Archive for Courses

A3 Problem-Solving Training

A3 Problem-Solving Online Training

Internal Audit training is a master course from QualityTrainingPortal.com

Course Objectives
Course Outline

Intended Audience

All levels and all roles of the organization.

Time To Complete

5 hours (0.5 CEUs)

Print Course Info

A3 Problem-Solving Training Online

A3 Problem-Solving Online Training is an easy and cost-effective way to get A3 Problem-Solving teams up and running without expensive consultants or resource draining in-house training efforts.

Check out our other Problem-Solving Courses:

Give your A3 Problem-Solving teams the tools they need

This training will equip A3 Problem-Solving Team members with the tools and process to solve problems using the A3 approach. Similar to most problem-solving models, A3 Problem-Solving is based on the Plan-Do-Check-Act cycle. In addition to detailed instruction on each of the nine steps of the A3 process, learners follow an actual A3 project throughout the course of the training. This helps bring the concepts to life and enables participants to see how the tools, techniques and process will work with their own projects. Upon successful completion of this training, participants will be ready to work on A3 Problem-Solving teams.

What is A3 Problem-Solving?

A3 Problem-Solving, like 8D and DMAIC Problem-Solving is a step-wise problem-solving process based on the Plan-Do-Check-Act cycle. What makes A3 Problem-Solving unique is the simple, concise visual reporting structure coupled with a focus on communicating the status and progress of solving a problem throughout the process.  The on-going reporting format is succinct and literally fits onto an A3 size of paper (11″ x 17″). The A3 Report is essentially a storyboard that concisely displays the A3 Team’s thought process, discoveries and action taken in real-time graphical form.

A3 Problem-Solving Training Enables Learners To…

  • See the link between the A3 Problem-Solving approach and the PDCA cycle.
  • Use the A3 problem-Solving model to solve problems.
  • Apply problem-solving tools throughout the problem-solving process.
  • Effectively use the visual reporting and communication aspects of the A3 approach.

Features of All Courses

Recommended Prerequisites

  • None.

You May Also Be Interested In…

  • Quality Improvement Fundamentals – This course focuses on gathering data and using that data with eight powerful data display tools that literally turn the data into pictures.
  • Mistake-Proofing Training – Comprehensive online training in poka yoke/mistake-proofing techniques for manufacturing operations.
  • The Five Whys – Focused training in how to use the Five Whys technique to get to the root cause of problems.

Pricing Info

A3 Problem-Solving Training Course Objectives

  • Understand how the A3 approach and the PDCA cycle are linked.
  • Learn how to use the A3 model to solve problems.
  • Apply the appropriate problem-solving tools throughout the problem-solving process.
  • Know how to effectively use the visual reporting and communication aspects of the A3 approach.

A3 Problem-Solving Course Outline

Lesson 1 | A3 & PDCA

  • Realize that the A3 Problem-Solving is based on the PDCA cycle.
  • Understand the similarities and differences between the A3, 8D and DMAIC problem-solving approaches.
  • Recognize how the A3 reporting structure provides a compelling visual means of tracking and communicating the progress of addressing a problem.

Lesson 2 | Plan: A3 Steps 1-6

  • Know how to clarify and validate the problem.
  • Be able to use data to identify the performance shortfall and where in the process is it falling short.
  • Understand how to contain “harm” and stabilize the process for the short-term.
  • Recognize how to establish a target for the future state.
  • Appreciate how to use tools and techniques to identify the root cause.
  • Understand how to develop countermeasures to the root cause.

Lesson 3 | Do: A3 Step 7

  • Understand how to develop Action Plans using either Simple or Complex Action Plans formats.
  • Learn how to use Project Management tools such as Activity Plans, PERT Charts and Gantt Charts to develop Action Plans to manage and track execution of the countermeasure.

Lesson 4 | Check: A3 Step 8

  • Confirm that the countermeasure will do what it was intended to do under all reasonable conditions.
  • Use techniques to ensure the problem does not recur.
  • Remove unnecessary “Contain & Stabilize” measures.

