process Control): in house, 1 day

Through this SPC (Statistical Process Control) training, EXEGENS® offers the attendees the opportunity to understand the importance to interpret changes in process parameters behavior changes and needed reactions by using a suite of statistical methods, particularly the control charts.

Summary of the training session:

  1. What is SPC? The role of SPC.
  2. When using SPC?
  3. SPC Process. What are control charts?
  4. Raising histograms. Data analysis. Exercices;
  5. SPC for variables. Analysis of indicators for process capability. Exercices;
  6. SPC – features: average and standard deviation; median and amplitude; individual values ​​and mobile amplitude;
  7. SPC for attributes: general concepts; types of sheets; symbols; p Sheet; np Sheet – features; c Sheet – features; u Sheet – features;
  8. Review. Conclusions. Discussions.

Who should attend: quality engineers, maintenance engineers, industrial engineers, process engineers, department managers, operators.

MSA (Measurement Systems Analysis): in house, 4 hours

Through this MSA (Measurement Systems Analysis) training, EXEGENS® offers the attendees the possibility of understanding the following: the MSA language, the use of MSA studies to determine where processes require measurements for the evaluation of special features and especially for the development of measurements to ensure capable and robust processes for special features.

Summary of the training session:

  1. Quality Statistics Review;
  2. MSA fundamental concepts: Systematic error; Repeatability; Reproducibility; Stability; Linearity;
  3. Instruments for measurement and control;
  4. Datat measurement; Calculation;
  5. MSA Studies – The R&R study;
  6. MSA studies evaluation;
  7. Variations caused by devices;
  8. Repeatability and reproducibility studies – R&R, exercices.
  9. Review. Conclusions. Open discussions.

Who should attend: quality engineers, maintenance engineers, industrial engineers, process engineers, department managers, operators.

PPAP (Production Part Approval Process): in house, 3 hours

Through this PPAP (Production Part Approval Process) training, EXEGENS® offers the attendees the possibility of understanding the following: the PPAP role in achieving products complying with the requirements; the connections between process, product and customer requirements, the PPAP role in supporting processes to satisfy all customer requirements.

Summary of the training session:

  1. Purpose; Applicability; Approach; Requirements;
  2. PPAP process flow;
  3. Stages for PPAP accomplishing;
  4. PPAP Approval;
  5. Disclosure requirements;
  6. Delivery to the customer – record levels;
  7. Pieces prezentation statute;
  8. Keeping records;
  9. PPAP example from automotive industry;
  10. Review. Conclusions. Open discussions.

Who should attend: quality engineers, maintenance engineers, industrial engineers, process engineers, department managers, operators.

RCA (Root Cause Analysis)

All these standard trainings can be tailored upon request. All training sessions can be followed by additional workshops and/ or integrated consulting projects.

Contact us to learn more about how we can help your organization with our consulting and our open/in house training services.