Core Tools (APQP, PPAP, FMEA, MSA, SPC and Problem Solving)

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mmtc.org

K. Seman

Advanced Product Quality Planning (APQP)

Production Part Approval Process (PPAP)
Failure Mode Effects Analysis (FMEA)
Measurement Systems Analysis (MSA)
Statistical Process Control (SPC) and
Root Cause Analysis and Reporting Methods
2-Day Risk Management using FMEA

MMTC trainers strive to stay on top of the latest versions of the

Core Tools and interpret the requirements for practical deployment.
Training sessions are offered in open enrollment format or on-site
for employees. Each attendee receives a copy of the latest reference
manual issued by AIAG. MMTC offers Core Tools training in APQP,
FMEA and PPAP combination, SPC, MSA, Root Cause Analysis and
Reporting Methods.

Core Tools: APQP, FMEA and PPAP (2-Day

Training) CEU Credits: 1.4

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Core Tools (APQP, PPAP, FMEA, MSA, SPC and Problem Solving)

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(Outline)
MMTC offers this combination class to train companies in the
planning, launch and validation of a new automotive product or
process. The course blends 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 our
injection molding process, 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. Content
includes:
TS 16949 requirements
Product design and development
Planning and defining the program
Validation of product and process
APQP team dynamics
Control plan methodology
Failure Mode Effects Analysis (FMEA) During day two of the
training, participants apply the latest version of FMEA to the plastic
parts to determine what can go wrong with the parts and the
process. Content includes:
What is FMEA; how does it fit into APQP
Robust design concepts (DFMEA)

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Core Tools (APQP, PPAP, FMEA, MSA, SPC and Problem Solving)

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Quality system requirements

Design and process FMEA objectives
Recommended FMEA process sequence
Production Part Approval Process (PPAP) 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. Content includes:
When is PPAP required (applicability)
Dimensional, material and test results
Process requirements
Floor layout (single process flow)
Offered on-site or in an open enrollment format the remaining Core
Tools are delivered in one day sessions.

Statistical Process Control (SPC) (1-day class)

CEU Credits: 0.7
(Outline)
Basic SPC is applied using the parts produced in the MMTC factory.
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
are 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.
Concepts of SPC detection vs. prevention

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Core Tools (APQP, PPAP, FMEA, MSA, SPC and Problem Solving)

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Basic fundamentals
Improving the process (attacking waste)
Gathering data and preparing charts
The 7 statistical tools
X bar and R charts (setting control limits)

Measurement System Analysis (MSA) (1-day

class) CEU Credits: 0.7
(Outline)
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 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

Problem Solving, Root Cause Analysis and

Reporting Methods (1-day class) CEU Credits:
0.7
(Outline)
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

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Core Tools (APQP, PPAP, FMEA, MSA, SPC and Problem Solving)

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these tools to identify, analyze and solve the issues and determine
root cause. Understanding is gained through practical hands-on
exercises using the tools listed below. Problems are introduced to
demonstrate the typical formats for reporting the findings, applying
solutions and corrections such as Global 8-D. Tools covered
include:
5-Whys
Brainstorming
Cause and effect
Process mapping and analysis
Scatter diagram

Risk Management Using FMEA (2-day class)

CEU Credits: 1.4
(Outline)
This training will orient participants to the steps of Risk
Management using the tool of Failure Mode Effects Analysis
(FMEA) to define, manage, and reduce risks. Processes also used in
this training include brainstorming, creating SIPOCs, and creating
Process Flowcharts to help in the understanding, and analasys of
the process. The training addresses each step of doing a FMEA,
with exercises designed to ensure maximum understanding of both
Design FMEA and Process FMEA. The first day of this program
includes training on tools used when doing an FMEA, how to do an
FMEA, and exercises to re-inforce understanding. Day two involves
having each company select a process to do a PFMEA on with
instructed guidance. The processes selected are taken through the
process taught, beginning with SIPOC and flowchart, sharing each
phase with the group. In this environment, each companys FMEA is
partially finished by the end of the second day.

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Core Tools (APQP, PPAP, FMEA, MSA, SPC and Problem Solving)

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An updated class listing can be found HERE.

For more information on MMTC's Core Tools program, contact

us at 888-414-6682 or via email at inquiry@mmtc.org.

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