Lesson 5 | Act: A3 Step 9

  • Know which associated documents and systems to update.
  • Recognize how powerful it can be to share Lessons Learned Remove candidates that are not practical, feasible or cost-effective from consideration.

Lesson 6 | Helpful Tips

  • To be aware of ten tips that can help A3 Teams be effective and efficient when conducting A3 Projects.

Challenge

  • An assessment of the learner’s progress in this course.

Layered Process Audits Training

Layered Process Audits Training, LPA, Online QualityTraining

Internal Audit training is a master course from QualityTrainingPortal.com

Course Outline
Course Objectives

Intended Audience

All levels (layers) and all roles in the organization.

Time To Complete

4 hours (0.4 CEUs)

Print Course Info

Layered Process Audits Training Online

Layered Process Audits (LPA) training helps the learner understand what LPAs are and how to use them. Participants will learn how to plan a comprehensive LPA program, develop a rollout strategy, conduct LPAs, make sure outcomes are assessed and the methodologies are continually improved. This course covers the steps for conducting an LPA while taking learners through examples that help bring the concepts to life.

Give your LPA team the tools they need

Layered Process Audits Training prepares people to serve on LPA teams. The course provides a foundation for conducting LPAs to assure that all those involved in the LPA have a common understanding of the process. If LPAs are just being implemented in your organization, this is a great way to get every “layer” of the organization using the same language and steps. It is also an excellent way to bring new members joining existing LPA teams up to speed quickly, efficiently and inexpensively.

Upon successful completion of this training, participants will have a solid comprehension of the purpose, objectives and benefits of LPAs and will be prepared to carry out the responsibilities of their role. They will know the purpose and process for each layer of the process audits.

What are Layered Process Audits?

LPAs are a unique technique designed to help improve organization-wide performance by engaging all levels or “layers” of the organization.  The LPA approach is a proven means to help align the entire organization on Key Performance Indicators, reinforce the responsibilities and accountabilities of all “layers” to meet those objectives and help identify opportunities to improve processes and their performance.

The term “Layered Process Audit” does not refer to a conventional internal audit but rather represents a technique that calls for short, focused audits performed by multiple levels (or layers) of the organization.  LPAs involve a wide range of people from the organization engaged in verifying the viability of selected processes, not a small team of internal auditors. This approach helps align the organizational “layers” into a continuum where all understand what is important to ensure outcomes are successful and that all members are committed to making it happen.

Layered Process Audits Training Enables Learners To…

  • Understand what an LPA is and recognize the benefits it can bring to an organization.
  • Be aware of a proven 10 step approach to plan, develop and rollout LPAs.
  • Know how to select audit teams of all layers and get them up to speed.
  • Realize how to monitor results, track progress, and make adjustment to the LPA program.

Features of All Courses

Recommended Prerequisites

  • None.

You May Also Be Interested In…

Pricing Info

Layered Process Audits Training Course Objectives

  • Understand what a Layered Process Audit is and recognize the benefits it can bring to an organization.
  • Be aware of a proven 10 step approach to plan, develop and rollout LPAs.
  • Know how to select audit teams of all layers and get them up to speed.
  • Realize how to monitor results, track progress, and make adjustment to the LPA program.

Layered Process Audits Course Outline

Lesson 1 | Explaining Layered Process Audits

  • Provide an overview of what Layered Process Audits are and how they work.
  • Preview the benefits of conducting Layered Process Audits.

Lesson 2 | Planning a Layered Process Audit

  • Become aware of a proven 10-step plan to develop an LPA program.
  • Understand the roles of the LPA Planning Team the Overall Process Owner and Local Process Owners.

Lesson 3 | Preparing to Rollout LPAs

  • Help Process Owners comprehend their role and how to carry it out.
  • Understand how to develop questions for a Layered Process Audit.
  • Realize what is involved in a Rollout of the LPA approach.

