CAR and 5 Core Tools (Highlight Review)

CAR and 5 core tools
(Highlight Review)
PREPARED BY : LE THANH TUNG
DATE : JULY 1st , 2019
Training Objectives
www.thermtrol.com Your Partner in Thermal Protection & Wire Harness
 Internal audtiors: có kiến thức để thực hiện công

việc đánh giá và chứng minh năng lực đánh giá (khi
được phỏng vấn bởi tổ chức đánh giá bên thứ hai,
bên thứ ba)
 Nhân viên thực hiện công việc: hiểu các yêu cầu
để thực hiện đúng đáp ứng các yêu cầu
Contents
Năng lực chuyên gia đánh giá
HĐKP và báo cáo HĐKP
Một số thuật ngữ thống kê
5 core tools (Highlights)
Review and Open Discussion

Training Agenda
1:00PM – 4:30PM
Training Method
• Nghe diễn giải

• Thảo luận và phát biểu
• Chia sẽ kinh nghiệm
Training Evaluation Method
Phỏng vấn, hỏi đáp trực tiếp lại lớp học để đánh giá
mức độ hiểu biết cho từng chủ đề training
Reference Documents
 ISO 9001:2015 Quality Management Systems - Requirements

 IATF 16949:2016 Automotive Quality Management Standard
 IATF 16949:2016 – Sanctioned Interpretations (SI 14-15)
 ISO 9000:2015 Quality Management Systems – Fundamental
and Vocabulary
 ISO 19011:2013 Guidelines for auditing management
systems
 5 core tools (current AIAG Reference Manuals)
Năng lực chuyên gia đánh giá

Auditor competency
7.2.3 Internal auditor competency

Auditor competency
7.2.4 Second-party auditor competency

Hành động khắc phục và báo cáo

hành động khắc phục
Corrective action
Corrective action
Qui trình báo cáo sự không phù hợp và hành động

khắc phục (đánh giá nội bộ)
Corrective action
8D report
Một số thuật ngữ thống kê

Statistical Concepts
Terms of Statistics
 Mean (X bar)
 Median
 Mode
 Range (R)
Terms of Statistics
 Ex1: 13, 18, 13, 14, 13, 16, 14, 21, 13
Mean = ? Median = ? Mode = ? Range = ?

Mean = (13 + 18 + 13 + 14 + 13 + 16 + 14 + 21 + 13) ÷ 9 = 15
Median
13, 13, 13, 13, 14, 14, 16, 18, 21
Median = 14
Mode = 13 vì 13 lặp lại nhiều nhất, 4 lần
Range = Max - Min = 21 - 13 = 8
Terms of Statistics
 Ex2: 1, 2, 4, 7

Mean = (1 + 2 + 4 + 7) ÷ 4 = 14 ÷ 4 = 3.5
Median
1, 2, 4, 7
Median = (2 + 4) ÷ 2 = 6 ÷ 2 = 3
Mode = Không có Mode vì không có phần tử nào lặp lại
Range = Max - Min = 7 - 1 = 6
Terms of Statistics
 Ex3: 8, 9, 11, 10, 10, 11, 10, 11, 12, 13

Mean = (8 + 9 + …+ 12 + 13) ÷ 10 = 105 ÷ 10 = 10.5
Median
8, 9, 10, 10, 10, 11, 11, 11, 12, 13
Meadian = (10 + 11) ÷ 2 = 21 ÷ 2 = 10,5
Mode = 10 và 11 vì hai giá trị này đều lặp lại nhiều nhất, 3 lần
Range = Max - Min = 13 - 8 = 5
Terms of Statistics
 Deviation = distance between observations and
the mean (or average)
Observations Deviations
8
10 10 - 8.4 = 1.6
7
10 9 9 – 8.4 = 0.6
8 8 8 – 8.4 = -0.4
9 8 8 – 8.4 = -0.4
7 7 – 8.4 = -1.4
averages 8.4
Terms of Statistics
 Variance
Observations Deviations Squared Deviations

7
7 7 - 6.6 = 0.4 0.16 6
7 7 - 6.6 = 0.4 0.16 7
7 7 - 6.6 = 0.4 0.16 7
6
6 6 – 6.6 = -0.6 0.36
6 6 – 6.6 = -0.6 0.36
averages 6.6 0.0 0.24 Variance
Terms of Statistics
 Standard Deviation (Sigma) = square root of
variance
Observations Deviations Squared Deviations

