Automotive Core Tools Fundamentals Webinar Dec 2, 2010
Automotive Core Tools
Fundamentals WebinarDec 2, 2010
2ASQ Automotive Division Ha Dao
Thank You for Joining
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About ASQ Automotive Division
Webinar Series
Automotive Core Tools
Questions & Answers
Agenda
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Session is being recorded
Session will last about 90 minutes
Participate thru polls, chat & questions
Will answer questions at the end• Last 10 minutes
• Please type your questions in panel box
• Go to www.asq-auto.org for presentation slides
Housekeeping Items
5ASQ Automotive Division Ha Dao
Ken Coll - Continental Automotive
Jennifer Schneider - Continental Automotive
Kevin Wu - ASQ China
Dick Shainin - Shainin LLC
Special Recognition
6ASQ Automotive Division Ha Dao
Ha Dao, ChairASQ Automotive Division
ASQ Fellow
MBB & Red X Master
15+ Yrs of Experience in
Automotive Industry
Troy, Ohio
About Me
Your Moderator
7ASQ Automotive Division Ha Dao
ASQ Automotive
Division is a Division
of ASQ, the Global
Voice for Quality.
ASQ Automotive Division
ASQ Automotive Division has more than
3200 members globally, who share a
common interest in the automotive
industry. Members include professionals
from almost every discipline in the
vehicle manufacturing and supplier
business in the automotive, heavy-truck,
off-highway, agricultural, industrial and
construction equipment industries.
8ASQ Automotive Division Ha Dao
ASQ Auto Webinars Series 2010-2011
The ASQ Automotive Division
is pleased to present a regular
series of webinars featuring
leading international experts,
practitioners, academics, and
consultants. The goal is to
provide a forum for the
continuing education
of automotive professionals.
The presentation slides are posted on our
website www.asq-auto.org. Recorded
webinars are also available for
viewing after the events. To register for a
webinar, see the listings at our website
www.asq-auto.org.
9ASQ Automotive Division Ha Dao
Call for Speakers & Volunteers
ASQ Automotive Division
is seeking volunteers for
leadership positions to
serve on the Division
Council.
ASQ Automotive Division
is seeking Topics and
Speakers for our
Webinar Series and for
our 2011 Symposium.
Contact Ha Dao, Chair
ASQ Automotive Division
10ASQ Automotive Division Webinar Series
Ken Coll, Quality Manager
Automotive Core Tools
Fundamentals Webinar
Continental Automotive
December 2, 2010
ASQ Automotive Division Webinar Series
7:00 pm – 8:30 pm EST
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ASQ Automotive Division Webinar Series
Speaker: Ken Coll, Quality Manager, Continental Automotive
Topic: Automotive Core Tools Fundamentals
Webinar Date: December 2, 2010 – 7:00 pm – 8:30 pm Eastern
Contact Info: 1 Continental Drive, Auburn Hills, MI 48326 [email protected] - 248-393-5868 www.asq-auto.org
Abstract: The six Automotive Core Tools (APQP, FMEA, Control Plan, PPAP, SPC, and MSA) are core requirements
for any supplier in the automotive industry. Proper use and application of the tools is essential to an effective quality system and satisfied customers.
This webinar gives an overview of the Core Tools, reviews the basic requirements and purposes of each, and looks at barriers to effectiveness.
Biography Ken Coll is a Quality Manager for Continental Automotive, and has over 35 years of experience in the
automotive industry as a Tier 1 supplier. His responsibilities include continual improvement, Lean Six Sigma, quality management systems, and quality auditor training and development in North America.
Ken has developed and taught a variety of quality and problem solving courses and has worked extensively with QS 9000 and TS16949 quality standards. His career has spanned production and corporate facilities, and he has worked as a production worker, material handler, inspector, quality systems auditor, and quality engineer.
He holds a B. A. degree in Management and Organizational Development from Spring Arbor University, an MBA from Northwood University, ASQ Quality Engineer Certification, is a Lean Six Sigma Black Belt, TS16949 lead auditor and is certified as a Master Trainer for TS16949 by Plexus International.
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Training Goals and Objectives
What This Training Will Do For You:
Provide an understanding of the basic requirements of each Core Tool
Review the purpose and intent of each Core Tool
Look at pitfalls (barriers to effectiveness) of each Core Tool
Help you improve customer satisfaction
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Automotive
Core
Tools
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Advanced Product Quality Planning (APQP)
Failure Mode and Effects Analysis (FMEA)
Control Plan
Production Part Approval Process (PPAP)
Statistical Process Control (SPC)
Measurement System Analysis (MSA)
Automotive Core Tools
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Automotive Core Tools
Examples: AIAG “Blue Book” Manuals
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Automotive Core Tools
Examples: Other Manuals
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APQP: 7.1 (Note)
FMEA: 7.3.3.1, 7.3.3.2
Control Plan: 7.5.1.1, Annex A
Product Approval Process (PPAP): 7.3.6.3
SPC: 8.1.2, 8.5.1.2
MSA: 7.6.1
Core Tools in ISO/TS 16949:2009
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APQP
Advanced Product Quality
Planning
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APQP
What is it?