Lesson 4 | Conducting a Layered Process Audit

  • Know how to establish the frequency of audits and set the audit frequency for each Layer.
  • Realize the role of preformatted LPA Check Sheets.
  • Recognize the value of visual data displays of audit results.
  • Understand the periodic reviews and adjustments necessary to retain the viability of the program.

Lesson 5 | Helpful Tips for LPAs

  • Be aware of tips and techniques that can lead to more effective Layered Process Audits and successful outcomes.

Challenge

  • An assessment of the learner’s progress in this course.

Managing Calibration Programs

Managing Calibration Systems Online Training course

Course Outline
Course Objectives

Intended Audience

Engineers, quality professionals, supervisors, metrology technicians.

Time To Complete

3 hours (0.3 CEUs)

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Managing Calibration Programs Online Training

Why is a program that Manages Calibration Systems necessary?

  • A measurement device that doesn’t read accurately and repeatably or is no longer in calibration compromises the integrity of the quality of your product and can unknowingly lead to the production of nonconforming parts.
  • We need to “trust” measuring devices to effectively and efficiently produce product. If the gages and instruments used are not controlled and calibrated, there is no way of knowing what the true output of a process really is!
  • Based on measurements that are taken during manufacturing, an organization may think that it is producing good parts only to find out that the parts are seriously defective or out-of-tolerance because the measuring device used is inaccurate, out-of-calibration, or not stable. When that happens, it is no difference than using a “rubber ruler” for measuring!

The Managing Calibration Programs course will help learners learn about the importance of measurement device calibration management.

This Training Enables Learners To…

  • Explain the importance of calibration and management.
  • Describe the primary sources of measurement error.
  • Show how the calibration of a measurement device is tied to ISO standards.
  • Specify requirements for measurement instrument management software, if you choose to computerize your records.

Recommended Prerequisites

  • None.

You May Also Be Interested In…

  • Gage Training – Comprehensive training in how to use a variety precision hand gages including an overview of basic measuring concepts, introductory blueprint reading, an overview of GD&T, and which gages to use when.
  • Measurement Systems Analysis – Comprehensive training in how to statistically measure the accuracy and reliability of measurement systems.
  • Internal Audit Training – Focused on the six steps of a clause-based internal audit process.

Managing Calibration Programs Course Outline

Lesson 1 | Formal Instrument Management

  • Identify the components of a good calibration program.
  • Explain why many industry standards require formal measurement device management programs.

Lesson 2 | Sources of Measurement Error

  • Explain the four major categories of measurement error: calibration, usage or handling damage, errors of judgment, measurement system variation.
  • Know what to do about sources of measurement error.

Lesson 3 | Calibration Practices

  • Understand the requirements of a measurement calibration system as defined by ISO 10012.
  • Establish calibration procedures to check the calibration of a measurement device.

Lesson 4 | Calibration Standards & Tools

  • Understand the traceability route of measurement standard back to primary national standards and ISO.
  • Select measurement standards appropriate for the measuring device.

Lesson 5 | Calibration Pitfalls

  • Become familiar with the 7 most common calibration pitfalls.
  • Overcome calibration pitfalls.

Lesson 6 | Records & Audits

  • Establish comprehensive records needed to document the management of measurement devices.
  • Develop an audit system to ensure the measurement management system is being used correctly.

Lesson 7 | Calibration Software Considerations

  • Explore common options of measurement management software.
  • Evaluate measurement management software to select the software program that best fits the needs of your organization.

Challenge

  • An assessment of the learner’s progress in this course.

Managing Calibration Programs Training Course Objectives

  • Explain the importance of calibration and management.
  • Describe the primary sources of measurement error.
  • Show how the calibration of a measurement device is tied to ISO standards.
  • Specify requirements for measurement instrument management software, if you choose to computerize your records.

AIAG-VDA FMEA-MSRs

AIAG-VDA FMEA-MSR Training

Course Outline
Course Objectives

Intended Audience

Quality Professionals, Engineers and Managers in the automotive sector who will be participating on an FMEA-MSR core team using the 2019 AIAG-VDA FMEA-MSR Process.

