by

Agata Lewkowska

WHAT DO YOU NEED TO KNOW

ABOUT

CORE TOOLS

IN

AUTOMOTIVE

by AIAG and VDA-QMC.

June 2022
 Hello!
Let me thank you for
downloading this e-book.

My name is Agata Lewkowska.

I am the founder of Qualitywise.pl.

For more than 15 years I have been working with "quality"

in organizations with a production profile in the automotive
supply chain.

Currently you can meet me in one of the activities I provide:

Trainings: ISO 9001 and IATF 16949, VDA 6.3, core tools,
auditing.
Consulting in the field of quality management in the
automotive industry.
1st and 2nd site audits for compliance with ISO 9001
and IATF 16949.
VDA 6.3 audits.
Rediness audits for ISO 9001 and IATF 16949
certification.
Quality management system maintanance.
Supplier evaluation / development.
Lectures in the discipline of management and quality
sciences

I hope this e-book will help you to gain mandatory basic

knowledge needed for understanding quality core tools
required by AIAG and VDA-QMC required in automotive
quality management systems.
Best regards,
Organizations in the automotive supply chain are required to certify their quality
management system for compliance with the requirements of IATF 16949. Of course,
you should be aware that the standard itself is not the only requirement that should
be implemented in the organization. Next to it there are customer specific
requirements, the so-called CSR, and core tools - in fact also required by CSR.

Key quality methods - what is it all about?

Key Quality Methods are staple tools in the automotive industry that have existed
since the 1990s. They are the key elements of an effective quality management
system that meets the needs and expectations of customers.
Many automotive OEMs and their suppliers require IATF 16949 core tools. These
tools have also been successfully implemented in other industries such as aerospace
/ defense - AS 9100, medicine - ISO 13845, telecommunications - TL 9000 etc.
These include: Advanced Product Quality Planning and Control (APQP), Part Approval
Process (PPAP), Failure Mode and Effects Analysis (FMEA), Statistical Process Control
(SPC), and Measurement System Analysis (MSA).
I would like to point out straight away that the above-mentioned key quality methods
relate to the American approach. These are the so-called Blue books published by
AIAG.
But the American approach is not the only one! We also have a German approach.
And here we will talk about the key quality methods issued by VDA-QMC.

Let's move on to a brief description of each of the methods.

APQP - Advanced product quality planning

Advanced Product Quality Planning (APQP) is used for project

management to reduce the complexity of product quality planning for
customers and suppliers to meet performance, schedule and cost
requirements.

APQP determines the required input and output data at each stage of
the product development process in 5 phases:
• project planning,
• product design,
• process design,
• product and process validation,
• production and feedback.

In APQP there is also a chapter dedicated to the control plan. The control
plans summarize the identified process and product parameters
required to maintain process control and product compliance.

The manual describing this method has been functioning unchanged

since July 2008. Unfortunately, this translates into the current "state of
the art." e.g. in the field of cybersecurity, which we will not find in this
manual.
VDA Maturity Level Assurance for New Parts

for all parts, components and systems in the supply chain. It is a

comprehensive presentation of phases in a project called "maturity
levels". Within each level, we have an objective assessment of the
maturity of the product and the production process by the contractor
and the recipient of the action. Using a structured method, projects are
monitored, assessed, and improved.

The requirements of the VDA MLA manual describe the approach to

cooperation between the customer and suppliers in the supply chain.
The requirements are specified in the form of maturity levels from PD0
to PD7.

The absolute advantage of this method is risk classification and

communication in the supply chain between the interested parties, i.e.
the customer-supplier.
FMEA – Failure Mode and Effect Analysis

This manual is copyrighted by AIAG and VDA as a result of their

collaboration to combine the American and German approaches. 2019
release valid.

The new AIAG and VDA Handbook (FMEA) was developed by a global
team of OEM subject matter experts and Tier 1 suppliers. The Design /
Process / MSR FMEA is an analytical system and function analysis
methodology for both product and process. The manual does not define
the requirements, it only explains the steps, procedures, tools necessary
for the technical creation of an FMEA.

What are its most important elements?

• new 7-step approach to FMEA development,
• Significantly revised Severity, Occurrence and Detection (SOD) tables,
• new methodology for Action Priorities (AP) and Tables identifying Risk
priorities as High, Medium, Low
• resignation from RPN = risk priority number.

The most significant changes from the fourth edition of the AIAG FMEA
Handbook and the VDA Volume 4 are listed in Appendix F.
MSA - Measurement Systems Analysis

It includes data collection, analysis and providing reliable information.

