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Production Part Approval Process (PPAP)

_____________________________________________________________
Days: 1
Prerequisites:

Knowledge of FMEA, Process Flow, Control Plan, MSA,


Capability Studies, etc.

Course Outline:
1.0
2.0
3.0
4.0
5.0
6.0

General Submission of PPAP


PPAP Requirements
Customer Notification and Submission Requirements
Submission to Customer Level of Evidence
Part Submission Status
Record Retention

In this course the participants will learn the PPAP process and how to apply
the voice of the customer (needs/wants/expectations). This course will give
the participant a general understanding of the Production Part Approval
Process with emphasis on customer satisfaction. This course is designed to
show the participant how to build a PPAP and submit it to the customer
based off of facts and data.

Statistical Process Control (SPC)


_____________________________________________________________
Days: 2
Prerequisites:

Knowledge of Shop Math, Algebra

Course Outline:
Variation and Probability
Measurement and Distribution
The Normal Curve
Quality
Control Charts
Control Chart Types
Interpretation of Control Chart Signals
In this course the participants will learn the following topics: range,
averages, standard deviation, variance, Cp, Cpk, Pp, Ppk, upper/lower
control limits (calculations), upper/lower specification limits,
controllable/non-controllable variables, special cause variation, common
cause variation, how to read a control chart, how to understand what the
chart is telling us, when to make a change, etc.

Accountability
_____________________________________________________________
Hours:
4
Prerequisites:

None

Course Outline:
The Victim Loop
Taking Charge of Your Life
Recognize Your Current Reality
The Power of Owning Your Part
The Gift of Forgiveness
The Art of Self-Examination
Be a Master Learner
Take Action
The Gift of Accountability
The object of this course is to teach the participants how to step out of the
victim loop and take accountability / responsibility for their actions,
comments, intentions and thoughts. This course will help the participant
recognize when they are in the victim loop and how to take charge and be
accountable.

Advanced Product Quality Planning (APQP)


_____________________________________________________________
Days: 2
Prerequisites:

Knowledge of FMEA, Process Flow, Control Plan, MSA,


and Project Management

Course Outline:
1.0

Plan and Define Program


This section covers the following topics: Voice of the Customer,
Business Planning, Benchmarking, Reliability Studies, Bill of
Materials, Process Flow, Special Characteristics, Product Assurance,
and Management Support

2.0

Product Design and Development


This section covers the following topics: Design Failure Mode and
Effects Analysis, Design for Manufacturability & Assembly, Design
Verification, Design Review, Prototype, Engineering Drawing,
Engineering Specifications, Engineering Change, New Equipment,
Special Characteristics, Team Feasibility, and Management Support

3.0

Process Design and Development


This section covers the following topics: Packaging, Product/Process
Quality System, Process Flow Diagram, Floor Plan Layout,
Characteristics Matrix, Process Failure Mode and Effects Analysis,
Process Instructions, Measurement System Analysis Plan, Process
Capability Study Plan, and Management Support

4.0

Product and Process Validation


This section covers the following topics: Production Trial Run,
Measurement System Analysis, Preliminary Process Capability
Studies, Production Part Approval, Production Control Plan, Quality
Planning Sign-Off and Management Support

5.0

Feedback, Assessment and Corrective Action

This section covers the following topics: Reduced Variation,


Customer Satisfaction, Delivery and Service
6.0

Control Plan Methodology


This section covers the following topics: Table of Contents,
Overview, Control Plan Column Descriptions, Process Analysis, and
Supplements

Failure Mode and Effects Analysis (FMEA)


_____________________________________________________________
Days: 1
Prerequisites:

None

Course Outline:
1.0
2.0
3.0

Design Failure Mode & Effects Analysis (DFMEA)


Process Failure Mode & Effects Analysis (PFMEA)
Follow-Up Actions

Other types of FMEAs: Machine, System, Product, etc.


In this course the participant will learn how to assemble a team, gather
information, prepare a FMEA (step by step), select the Severity, Occurrence,
and Detection levels, actions needed based off of the Risk Priority Number
(RPN or customer concerns), Corrective Action, and Follow-Up Actions.
Most important of allthe understanding that the FMEA is a living
document and it will continually change.

Getting Things Done When You Are Not In Charge


_____________________________________________________________
Hours:
4
Prerequisites:

None

Course Outline:
A Model For Getting Things Done
Why Is That Important?
Pursuing Your Aspirations
Discovering Dreams
What Is Really Happening?
Build Common Understanding
Face The Politics
Seek The Priorities
Who Makes A Difference?
Enlist Able Partners
Controlling Work Dynamics
Dealing With Decision Makers
How Might You Help?
Find The Courage To Risk
Making Your Work Rewarding
Create Change
Actions That Get Things Done
This course teaches the participant how to assess the situation, determine
what is important, build partners, deal with obstacles, prioritize, and take a
risk and how to make a change. Above all of thishave a PLAN OF
ACTION.

ISO9001:2000 Auditor
_____________________________________________________________
Days: 3
Prerequisites:

Experience in a Service, Manufacturing, Retail, etc.