Time To Complete

4 hours (0.4 CEUs)

Print Course Info

AIAG-VDA FMEA-MSR Online Training

This online training prepares learners to participate on the core team of an Supplemental FMEA for Monitoring and System Response (FMEA-MSR) using the 2019 AIAG-VDA FMEA Handbook. The course provides a background understanding of FMEAs, provides detailed instruction for participating on an FMEA-MSR Core Team and shows how DFMEAs and FMEA-MSRs are linked.

IMPORTANT NOTE: While the AIAG-VDA FMEA-MSRs course is in line with the AIAG-VDA FMEA Handbook, it is not intended as a replacement for the source Handbook.  We recommend that this course be used in conjunction with the official Handbook.

Compare All FMEA Courses

What is AIAG-VDA Failure Mode and Effects Analysis?

Failure Mode and Effects Analysis (FMEA) techniques have been used for over 70 (yes, SEVENTY!) years.  In recent years, use of FMEAs has gained popularity as a quality improvement tool.  Most industries are now using FMEA techniques as part of their risk assessment and risk mitigation strategies. Unlike many quality improvement tools, FMEAs do not require complicated statistics.  FMEA studies can yield significant savings for a company as well as reduce potential risks and associated liabilities of a product or process that does not perform as intended.

In 2019, AIAG (Automotive Industry Action Group, www.aiag.org) and VDA (Verband der Automobilindustrie, www.vda.de), two of the leading automotive trade associations, unveiled a major revision to FMEA methodology with the release of the AIAG-VDA FMEA Handbook.

Learn more about FMEA in our FMEA Resource Center.

This Training Enables Learners To…

  • Effectively participate and contribute as a core team member of an FMEA-MSR team.

Features of All Courses

Recommended Prerequisites

You May Also Be Interested In…

  • Mistake-Proofing Training – Comprehensive online training in poka yoke/mistake-proofing techniques for manufacturing operations.
  • 8D Problem-Solving – Step-by-step training in how to work on a problem-solving team follow the 8D methodology including tools and techniques that are used in each step.
  • Root Cause Analysis with Corrective Action – Leads the learner through a four-step process to get to the root cause (source) of problems to eliminated problems for good.

Pricing Info

AIAG-VDA FMEA-MSRs Course Outline

Lesson 1 | Why Conduct FMEA-MSRs and How They Fit with DFMEAs
Lesson 2 | Overview of the FMEA-MSR Process
Lesson 3 | System Analysis (Steps 1, 2 & 3)
Lesson 4 | Failure Analysis and Risk Mitigation (Steps 4, 5 & 6)
Lesson 5 | Communication (Step 7)
Lesson 6 | Helpful Tips

Challenge

  • An assessment of the learner’s progress in this course.

AIAG-VDA FMEA-MSRs Training Course Objectives

  • Explain the purpose of conducting an FMEA-MSR and how it is related to a DFMEA.
  • Explain the methodology of the AIAG-VDA FMEA-MSR process.
  • Use the 5 T’s to plan and prepare for an FMEA-MSR study.
  • Work though each step of the 7 steps for conducting an FMEA-MSR.
  • Use the FMEA-MSR Analysis Worksheet to document the results of the study.
  • Customize the Severity, Frequency and Monitoring/System-Response Ranking Scales.
  • Use the results of an FMEA-MSR to continue to reduce risk.

AIAG-VDA Design-FMEAs

AIAG-VDA Design-FMEA Training

Course Outline
Course Objectives

Intended Audience

Quality Professionals, Engineers and Managers in the automotive sector who will be participating on a Design-FMEA Team using the 2019 AIAG-VDA DFMEA Process.

