Paper on some Core Tools Definitions. Authors: Geoff Vorley, John Dedman, help@qmt.co.uk 26 September 2023
Modern approaches to managing quality specifically in the automotive, aerospace, defence, medical and drug industries have undergone enormous change in recent years. Particularly with reference to Advanced Product Quality Planning (APQP), Production Part Approval Process (PPAP) and the associated Core Tools.
These approaches have achieved huge improvement in quality performance, one example being the demonstrably continued and continuous improvement in automotive reliability.
Below are detailed some definitions of these approaches and where to find further information (such as webinars and training schemes). The webinars (sponsored by the CQI) are a short (45 min) introductory video to each topic.
Core Tools Programme
The Core Tools comprise a best practice methodology and a series of key tools and techniques for introducing new products and processes into production. The Core Tools are defined as the five supplemental techniques and methods used within a variety of industry sectors including automotive, aerospace, defence, medical and pharmaceutical.
The Core Tools also support the requirements and expectations of quality management systems such as IATF 16949 and AS9100
Although the Core Tools can be utilised individually, they are most effective when applied in a coordinated way, within a defined process for new product introduction.
The Core Tools Programme comprises the following key topics:
• Advanced Product Quality Planning (APQP)
• Failure Mode and Effects Analysis (FMEA)
• Measurement Systems Analysis (MSA)
• Statistical Process Control (SPC)
• Production Part Approval Process (PPAP)
Each Core Tool is defined in greater detail below…
Further information:
Core Tools (Webinar) – QMT elearning (qmt-learning.co.uk)
Core Tools Programme [#036]
Advanced Product Quality Planning (APQP)
Advanced Product Quality Planning (APQP) is an established and recognised methodology for introducing new products and processes into production.
APQP is a project management approach that continually reinforces identification and mitigation of risks, monitors status of tasks and deliverables, and escalates issues to management as necessary.
The purpose of APQP is to assure that new products satisfy customer needs and wants. To accomplish this, necessary activities need to take place at the appropriate time within the product realisation process.
Further information:
Core Tools (Webinar) – QMT elearning (qmt-learning.co.uk)
APQP – Advanced Product Quality Planning [#060]
Failure Mode and Effects Analysis (FMEA)
Failure Mode and Effects Analysis (FMEA) is an established technique used to identify and mitigate risks associated with designs, manufacturing and assembly processes.
FMEA is applicable to a broad range of processes, including those which produce a raw material, an individual component, a sub-assembly, or a complete assembly.
The purpose of FMEA is to avoid costly process problems and product failures.
Further information:
Failure Mode Effects Analysis (Webinar) – QMT elearning (qmt-learning.co.uk)
Failure Mode & Effects Analysis (FMEA) [#057]
Introduction to Risk Management – FD103
Measurement Systems Analysis (MSA)
Measurement Systems Analysis (MSA) is used for the purpose of assessing the capability of inspection, measurement and test equipment systems for specific tasks.
Measurement data are used in a variety of ways, often for decision-making in respect of product conformity, and monitoring of process performance.
It is important that the measurement data is reliable, otherwise incorrect decisions could be made which could result, for example, in nonconforming products being shipped to a customer.
Further information:
IATF 16949 Quality Standard (Webinar) – QMT elearning (qmt-learning.co.uk)
Core Tools (Webinar) – QMT elearning (qmt-learning.co.uk)
Measurement Systems Analysis (MSA) [#053]
Statistical Process Control (SPC)
Statistical Process Control (SPC) is used for the purposes of process qualification, problem solving, process monitoring, and continual improvement.
SPC is applicable to a wide range of process situations, where data is used to understand and manage the performance of manufacturing and non-manufacturing processes.
Keys tools and techniques utilised for SPC include:
Control charts: To achieve a process performance which is in ‘statistical control’ (stable), and hence predictable.
Process capability: Process studies to achieve a process performance which conforms to the specification.
Further information:
Statistical Process Control (Webinar) – QMT elearning (qmt-learning.co.uk)
Statistical Process Control (SPC) [#050]
Production Part Approval Process (PPAP)
Production Part Approval Process (PPAP) is applied in manufacturing organisations, to approve initial parts manufactured, for eventual introduction into their future production runs.
PPAP defines requirements for this initial part manufacture approval (including production and bulk materials). The objective is to determine if all customer specifications and requirements are properly understood by the supplier. Also confirming that the process has the potential to produce product consistently and reliability to these requirements, under actual production ‘run-at-rate’ conditions.
Further information:
Core Tools (Webinar) – QMT elearning (qmt-learning.co.uk)
PPAP – Production Part Approval Process [#059]
Managing Supply Chains – PT206
IATF 16949 Quality Standard
IATF 16949 is a globally recognised quality standard used mainly in the automotive industry. The standard is supplemental to the ISO 9001 standard and contains additional requirements to meet the needs of the automotive industry such as Quality Planning, Failure Mode and Effects Analysis, Statistical Quality Control, Measurement Systems Analysis, and Production Part Approval.
Further information:
IATF 16949 Quality Standard (Webinar) – QMT elearning (qmt-learning.co.uk)
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