IATF 16949 Core Tool Training Automotive & Manufacturing

IATF 16949 Core Tool is the framework for a strong Quality Management System. Apart from being a mandate requirement for automotive, manufacturing are now also acknowledging its importance. It plays a vital role in product launch and establishing built in quality. As organizations are coming together in the North America region, they are understanding the benefit of the Core tools application. The Automotive Core Tools — APQP, PPAP, FMEA, SPC, and MSA — is driving changes and high improvements. It embeds built in quality value in the roots of the organizations culture.

Without proper training and skillset, organizations can not achieve the intended results of the core tool. Poor core tool application leads to poor process controls, delay in product launch, high defect rate, increase 3^rd party cost and line stoppage at customer end. This further weakens the Quality Management System and jeopardizes the certification.

Kadmar Consultants just not provide a training— We empower individuals by providing the correct practical knowledge aligned with the organization’s scope.

Let’s discuss the IATF 16949 Core Tools and how you can integrate them in your Quality Management System to get maximum benefit out of it:

IATF 16949 Core Tool

Advanced Product Quality Planning (APQP)

APQP is a primarily tool that promotes built in quality. It assesses risks at each stage of product development from concept phase till product has delivered and performed as required. APQP has 5 phases:

Phase 1 -Phase 2

Planning Phase: In this phase you will gather information from the customer on product requirements and expectation such as drawing and spec, material requirement, special characteristic, GD&T and regulatory requirements. It is important to carryout preliminary feasibility study to answer all the questions; can we make the product? Can we meet the design? Do we have the resource, technology?

To have an answer for all these questions, the feasibility report needs to review technical capability. Review machine, tool and measurement capability. Is .001” tolerance achievable by our current tooling and machine? Do we have measurement equipment for tight tolerance? Review special processes needed (coating, welding, painting) and supplier feasibility. Can we support the volume? Review process capability and Takt Time and finally capital investment needed.

Product Design & Development: This phase helps us understand how to make the product effectively. The drawing and spec are finalized in this stage by validating all the GD&T, assembly, finish and material requirements are achievable and controls are defined for special characteristics. DFMEA, Prototype Control Plan, and preliminary tests are completed to validate design meets all functional, safety, and customer requirements.

Phase 3 -Phase 4

Process Design & Development: This phase revolves around defining, validating and documenting the correct process with controls in place based on the risks associated with it. This phase is directly linked to PPAP. Process Flow, Process FMEA, Production Control Plan, Inspection Test Plan, Work Instructions, SOPs, Process Capability, Packaging & Material Handling are the outcome of 3^rd phase.

Product and Process Validation: This phase is the final validation of product and process. It includes Production trial runs, PPAP submission, Final product testing.

Phase 5: Feedback, Assessment, and Corrective Action: Ongoing improvement and maintenance of product and process.

Production Part Approval Process (PPAP)

PPAP is a tool that provides the key requirements to the suppliers that are mandatory to fulfil to prove quality standard and quality product. There are 5 levels of PPAP. PPAP Level 1 includes Part Submission Warrant (PSW) submission to customer only. The 2nd Level involves PSW, Product Samples and Limited supporting documents to customer. Level 3 adds complete layer of supporting documents. The 4th Level is PSW with Specific customer requirements. Finally the last level is PSW, Product Samples, Complete document, and Customer witness at supplier.

Failure Mode and Effects Analysis (FMEA)

FMEA is a strategic proactive tool used to anticipate failure associated with each step of the process from start to finish. A great risk assessment tool that helps organization to mitigate risk and achieve operational excellence. This helps eliminate repeat issue, reduce process waste and scrap, help achieve On Time Delivery and builds the foundation for strong Quality Management System. FMEA helps evaluate the combined effect of severity, probability and current controls and guides through the next step of building robust system with built in quality.

Statistical Process Control (SPC)

SPC is quality control tool that helps to collect, analyze and monitor trend that aids in problem analysis and solution. This will help identify true root cause of the actual problem instead of the symptom that most of the organizations are globally facing. There is list of quality control tools included in SPC Control Charts, Process Capability, Histogram, Pareto Analysis, Scatter Diagram, Fishbone Diagram, Run Charts, Check Sheets, Process Flow Diagram, Scatter Diagram, Statistical tools.

Measurement System Analysis (MSA)

MSA determines the capability of the measurement system. It helps validate you have the correct tool and resource to verify your Quality Management System. Tools MSA includes are Gage R&R, Bias Study, Linearity Study, Stability Study, Resolution / Sensitivity Check, Attribute Agreement Analysis, Control Charts for Measurement Systems.

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Kadmar Consultants provides IATF 16949 Implementation for manufacturers and automotive organizations globally with regional support across Canada and the United States.

Author: Asma Rashid