Time To Complete

6 hours (0.6 CEUs)

Print Course Info

AIAG-VDA Design-FMEAs Online Training

This online training prepares learners to participate on the core team of a Design-FMEA (DFMEA) using the 2019 AIAG-VDA FMEA Process. The course provides a background understanding of FMEAs, provides detailed instruction for participating on a DFMEA Core Team and conceptually introduces FMEAs for Monitoring and System Response (FMEA-MSR).

IMPORTANT NOTE: While the AIAG-VDA Design-FMEAs course is in line with the AIAG-VDA FMEA Handbook, it is not intended as a replacement for the source Handbook.  We recommend that this course be used in conjunction with the official Handbook.

Compare All FMEA Courses

What is AIAG-VDA Failure Mode and Effects Analysis?

Failure Mode and Effects Analysis (FMEA) techniques have been used for over 70 (yes, SEVENTY!) years.  In recent years, use of FMEAs has gained popularity as a quality improvement tool.  Most industries are now using FMEA techniques as part of their risk assessment and risk mitigation strategies. Unlike many quality improvement tools, FMEAs do not require complicated statistics.  FMEA studies can yield significant savings for a company as well as reduce potential risks and associated liabilities of a product or process that does not perform as intended.

In 2019, AIAG (Automotive Industry Action Group, www.aiag.org) and VDA (Verband der Automobilindustrie, www.vda.de), two of the leading automotive trade associations, unveiled a major revision to FMEA methodology with the release of the AIAG-VDA FMEA Handbook.

Learn more about FMEA in our FMEA Resource Center.

This Training Enables Learners To…

  • Effectively participate and contribute as a core team member of a DFMEA team.

Features of All Courses

Recommended Prerequisites

  • None.

You May Also Be Interested In…

  • Mistake-Proofing Training – Comprehensive online training in poka yoke/mistake-proofing techniques for manufacturing operations.
  • 8D Problem-Solving – Step-by-step training in how to work on a problem-solving team follow the 8D methodology including tools and techniques that are used in each step.
  • Root Cause Analysis with Corrective Action – Leads the learner through a four-step process to get to the root cause (source) of problems to eliminated problems for good.

Pricing Info

AIAG-VDA Design-FMEAs Training Course Objectives

  • Describe the systematic approach that FMEAs take to identify and reduce risks.
  • Compare and contrast the different types of FMEAs and describe the relationship between DFMEAs and FMEA-MSRs.
  • Define what the Five T’s are and explain how they are used to ensure successful FMEA team start-ups.
  • Learn to use the Seven-Step AIAG-VDA DFMEA process.
  • Describe the “Failure Chain” concept in FMEAs.
  • Understand how evaluation criteria is used to rate the levels of Severity, Occurrence and Detection and how the S-O-D rating is used to establish the Action Priority Level of potential failure modes.
  • Develop action plans to reduce risks and make the process more robust.
  • Understand what FMEA-MSRs are and how they supplement DFMEAs.
  • Identify key factors to improve the effectiveness of DFMEAs.

AIAG-VDA Design-FMEAs Course Outline

Lesson 1 | Why Conduct DFMEAs?

  • Know what a DFMEA is and why a DFMEA is used.
  • Understand how a DFMEA is conducted on a conceptual basis.

Lesson 2 | Brief History of FMEAs

  • To gain an appreciation of the historical evolution of FMEAs, the types of FMEAs that are used and the industries that use them.

Lesson 3 | Overview of the DFMEA Process

  • To understand the scope and scale of the seven-step DFMEA process.

Lesson 4 | System Analysis (Steps 1, 2 & 3)

  • To appreciate how to charter and start-up a DFMEA team.
  • To understand how to analyze the structure of the design under study.
  • To learn how to identify the functions of each design component.

Lesson 5 | Failure Analysis and Risk Mitigation (Steps 4, 5 & 6)

  • To understand the concept of a Failure Chain.
  • To use the Failure Chain model to identify failure modes, failure effects and failure causes for each design element.
  • To realize how to use Evaluation Criteria to rate the Severity, Occurrence and Detection for each failure.
  • To understand how to create custom Evaluation Criteria.
  • To learn how to use the Action Priority Tables to assign AP Levels.
  • To use common problem-solving tools to develop risk mitigation plans.