Management of product development
Why do we use it?
To understand what our customer wants and
fulfill those wants
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CONCEPT
INITIATION/
APPROVAL
Feedback,
Assessment
& Corrective
Action
INPUTS
|
F, A & CA
OUTPUTS
Planning INPUTS
|Planning OUTPUTS
Product Design &
Dev. INPUTS|
Product
Design &Dev.
OUTPUTS
Process Design &
Dev. INPUTS|
Process Design
&Dev. OUTPUTS
Product &
Process
Validation
INPUTS
|
Product &
Process
Validation
OUTPUTS
PROGRAM
APPROVALPROTOTYPE PILOT LAUNCH
PLANNING
PRODUCTION
PLANNING
PRODUCT DESIGN AND DEV.
PROCESS DESIGN AND DEVELOPMENT
PRODUCT & PROCESS VALIDATION
FEEDBACK ASSESSMENT AND CORRECTIVE ACTION
ADVANCED PRODUCT QUALITY PLANNING
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APQP Plan and Define Phase
Inputs:
• Voice of the Customer
• Market Research (Including OEM Vehicle Timing and
Volume Expectations
• Historical Warranty and Quality Information
• Team Experience
• Business Plan/Marketing Strategy
• Product/Process Benchmark Data
• Product/Process Assumptions
• Product Reliability Studies
• Customer Inputs
Concept Initiation/Approval
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APQP Plan and Define Phase
Outputs:
• Design Goals
• Reliability and Quality Goals
• Preliminary Bill of Materials
• Preliminary Process Flow Chart
• Preliminary Listing of Special Product and Process
Characteristics
• Product Assurance Plan
• Management Support
Concept Initiation/Approval
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APQP Product Design and Development Phase
Design Outputs:
• Design Failure Mode and Effects
Analysis (DFMEA)
• Design for Manufacturability and
Assembly
• Design Verification
• Design Reviews
• Prototype Build -- Control Plan
• Engineering Drawings (Including
Math Data)
• Engineering Specifications
• Material Specifications
• Drawing and Specification
Changes
APQP Outputs:
• New Equipment, Tooling and
Facilities Requirements
• Special Product and Process
Characteristics
• Gages / Testing Equipment
Requirements
• Team Feasibility Commitment
& Management Support
Program Approval
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Outputs:
• Packaging Standards and Specifications
• Product/Process Quality System Review
• Process Flow Chart
• Floor Plan Layout
• Process Failure Mode and Effects Analysis (PFMEA)
• Characteristics Matrix
• Pre-Launch Control Plan
• Process Instructions
• Measurement System Analysis Plan
• Management Support
• Preliminary Process Capability Study Plan
APQP Process Design and Development Phase
Prototype
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Outputs:
• Significant Production Run
• Measurement Systems Evaluation
• Preliminary Process Capability Study
• Production Part Approval
• Production Validation Testing
• Packaging Evaluation
• Production Control Plan
• Quality Planning Sign-Off and Management Support
APQP Product and Process Validation Phase
Pilot
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Outputs:
• Reduced Variation
• Improved Customer Satisfaction
• Improved Delivery and Service
• Effective Use of Lessons Learned/Best Practice
APQP Feedback, Assessment and Corrective Action Phase
Launch
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Pitfalls
• APQP treated as a “Quality Department Responsibility”
• APQP a separate process, not integrated into product
development
• Key stakeholders brought in late (quality, production,
suppliers)
• Milestones and deliverables ignored
• No top management involvement/support
ADVANCED PRODUCT QUALITY PLANNING
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FMEA
Failure Mode and Effects
Analysis
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FMEA
What is it?
A risk analysis of a part or process
Why do we use it?
To find and fix a problem before
something breaks or someone gets hurt
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Design FMEA
Process FMEA
Types of FMEAs
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Others:
System FMEA
Concept FMEA
Environmental FMEA
Machinery FMEA
Software FMEA
Types of FMEAs
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FMEA Process
Subsystem C Potential O D
Potential Potential S l Cause(s)/ c e R. Recommended Responsibility Action Results
Failure Effect(s) of e a Mechanism(s) c t P. Action(s) & Target Actions S O D R.
Function Mode Failure v s of Failure u Prevention Detection e N. Completion Date Taken e c e P.
Requirements s r c v c t N.
Current
Controls
What are the
Functions, Features
or Requirements?
What can go
wrong?
–No function
– Partial / Over
/Degraded
Function
– Intermittent
Function
– Unintended
Function
What are
the Effects?
