Measurement system analysis MSA studies
Automotive Quality Techniques/Tools are well used in automotive industries to solve vast majority of quality problems and initiate improvement measures in process i.e MSA studies.
1) Measurement system analysis MSA studies
- Meaning of MSA studies
- Purpose of MSA studies
- Characterization of MSA studies:
- Location (Average measurement value VS Actual value)
- Variation (Spread of measurement values precision)
- Measurement system analysis procedures
- Stability assessment
- Bias Assessment
- Repeatability and Reproducibility Assessment (Gage R&R method).
- Graphical representation of Repeatability Assessment (Gage R&R method)
4) Matrix techniques: meaning of matrix techniques, uses of matrix techniques as a quality tools.
5) Pre-control techniques: meaning of pre-control techniques, uses of pre control techniques as a qualtiy tools.
6) Benchmarking principles
- Meaning of benchmarking principles
- Why benchmarking?
- Types of benchmarking
- Hints on how to conduct critical steps in benchmarking process.
- Essential steps to successful benchmarking principles in automotive industries.
7) PDCA Cycle
- Meaning of PDCA cycle, what is it?
- When to use PDCA cycle, How to use it?
- Graphical representation of PDCA cycle
- PDCA cycle: explanations.
8) Cause and effect diagram
- Meaning of Cause and effect diagram
- When to use Cause and effect diagram, How to use it?
- Graphical representation of Cause and effect diagram.
9) Control Charts
- Meaning of control charts
- When to use X-bar and R Control charts
- How do control chart help to avoid defects
- Brief history of control charts
- Cause of variation: a. Common causes of variation
- Special causes of variation.
- Statistical Process Control –SPC- test rules. Graphical representation of the test rules.
Other techniques and tools:
Advanced Product Quality Planning (APQP)
APQP is a structured approach to product and process design. This framework is a standardized set of quality requirements that enable suppliers to design a product that satisfies the customer.
The primary goal of product quality planning is to facilitate communication and collaboration between engineering activities. A Cross Functional Team (CFT), involving marketing, product design, procurement, manufacturing and distribution, is used in the APQP process. APQP ensures the Voice of the Customer (VOC) is clearly understood, translated into requirements, technical specifications and special characteristics. The product or process benefits are designed in through prevention.
Failure Mode and Effects Analysis
Failure Mode and Effects Analysis (FMEA) is a structured approach to discovering potential failures that may exist within the design of a product or process.
Failure modes are the ways in which a process can fail. Effects are the ways that these failures can lead to waste, defects or harmful outcomes for the customer. Failure Mode and Effects Analysis is designed to identify, prioritize and limit these failure modes.
Production Part Approval Process PPAP
PPAP defines the approval process for new or revised parts, or parts produced from new or significantly revised production methods. The PPAP process consists of 18 elements that may be required for approval of production level parts. Not all of the elements are required for every submission. There are five generally accepted PPAP submission levels. The PPAP manual contains detailed information, guidelines and sample documents useful for completing the process requirements. The resulting PPAP submission provides the evidence that the supplier has met or exceeded the customer’s requirements and the process is capable of consistently reproducing quality parts.