Measurement Systems Analysis (MSA) is key to determining what
variation is present in the product and how much variation is due to the
measurement system. Placing controls and making improvements to
equipment and operators will reduce uncertainty (i.e. measurement
error) and increase confidence in making firm decisions about process
and product quality.
VDA 5 - Measurement and control processes, suitability, planning
and management

VDA 5 deals with the suitability of measurement and control processes.

The German approach is not only about monitoring and measuring
equipment, but about all necessary resources, from spatial conditions,
through appropriately trained personnel, appropriate control measures,
measuring equipment including software, to the necessary aids and
methods that have an impact on obtaining important and reliable
monitoring and measurement results. All this must correspond to the
purpose of the compliance of products and services, i.e. it must be
ensured that the customer is provided only with the guaranteed quality.

We can find here, among others:

• Harmonization strategies with the AIAG Core Tool MSA (4th edition),
• Recommendations for procurement of measurement systems (e.g.
terms of reference),
• Dealing with small tolerances,
• Procedure in the case of an insufficient sample size in tests of the
"measurement system" and "measurement process",
• Handling of small series in pre-series production and production
batches in development and production,
• Consideration and evaluation of the current suitability through stability
measurements,
• Methods of calculating the measurement uncertainty.
SPC - Statistical Process Control

Statistical process control (SPC) was first implemented by manufacturers

in the 1930s to monitor and analyze the process. The aim was to
determine if it is under control and to determine whether the variability
is due to a special cause (i.e. abnormal behavior) or a common cause
(inherent behavior caused by the system).

By identifying and eliminating sources of variation with special causes,

the process will have predictable performance and will be able to
determine the capability of the process as expressed by appropriate
indicators to meet the requirements.
VDA 4 - Quality Assurance In The Process Landscape. Sections 1-4.

In German approach, this method has been divided into:

Section 1: General Requirements

Method review, basic aids, development processes

Section 2: Risk Analysis

Failure Tree Analysis (FTA), Failure Modes and Effects Analysis (FMEA),
SWOT Analysis (Strengths - Weaknesses - Opportunities - Threats)

Section 3: Methods
Design for Manufacturing and Assembly Processes (DFMA), Digitally
Aided Design (DMU) Model, Experiment Design (DoE) - Test Method,
Manufacturing Feasibility Analysis, POKA YOKE, QFD Method, TRIZ,
Economical Process Design and Process Control, 8D Method , 5Why
method (5x why), selection of preventive quality management methods

Section 4: Process models

Six Sigma, designing for Six Sigma (DFSS), tolerating industrial processes
PPAP

The Production Part Approval (PPAP) process is designed to ensure that

the requirements have been met with objective evidence in order to
obtain approval for production and approval of significant changes /
modifications. Applying this process between customer and suppliers
with APQP reduces delays, non-conformities, and other issues during
part approval, and ensures that high-quality parts can be consistently
delivered on time and within cost constraints.
VDA 2, Securing the Quality of Supplies Production process and
product approval

VDA 2 "Supply Quality Assurance" describes the procedure for approving

the production process and the product. It constitutes an agreement on
the PPA procedure to emphasize the agreements between the
organization and the client regarding the scope, content and timing of
the PPA procedure. This method confirms the qualitative ability of the
processes under the conditions of serial production and the compliance
of the products with the use of appropriate documents, records and
samples.

By abolishing submission levels, individual customer expectations,

product variety and the large number of possible documents are taken
into account. The German approach defines six areas for which, as
agreed with the client, appropriate evidence should be prepared.
 At the end...

Hope this knowledge will be helpful for you to understand

what are core tools by AIAG and VDA-QMC.
Having this deep understanding now you will be able to understand
and apply this knowledge based on thorough quality warness.

I wish you a fruitfill journey through Quality!

And remember:
if you would need further support in your organization, I can help!

All content in this e-book is a private interpretation of publicaly available information.

Any convergence of the described situations with people, organizations, companies is
accidental. The content presented in this e-book does not represent the views of any
companies or institutions.
Let me invite you to my SOCIAL MEDIA!

And...

Facebook group:

ISO 9001 & IATF 16949

QualityWise Group

where you will have great opportunity to:

exchange your knowledge
share your experience
raise questions on quality issues.

I TUTOR.

YOU LEARN.

Visit www.qualitywise.pl for the complete details.

For inquiries or concerns regarding quality
management please e-mail:
agata.lewkowska@qualitywise.pl
or call: +48 603 880 578.