How bad
is it?
What are
the
Cause(s)?
What can be
done?
–Design
Changes
– Process
Changes
– Special
Controls
– Changes to
Standards,
Procedures, or
guides
How
often
does it
happen?
How good is
this method at
detecting it?
How can this be
prevented and
detected?
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Risk Action Strategies
1st Priority is Severity. Severity has a direct impact on the customer.
2nd Priority is Criticality (Severity times Occurrence: S x O). Criticality
evaluates the risk that an event with a high impact on the customer
will occur.
3rd Priority is RPN. RPN evaluates the ability to detect and contain
poor quality.
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Pitfalls
• FMEA started late in the development process (just in time
for PPAP!)
• FMEA never updated after release
• FMEA not updated from nonconformity corrective actions
• Right side (action area) is blank
• RPN thresholds
• FMEA written by one person
• FMEA treated as a “Quality Department Responsibility”
Failure Mode and Effects Analysis
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Control Plan
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Control Plan
What is it?
A summary of controls used to make sure my
customer gets good product
Why do we use it?
To make sure controls are used and stay in
place
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CONTROL PLAN
Control Plan Number Key Contact/Phone Date (Orig.) Date (Rev.)
Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)
Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.)
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
MACHINE,PART/ PROCESS NAME/ DEVICE, SPECIAL
PROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS EVALUATION/ SAMPLE REACTIONNUMBER DESCRIPTION FOR MFG. NO. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT SIZE FREQ. CONTROL PLAN
TOLERANCE TECHNIQUE METHOD
CHARACTERISTICS METHODS
Prototype Pre-Launch Production
Control Plan
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A.2 Elements of the control plan
The organization shall develop a control plan that includes, as a minimum, the following contents.
a) General data
⎯ control plan number,
⎯ issue date and revision date, if any,
⎯ customer information (see customer requirements),
⎯ organization's name/site designation,
⎯ part number(s),
⎯ part name/description,
⎯ engineering change level,
⎯ phase covered (prototype, pre-launch, production),
⎯ key contact,
⎯ part/process step number,
⎯ process name/operation description.
b) Product control
⎯ product-related special characteristics,
⎯ other characteristics for control (number, product or process),
⎯ specification/tolerance.
c) Process control
⎯ process parameters,
⎯ process-related special characteristics,
⎯ machines, jigs, fixtures, tools for manufacturing.
d) Methods
⎯ evaluation measurement technique,
⎯ error-proofing,
⎯ sample size and frequency,
⎯ control method.
e) Reaction plan and corrective actions
⎯ reaction plan (include or reference),
⎯ corrective action.
Control Plan Elements
TS 16949 Annex A
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Pitfalls
• Control plan and PFMEA not aligned
• Control plan and operator instructions not aligned
• Control plan out of date
• Control plan not updated from nonconformity corrective
actions
Control Plan
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PPAP
Production Part Approval
Process
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PPAPWhat is it?
Requirements for approval of production parts.
Why do we use it?
To make sure that I understand all my customer
requirements, and that I can meet them under
actual production conditions.
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PPAP
11 Initial Process Study
12 Qualified Laboratory Documentation
13 Appearance Approval Report
14 Sample Production Parts
15 Master Samples
16 Checking Aids
17 Customer-Specific Requirements (Records)
18 Part Submission Warrant
Bulk Material Requirements Checklist
1 Design Records
2 Authorized Engineering Change Documents
3 Customer Engineering Approval
4 Design FMEA
5 Process Flow Diagrams
6 Process FMEA
7 Control Plan
8 Measurement System Analysis Studies
9 Dimensional Results
10 Material / Performance Test Results
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Pitfalls
• PPAP is treated as a separate process, rather than integrated
into product development
• Incomplete PPAP
• Assuming that submission levels are what’s required, rather
than what’s submitted
Production Part Approval Process
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SPC
Statistical Process
Control
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SPCWhat is it?
A collection of statistical methods, especially
control charts, used to analyze and control a
process
Why do we use it?
To know when processes change and respond
accordingly
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Variation
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Mean = Average or
Distributions can vary in Location
X
Location (Center): 3 key measures
Median = Middle (by count)
Mode = Most often
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Distributions can vary in Spread
Spread: 3 key measures
Standard Deviation = or s
Variance =2
Range = R
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Distributions can vary in Shape
68.25%
95.46%
99.73%
X 2 323
Normal Distribution
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Control vs. Capability
If only common causes of variation are present, the output of a process forms a distribution that is stable over time and is predictable
If special causes of variation are present, the process output is not stable over time
Common and Special Causes
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In- Control
(Common Cause)
Out-of-Control
(Special Cause)
Acceptable Case 1 Case 3
Unacceptable Case 2 Case 4
Statistical Control
Variation
(Capability)
Control vs. Capability
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Cp, Cpk, Pp & Ppk
Cp / Pp: can the car
fit into the garage?
