Four-day course
This workshop will provide participants with fundamental knowledge and hands-on practice with the Advanced Product Quality Planning (APQP) process and key tools of failure mode and effects analysis (FMEA), control plans, and error proofing. The program is designed for all levels of design and manufacturing personnel as well as experienced engineering and management personnel, especially those involved in developing new products or processes. Why all four topics together? APQP, FMEAs, Control Plans, and Error Proofing are all interrelated and build on each other. Training that focuses only on one of these subjects at a time cannot show how these tools work together to minimize effort, improve quality, and complete programs more quickly with less headaches before, during, and after launch. Participants will apply these key tools together to bring a product from concept to production during this comprehensive, start-to-finish workshop.
This course is designed for individuals with minimal experience with the APQP process and its related key tools. However, many experienced individuals attend the course to refresh their knowledge, gain advanced strategies, and practice development and application of these tools with an experienced facilitator. Program managers, design-responsible engineers or managers, potential APQP or FMEA team members such as operators and technicians, quality personnel, and other product design and manufacturing personnel who are interested in continuous improvement strategies will all benefit.
- APQP phases, milestones, and deliverables
- The relationship between APQP, PPAP, FMEAs, and Control Plans, and Error Proofing
- Step-by-step instructions for completing Design and Process FMEAs
- How to avoid some of the most common FMEA pitfalls
- How to use FMEAs and other inputs to complete Control Plans easily and quickly
- Error proofing and mistake proofing concepts, applications, and opportunities throughout the APQP process.
Advanced Product Quality Planning
- Pre-Assessment
- Product Quality Planning Responsibility Matrix
- Fundamentals of Product Quality Planning
- Product Quality Planning Timing Chart
- Plan and Define Program
- Voice of the customer
- Design goals
- Reliability and quality goals
- Product assurance plan
- Management support
- Product Design and Development
- Process Design and Development
- Product and Process Validation
- Feedback, Assessment and Corrective Action
Failure Mode and Effects Analysis
- Pre-assessment
- Instructor-lead development of a sample FMEA
- FMEA definition, questions, purpose, and benefits
- Types of FMEAs, their focus, and their relationship with QS-9000
- Timing of FMEA development and revisions
- FMEA team composition and data inputs
- Design FMEA Development
- Process FMEA Development
- FMEA Application Workshop
- FMEA Summary and Advanced Strategies
Control Plans
- Pre-Assessment
- What is a Control Plan?
- How is a Control Plan Developed?
- The Benefits of a Control Plan
- Control Plans and the Product Life Cycle
- Control Plan Inputs
- The Control Plan Team (Process Team)
- Process Flow and Characteristics
- Standardization and Continuous Improvement
Error Proofing and Workshop Summary
- Pre-assessment
- The philosophy of process-focused quality
- What is Error Proofing and Mistake Proofing?
- Everyday examples of Error Proofing
- Manufacturing examples of Error Proofing
- Purpose and Benefits of Error Proofing
- The Key Elements of Error Proofing
- Error Proofing Case Studies
- Error Proofing, QS-9000, and the APQP process
- Error Proofing Case Study Workshop
- Error Proofing Summary and Advanced Strategies