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Core Tools for Quality

Core Tools for QualityStruggling with delayed product launches or product recalls due to quality issues?

Competition is becoming increasingly fierce, and many new product launches are delayed or compromised due to quality performance shortfalls. Issues like these create the need for a workforce proficient in the principles and practices of quality core tools.

Whether your company is launching a new product or has had quality issues in the past, The Michigan Manufacturing Technology Center-West (The Center) offers training on a variety of core tools that support the development of your employee's abilities to prevent these issues from happening and address them if they arise.

Facilitation is a combination of:

  • Conceptual learning: what the tool is and how to it's used
  • Experiential learning: using the tool in a real application on the shop floor

Available Training

Statistical Process Control (SPC)

Participants run a group of sequentially produced parts and then measure them to determine average, range, and sigma. Control limits are calculated using these same parts and additional samples and measured and plotted to determine where the process is going and why. Interpretations of results are part of this course as well as capability study exercises. Content includes:

  • Concepts of SPC detection vs. prevention
  • Improving the process (attacking waste)
  • The 7 statistical tools
  • Basic fundamentals
  • Gathering data and preparing charts
  • X bar and R charts (setting control limits)

Measurement System Analysis (MSA)

If measurements are used to guide decisions, then it follows logically that the more error there is in the measurements, the more error there will be in the decisions based on those measurements. The purpose of the Measurement System Analysis is to qualify a measurement system for use by quantifying its accuracy, precision, and stability. Content includes:

  • Over-correction/tampering
  • Understanding your measurement system
  • Basic concepts of gage analysis

Root Cause Analysis and Reporting Methods

Root cause analysis and problem-solving tools are presented and demonstrated in this session. Both internal (yield issues) and external (warranty, field failure, customer complaint) problems are introduced in the manner they are typically encountered. Teams use these tools to identify, analyze, and solve the issues and determine root cause. Understanding is gained through practical hands-on exercises using common measurement gauges. Problems are introduced to demonstrate the typical forms for reporting the findings and applying solutions and corrections such as Global 8-D and 7 step. Tools covered include:

  • 5-Whys
  • Cause and effect
  • Scatter diagram
  • Brainstorming
  • Process mapping and analysis

Core Tools: Advance Product Quality Planning and Control (APQA), Failure Mode and Effects Analysis (FMEA), and Production Part Approval Process (PPAP)

Companies participate in the planning, launch, and validation of a new automotive product of process. The course blends the three powerful tools to guide participants through all steps of the launch process. With an emphasis on contextual learning, attendees will use actual production parts in all phases of training.

Advanced Product Quality Planning (APQP) is applied to injection molding processes, which produces several different components that are assembled later. Participants use blueprint drawings for the parts as they learn project management skills in planning the sequence, selecting the gages, inspection points in the process, floor layout, and generating the control plan.

  • TS 16949 requirements
  • Planning and defining the program
  • APQP team dynamics

Failure Mode Effects Analysis (FMEA) Participants apply the latest version of FMEA to the plastic parts to determine “what can go wrong” with the parts and the process.

  • What is FMEA; how does it fit into APQP
  • Quality system requirements
  • Recommended FMEA process sequence
  • Robust design concepts (DFMEA)
  • Design & process FMEA objectives

Production Part Approval Process (PPAP) Design & process FMEA objectives as the PPAP process is introduced; it is applied to the parts produced. Actual measurements are taken and are used to complete the various test sheets of PPAP.

  • When is PPAP required (applicability)
  • Process requirements
  • Dimensional, material, & test results
  • Floor layout (single process flow)

To learn more about our quality and safety management tools, please contact us.