Cpk / Ppk: does the
car fit into the garage?
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Overall Variation
Within Subgroup Variation
if stable
Performance Ppk Cpk
Capability
If centeredPp Cp
Overall
Variation
Overall
Within
Subgroup
Variation
Within
Kenneth J Kortge
Measures of Process Capability
(Capability Index)
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Index 1.67 Acceptable
1.33 ≤ Index ≤ 1.67 May Be AcceptableMay require an improvement plan
Index 1.33 Not Acceptable
Capability Metrics – Acceptance Criteria
Typical:
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2 Types of Data
Variable
Attribute
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Variables Charts
Chart Type
X-Bar & R MedianIndividual & Moving
Range (MR)
Primary Usage
Routine monitoring of manufacturing processes
Usually used as a monitoring tool for product or processes
Used when only one sample is possible
What Is Charted
Plots the average size and the range of the part sizes
Plots the individual sizes of the parts and the median of the part sizes
Plots the sample size and the moving range of the sample size
Sample Subgroup Size
Usually 3 to 6Should be an odd number: 3, 5, 7, etc.
One
Typical:
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Attribute Charts
Chart Type P Chart nP Chart C Chart U Chart
Primary Usage
Used for analyzing proportion or percent nonconforming or defective parts
Used for analyzing the number nonconforming or defective parts
Used for analyzing nonconformities or defects
Used for analyzing nonconformities per unit
What is Charted
Plots the proportion or percent of the nonconforming units
Plots the number of nonconforming items
Plots the count of all nonconformities found in the sample
Plots the average number of nonconformities in each sample
Sample Subgroup Size
Variable Fixed Fixed Variable
Typical:
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RX & Chart
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UCLX
X
LCLX
How Control Charts Work
UCLX
X
LCLX
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Special Cause Criteria
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Special Cause Criteria
1. Most measurements cluster around the center (average) line
2. A few measurements approach the edges (control limits)
3. No measurements outside the control limits
4. Same number of measurements on both sides of the center
(mirror image)
5. Random (no patterns)
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Pitfalls
• Ignoring out of control conditions
• Comparing control limits to spec limits
• Making process adjustments without understanding the
source of the special cause variation
• Putting SPC charts on everything
Statistical Process Control
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MSA
Measurement Systems
Analysis
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MSAWhat is it?
A collection of statistical methods used to assess
how much I can trust the information from a
gauge
Why do we use it?
Since all my information about a part/process
comes from gauges, I need to know when the
gauge information is dependable, and do
something when it’s not
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Bias: difference between the measurement
and the "true" value
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Stability: change in bias over time
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Linearity: change in bias across expected range of
measurements
Note that unacceptable linearity can happen in a variety of ways.
Do not assume a constant bias.
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Variable, replicable measurements
Typical:
10 Parts
3 Appraisers
3 Trials
Gage Repeatability and Reproducibility = GRR = R&R
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2GRR =
2Reproducibility
+ 2Repeatability
GRR / R&R
% Total Variation vs. % Tolerance
Number of Distinct Categories (NDC)
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Repeatability
Appraiser A
Repeatability: gage-induced variation
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Reproducibility
Appraiser A C B
Reproducibility: operator-induced variation
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Total Variation = Process Variation + Measurement Variation
Think of a
right triangle
“Observed” “Actual”
MeasurementVariation
Process Variation
2Total = 2
Process + 2Measurement
The Effect of Measurement Error
Kenneth J Kortge
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MeasurementVariation
What You Want to Know
2Total = 2
Process + 2Measurement
Total Variation = Process Variation + Measurement Variation
The Effect of Measurement Error
Kenneth J Kortge
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% R&R
Number of Distinct Categories (NDC):
Greater than or equal to 5 – Acceptable
Less than 5 – Generally Not Acceptable
Under 10% error – Acceptable
10% - 30% error – May be acceptable based upon
importance of application, cost of measurement device, cost
of repair, etc.
Over 30% error – Not Acceptable. Every effort should be
made to improve the measurement system
Gage R&R Acceptance Criteria (Typical)
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Pitfalls
• Using MSA to obtain a number, rather than to understand
gage variation
• Not documenting a conclusion and any actions needed, as
part of the study
• Not conducting MSA for all gages on the control plan (TS
16949 requirement)
• Not validating Software (TS 16949 requirement)
• Using wrong analysis method (non-replicable, attribute, etc.)
Measurement Systems Analysis
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Advanced Product Quality Planning (APQP)
Failure Mode and Effects Analysis (FMEA)
Control Plan
Production Part Approval Process (PPAP)
Statistical Process Control (SPC)
Measurement System Analysis (MSA)
Automotive Core Tools
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Questions & Answers
Please type your questions in the question box
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