7
7 7 - 6.6 = 0.4 0.16 6
7 7 - 6.6 = 0.4 0.16 7
7 7 - 6.6 = 0.4 0.16 7
6
6 6 – 6.6 = -0.6 0.36
6 6 – 6.6 = -0.6 0.36
averages 6.6 0.0 0.24 Variance
Standard Deviation = square root (0.24) = 0.48
Terms of Statistics
 Standard Distribution (Normal/Gauss Dis.)
 Bell-shaped Curve (symmetric)

 Mean = Median = Mode
Terms of Statistics
 Standard Distribution
Terms of Statistics
 Variable data (Continuous data ) = dimension,
weight, temperature,…
 Attribute data (Discrete data) = yes/no,

Passed/Failed, Go/No-Go,…
Variation
Variation exists in everything

Too much variation lead to rework, scrap, or
customer problem
A perfect process would be no variation. No that
process
Variation is reduced = Process output is improved
Common Causes and Special Causes

 Common causes (natural causes) refers to the
many sources of variations that consistently
acting on the process. If only common causes of
variation are present and do not change, the
output of the process is predictable.
 Special causes (assignable causes) refer to

any factors causing variation that only affect only
some of the process output.
Common Causes and Special Causes

Process Control and Process Capability

Two mistakes and Over-adjustment

 Mistake 1: Ascribe a variation to a special
causes, when in fact the causes belong to the
system (common causes).
 Mistake 2: Ascribe a variation to a system
(common causes), when in fact the cause was
special.
 Over-adjustment (tempering) is a common
example of mistake 1. Over-adjustment actually
increases variation by adding more variation
each time the process is changed
Type I & Type II error
 False alarm (Over reject) = Type I error

 Miss (Under reject) = Type II error
5 core tools
5 core tools
What are 5 core tools?

 SPC - Statistical Process Control
 MSA - Measurement System Analysis
 FMEA - Failure Mode and Effect Analysis
 APQP - Advanced Product Quality Planning
 PPAP - Production Part Approval Process

Statistical Process Control

(SPC)
Statistic Process Control (SPC)
What is SPC?
SPC = Statistical Process Control
SPC Second Edition, Issued July 2005

Developed by Work Group
Chrysler, Ford & Genneral Motors
collaborated with AIAG
Why do we need SPC?

 SPC = a prevention tool
Inspection = defect detection
SPC = detect process change

defect prevention
SPC Goal: detect, reduce & monitor variation

Control chart
Note: áp dụng u, c, cp, p chart khi số lượng lỗi đủ lớn (≥ 5)

Control chart
 Specification limits (Norminal, ULS, LSL)
 Control limits (CL, UCL, LCL)
 Sampling plans (Subgroup size, Subgroup
Frequency, Number of Subgroups,
Sampling Scheme)
Control chart
Control chart Formulas
Average and Range chart (Xbar R)

Defining “Out-of-Control” Signals

Process Capability and Performance
Pp, Ppk, Cp, Cpk

 Pp = Process Performance
 Ppk = Process Performance Index
 Cp = Process Capability
 Cpk = Process Capability Index
Pp, Ppk, Cp, Cpk

Norminal Spec = T (Target)
tolerance range
Mean
parts spread width
tolerance range
parts spread width

Process Capability Caculation

tolerance range
parts spread width
 part spread width > tolerance range → Cp < 1

 part spread width = tolerance range → Cp = 1
 part spread width = 3/4 tolerance range → Cp = 1.33
Pp, Ppk, Cp, Cpk

Pp, Ppk, Cp, Cpk

T
LSL Mean USL

Pp, Ppk, Cp, Cpk

Acceptance Criteria
Results Interpretation
Index > 1.67 Meets acceptance criteria
1.33≤ Index ≤ 1.67 May be acceptable
Index ≤ 1.33 Does not meet acceptance criteria
(Sourse: AIAG PPAP 4th Edition)

Measurement System Analysis

(MSA)
Measurement System Analysis (MSA)
What is MSA?
MSA = Measurement System Analysis
MSA Fourth Edition, Issued June 2010

Highlights
 True value, Reference value, Observed value
 Discrimination, readability, resolution
(rule of 10, ndc)
 Replicable and Non-Replicable Measurement
Systems
 Accuracy: Bias, Stability, Linearity
 Precision: Repeatability, Reproducibility, GRR
 Agreement: Kappa, Miss rate, False alarm rate
 Acceptance criteria for a measument system
Summary of Terms
Accuracy vs. Precision

Acceptance Criteria
Potential Failure Mode

and Effects Analysis(FMEA)
Failure Mode and Effects Analysis (FMEA)
What is FMEA?
FMEA = Failure Mode and Effect Analysis
FMEA Fourth Edition, Issued June 2008

Highlights
 DFMEA & PFMEA
 S, O, D, RPN
Risk Priority Number (RPN)

