Master automotive quality with practical training on the six core tools: APQP, FMEA, Control Plan, MSA, SPC and PPAP. 7QC and 5S courses are also available.
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The core tools are the standard quality methods of the automotive supply chain, built around defect prevention and process control. AIAG's core tools are APQP, FMEA, MSA, SPC and PPAP, and since March 2024 the Control Plan has its own AIAG manual as well. That is why many programs, including this course, now teach six core tools.
Typical placement of the tools within the five APQP phases, based on the AIAG APQP manual. Exact deliverables depend on customer requirements.
APQP is a project management tool that ensures products meet customer requirements through structured planning and error prevention. It divides the product development process into five phases, further breaking them into activities for precise management.
FMEA is a structured risk assessment methodology used to identify potential failure modes in a process, product, or system. It evaluates the impact, severity, and likelihood of failures, helping organizations proactively address risks before they occur.
A Control Plan outlines key processes and controls to ensure consistent product quality. It defines monitoring methods and response strategies for process deviations, helping maintain compliance with quality standards.
Measurement is crucial in Six Sigma. MSA is a systematic approach to evaluating the accuracy, reliability, and variability of a measurement system. It helps determine how much measurement variation affects overall process performance, ensuring data integrity for effective decision-making.
SPC uses statistical tools to monitor process behavior, identify system inefficiencies, and resolve production issues. It supports quality control by detecting variation and maintaining process stability, and is often used interchangeably with Statistical Quality Control (SQC).
PPAP is a standardized process that ensures suppliers understand customer requirements, adhere to documented expectations, and consistently produce reliable, high-quality parts and products. It validates manufacturing processes for repeatability and compliance.
Problem solving and root cause analysis
The seven basic quality control tools are used to make continuous improvements in any process, regardless of sector.
Trust your measurement data
This course introduces Measurement Systems Analysis (MSA) and the methodologies used to examine both attribute and variable measurement systems, as described in the Measurement Systems Analysis reference handbook.
Recognise problems before they happen
A stitch in time saves nine. FMEA (Failure Mode and Effects Analysis) is used to recognize problems and solve them using effective techniques.
Monitor and control your processes
SPC is a method for analyzing, monitoring and controlling processes using statistical methods and techniques. It helps the process run smoothly, resulting in more specification-conforming goods with less waste (rework or scrap).
Visual management and waste removal
5S is a method of visual management that uses everything from floor tape to operations manuals. It is not only about keeping things clean and organized; it is also about increasing efficiency and profit. It is a framework that emphasizes a specific mindset and set of tools to generate efficiency and value, and includes observing, evaluating, collaborating and looking for waste, as well as removing it.
The six core tools taught here are APQP, FMEA, Control Plan, MSA, SPC and PPAP. AIAG's core tools are APQP, FMEA, MSA, SPC and PPAP. Since March 2024 the Control Plan is also published as its own AIAG manual, so many training programs now teach it as the sixth core tool.
APQP (Advanced Product Quality Planning) is a project management tool that ensures products meet customer requirements through structured planning and error prevention. It divides product development into five phases, each broken into activities.
DFMEA analyzes potential failures in a product design, while PFMEA analyzes potential failures in a manufacturing process. Both identify failure modes, their effects and their risk so that actions can be taken before failures occur.
SPC relies on measurement data. MSA checks that the measurement system is accurate and repeatable enough for that data to be trusted, so control charts and capability studies reflect the process and not measurement error.
PPAP (Production Part Approval Process) is a standardized process that ensures suppliers understand customer requirements, follow documented expectations and consistently produce reliable, high-quality parts. It validates manufacturing processes for repeatability and compliance.
IATF 16949 expects organizations to apply these tools, such as APQP, FMEA, MSA, SPC, control plans and PPAP, where the standard and customer-specific requirements call for them. Check your standard and customer requirements for the exact obligations.
Quality, process and manufacturing engineers, supervisors, managers and anyone supporting APQP, FMEA, MSA, SPC or PPAP work. Each course on this page lists its own audience. Training is available for individuals and for corporate teams.
Talk to Intelligence Quality about core tools training for yourself or your team.