Course Outline:
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0

Scope
Normative Reference
Terms and Definitions
Quality Management System
Management Responsibility
Resource Management
Production Realization
Measurement. Analysis and Improvement

In this course the participant will learn the ISO9001:2000 standard in its
entirety, how to process audit, understand compliance and non-compliance,
understand terms and definitions. The participants will learn the significant
impacts of the Quality Policy, Quality Objectives, Communication,
Training, Effectiveness, Monitoring/Measuring, Corrective / Preventive
Action, Management Review, etc.

ISO9001:2000 Lead Auditor


_____________________________________________________________
Days: 5
Prerequisites:

Experience in a Service, Manufacturing, Retail, etc.

Course Outline:
9.0 Scope
10.0
Normative Reference
11.0
Terms and Definitions
12.0
Quality Management System
13.0
Management Responsibility
14.0
Resource Management
15.0
Production Realization
16.0
Measurement. Analysis and Improvement
A.
B.
C.
D.
E.
F.

How to manage Internal Audit Team


How to setup an Internal Audit and Conduct Internal Audit
How to write-up findings and communicate
How to conduct an Opening Meeting
How to conduct a Closing Meeting
How to issue Corrective Action and Follow-Up Actions

In this course the participant will learn the ISO9001:2000 standard in its
entirety, how to process audit, understand compliance and non-compliance,
understand terms and definitions. The participants will learn the significant
impacts of the Quality Policy, Quality Objectives, Communication,
Training, Effectiveness, Monitoring/Measuring, Corrective / Preventive
Action, Management Review, etc.

ISO9001:2000 Self-Declaration (17050-1 & 17050-2)


_____________________________________________________________
Hours:
4
Prerequisites:

Experience in a Service, Manufacturing, Retail, etc.

Course Outline:
17.0
18.0
19.0
20.0
21.0
22.0
23.0
24.0

Scope
Normative Reference
Terms and Definitions
Quality Management System
Management Responsibility
Resource Management
Production Realization
Measurement. Analysis and Improvement

In this course the participant will learn the ISO9001:2000 self declaration
standards. This course will show the small business that if you can not
afford to be certified, you can be self certified and still meet the
requirements of ISO9001:2000.

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ISO/TS 16949:2002 Auditor


_____________________________________________________________
Days: 3
Prerequisites:

Experience in a Service, Manufacturing, Retail, etc.

Course Outline:
25.0
26.0
27.0
28.0
29.0
30.0
31.0
32.0

Scope
Normative Reference
Terms and Definitions
Quality Management System
Management Responsibility
Resource Management
Production Realization
Measurement. Analysis and Improvement

In this course the participant will learn the ISO/TS16949:2002 standard in its
entirety, how to process audit, understand compliance and non-compliance,
understand terms and definitions. The participants will learn the significant
impacts of the Quality Policy, Quality Objectives, Communication,
Training, Effectiveness, Monitoring/Measuring, Corrective / Preventive
Action, Management Review, etc.

11

ISO/TS 16949:2002 Lead Auditor


_____________________________________________________________
Days: 5
Prerequisites:

Experience in a Service, Manufacturing, Retail, etc.

Course Outline:
33.0
34.0
35.0
36.0
37.0
38.0
39.0
40.0
G.
H.
I.
J.
K.
L.

Scope
Normative Reference
Terms and Definitions
Quality Management System
Management Responsibility
Resource Management
Production Realization
Measurement. Analysis and Improvement
How to manage Internal Audit Team
How to setup an Internal Audit and Conduct Internal Audit
How to write-up findings and communicate
How to conduct an Opening Meeting
How to conduct a Closing Meeting
How to issue Corrective Action and Follow-Up Actions

In this course the participant will learn the ISO/TS16949:2002 standard in its
entirety, how to process audit, understand compliance and non-compliance,
understand terms and definitions. The participants will learn the significant
impacts of the Quality Policy, Quality Objectives, Communication,
Training, Effectiveness, Monitoring/Measuring, Corrective / Preventive
Action, Management Review, etc.

12

Measurement System Analysis (MSA)


_____________________________________________________________
Days: 2
Prerequisites:

Knowledge of Shop Math, Algebra

Course Outline:
Chapter 1
General Measurement Systems Guidelines
-Introduction, Purpose, and Terminology
Measurement Process
The effects of Measurement System Variability
Measurement Strategy and Planning
Measurement Source Development
Gage Source Selection Process
Measurement Issues
Measurement Uncertainty
Measurement Problem Analysis
Chapter 2
General Concepts for Assessing Measurement Systems
Selecting/Developing Test Procedure
Preparation fro a Measurement System Study
Analysis of the Results
Chapter 3
Test Procedure
Variable Measurement System Study
Range Method
Average and Range Method
Attribute Measurement System Study

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Chapter 4
Practices for Complex or Non-Replicable Measurement Systems
Stability Studies
Variability Studies
Chapter 5
Other Measurement Concepts
Recognizing the Effect of Excessive Within-Part Variation
Average and Range Method
Gage Performance Curve
Reducing Variation Through Multiple Readings
Pooled Standard Deviation Approach to GRR

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