Severity x Occurrence x Detection= RPN
Highlights
Advanced Product Quality

Planning (APQP)
Advanced Product Quality Planning (APQP)
What is APQP?
APQP = Advanced Product Quality Planning
APQP Second Edition, Issued July 2008

Highlights
 Product quality planning timing (5 stages)
 Control plan
 Product-safety, special characteristics
Highlights
Highlights
Production Part Approval Process

(PPAP)
Production Part Approval Process (PPAP)
What is PPAP?
PPAP = Production Part Approval Process
PPAP Fourth Edition, Issued March 2006

What is PPAP?
• Provide evidences that all customer engineering
design record and specification requirements are
properly understood by the organization
• To demonstrate that the manufacturing process has

the potential to produce product that consistently
meets all requirements during an actual production
run
Highlights
 Submission level
 Part Submission Warrent
PPAP Submission Level Table

Requirement Level 1 Level 2 Level 3 Level 4 Level 5
1.Design Record R S S * R
2.Engineering Change Documents, if any R S S * R
3.Customer Engineering approval, if required R R S * R
4.Design FMEA R R S * R
5.Process Flow Diagrams R R S * R
6.Process FMEA R R S * R
7.Control Plan R R S * R
8.Measurement System Analysis studies R R S * R
9.Dimensional Results R S S * R
10.Material, Performance Test Results R S S * R
11.Initial Process Studies R R S * R
12.Qualified Laboratory Documentation R S S * R
13.Appearance Approval Report (AAR), if applicable S S S * R
14.Sample Product R S S * R
15.Master Sample R R R * R
16.Checking Aids R R R * R
17.Records of Compliance With Customer Specific Requirements R R S * R
18.Part Submission Warrant S S S S R
19.Bulk Material Checklist S S S S R
S = The organization shall submit to the customer and retain a copy of records or documentation items at appropriate
locations
R = The organization shall retain at appropriate locations and make available to the customer upon request
* = The organization shall retain at the appropriate location and submit to the customer upon request

CAR and 5 Core Tools (Highlight Review)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

CAR and 5 Core Tools (Highlight Review)

Uploaded by

Copyright:

Available Formats

CAR and 5 core tools

 Internal audtiors: có kiến thức để thực hiện công

Năng lực chuyên gia đánh giá

HĐKP và báo cáo HĐKP

Một số thuật ngữ thống kê

5 core tools (Highlights)

Review and Open Discussion

• Nghe diễn giải

 ISO 9001:2015 Quality Management Systems - Requirements

Năng lực chuyên gia đánh giá

7.2.3 Internal auditor competency

7.2.4 Second-party auditor competency

Hành động khắc phục và báo cáo

Qui trình báo cáo sự không phù hợp và hành động

Một số thuật ngữ thống kê

Mean = ? Median = ? Mode = ? Range = ?

Mean = ? Median = ? Mode = ? Range = ?

Mean = ? Median = ? Mode = ? Range = ?

Observations Deviations Squared Deviations

Observations Deviations Squared Deviations

 Bell-shaped Curve (symmetric)

 Attribute data (Discrete data) = yes/no,

Variation exists in everything

Common Causes and Special Causes

 Special causes (assignable causes) refer to

Common Causes and Special Causes

Process Control and Process Capability

Two mistakes and Over-adjustment

Type I & Type II error

 False alarm (Over reject) = Type I error

What are 5 core tools?

 MSA - Measurement System Analysis

 FMEA - Failure Mode and Effect Analysis

 APQP - Advanced Product Quality Planning

 PPAP - Production Part Approval Process

Statistical Process Control

SPC = Statistical Process Control

SPC Second Edition, Issued July 2005

Why do we need SPC?

Inspection = defect detection

SPC = detect process change

SPC Goal: detect, reduce & monitor variation

Note: áp dụng u, c, cp, p chart khi số lượng lỗi đủ lớn (≥ 5)

Control chart Formulas

Average and Range chart (Xbar R)

Defining “Out-of-Control” Signals

Pp, Ppk, Cp, Cpk

Pp, Ppk, Cp, Cpk

parts spread width

parts spread width

Process Capability Caculation

parts spread width

 part spread width > tolerance range → Cp < 1

Pp, Ppk, Cp, Cpk

Pp, Ppk, Cp, Cpk

LSL Mean USL

Pp, Ppk, Cp, Cpk

(Sourse: AIAG PPAP 4th Edition)

Measurement System Analysis

MSA = Measurement System Analysis

MSA Fourth Edition, Issued June 2010

Accuracy vs. Precision

Potential Failure Mode