• Quality Tools
  • FMEA
  • SPC
  • MSA
  • AQP
  • Control Plans
  • Problem Solving
  • Mistake Proofing

• Management Systems

• Audit Practice

• e-Training Materials & Software

• e-Examinations / Certification

Quality Tools

 Core Quality Tools

Failure Mode & Effects Analysis (FMEA)		Mandatory for Automotive Industry
	The FMEA / FMECA analysis procedure is a tool that has been adapted in many different ways for many different purposes. FMEA contributes to improved designs for products and processes, resulting in enhanced reliability, quality, safety, customer satisfaction and reduced costs. FMEA is often required to comply with safety, quality and environmental requirements, such as ISO 9001, ISO/TS 16949, OHSAS 18001 and ISO 14001.
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Practical Statistical Process Control (SPC)		Mandatory for Automotive Industry
	A process in a state of statistical control is said to be statistically stable.  Control charts are used to detect assignable (special) causes of variation in the process. Process capability examines the variance in process characteristics to the extent that the process is capable of producing products which conform to specifications. SPC is an optimisation philosophy concerned with continuous process improvements, using a collection of statistical tools for decision making.
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Measurement Systems Analysis (MSA)		Mandatory for Automotive Industry
	MSA analysis is critical to the success of every measurement to ensure that measurements accurately represent the measured characteristic. A measurement system should be both precise and accurate. If the repeatability variation component is high, it is an indication that the measurement device is unreliable. Poor MSA negatively affects the process capability, reducing CP / Cpk values by over 30% and generating disproportionate additional production costs.
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Advanced Product Quality Planning (AQP)		Mandatory for Automotive Industry
	Advanced Quality Planning is a process to develop quality information in order to develop counter-measures for avoiding similar problems with current and future products. AQP (APQP) creates product and process definition, manufacturing preparedness and maintainability, and ensures their effective and efficient implementation. The objective of AQP is to produce a product quality plan which supports the development of products or services that economically satisfy a Customer’s requirements.
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Control Plans		Mandatory for Automotive Industry
	A Control Plan deals with the same information explored in FMEA’s and is directly traceable to the Process Flow charts. Special attention is typically given to potential failures with high RPN’s and those characteristics that are critical to the customer. Control Plans describe controls required at all phases of the manufacturing process including receiving, in-process, outgoing and periodic to ensure a state of control.
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 Quality Support Tools

Problem Solving Techniques (8D Tops)		Recommended Quality Tool
	Problem Solving is a key element in any human endeavor. From the cradle to the grave we are confronted with the need to make decisions and to remove obstacles. If you don't ask the right questions, you don't get the right answers. A question asked in the right way often points to its own answer. It is a common mistake of problem solving teams to jump to conclusions and make decisions based on feelings and non verified observations, as opposed to factual based decisions.
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Mistake Proofing		Recommended Quality Tool
	Only mistake-proofing and 100% automated inspection techniques can produce and sustain defect rates at a realistic parts per million (ppm). Elimination of undesirable production shutdowns is the incentive for eliminating defects & use of mistake-proofing. Sustained production flow can not be achieved without Poka Yoke. Handling scrap, or performing rework and repair are only necessary because the work was not done correctly the first time and Poka Yoke is a tool to achieve this.
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