Lesson 6 | Communication (Step 7)

  • To know how to document and communicate DFMEA results.

Lesson 7 | Overview of FMEA-MSRs

  • Understand what FMEA-MSRs are and how they supplement DFMEAs.

Lesson 8 | Helpful Tips

  • To be aware of approaches that can help teams conduct DFMEAs more effectively and efficiently.

Challenge

  • An assessment of the learner’s progress in this course.

AIAG-VDA Process-FMEAs

AIAG-VDA Process-FMEA Training

Course Outline
Course Objectives

Intended Audience

Quality Professionals, Engineers and Managers in the automotive sector who will be participating on a Process-FMEA Team using the 2019 AIAG-VDA PFMEA Process.

Time To Complete

5 hours (0.5 CEUs)

Print Course Info

AIAG-VDA Process-FMEAs Online Training

This online training prepares learners to participate on the core team of a Process-FMEA (PFMEA) using the 2019 AIAG-VDA FMEA Process. The course provides a background understanding of FMEAs including their history, detailed instruction on how to use the seven-step FMEA process and highlights tips for getting the most out of PFMEAs.

IMPORTANT NOTE: While the AIAG-VDA Process-FMEAs course is in line with the AIAG-VDA FMEA Handbook, it is not intended as a replacement for the source Handbook.  We recommend that this course be used in conjunction with the official Handbook.

Compare All FMEA Courses

What is AIAG-VDA Failure Mode and Effects Analysis?

Failure Mode and Effects Analysis (FMEA) techniques have been used for over 70 (yes, SEVENTY!) years.  In recent years, use of FMEAs has gained popularity as a quality improvement tool.  Most industries are now using FMEA techniques as part of their risk assessment and risk mitigation strategies. Unlike many quality improvement tools, FMEAs do not require complicated statistics yet they can yield significant savings for a company as well as reduce potential risks and associated liabilities of a product or process that does not perform as intended.

In 2019, AIAG (Automotive Industry Action Group, www.aiag.org) and VDA (Verband der Automobilindustrie, www.vda.de), two of the leading automotive trade associations, unveiled a major revision to FMEA methodology with the release of the AIAG-VDA FMEA Handbook.

This Training Enables Learners To…

  • Effectively participate and contribute as a core team member of a Process-FMEA team using AIAG-VDA seven-step methodology.

Features of All Courses

Recommended Prerequisites

  • None.

You May Also Be Interested In…

  • Mistake-Proofing Training – Comprehensive online training in poka yoke/mistake-proofing techniques for manufacturing operations.
  • 8D Problem-Solving – Step-by-step training in how to work on a problem-solving team follow the 8D methodology including tools and techniques that are used in each step.
  • Root Cause Analysis with Corrective Action – Leads the learner through a four-step process to get to the root cause (source) of problems to eliminated problems for good.

Pricing Info

AIAG-VDA Process-FMEAs Training Course Objectives

  • Describe the systematic approach that FMEAs take to identify and reduce risks.
  • Compare and contrast the different types of FMEAs and describe the relationship between DFMEAs and PFMEAs.
  • Define what the Five T’s are and explain how they are used to ensure successful FMEA team start-ups.
  • Learn to use the Seven-Step AIAG-VDA PFMEA process.
  • Describe the “Failure Chain” concept in FMEAs.
  • Understand how evaluation criteria is used to rate the levels of Severity, Occurrence and Detection and how the S-O-D rating is used to establish the Action Priority Level of potential failure modes.
  • Develop action plans to reduce risks and make the process more robust.
  • Explain the relationship between PFMEAs and Control Plans.
  • Identify key factors to improve the effectiveness of PFMEAs.

AIAG-VDA Process-FMEAs Course Outline

Lesson 1 | Why Conduct PFMEAs?

  • Know what an FMEA is and why an FMEA is used.
  • Understand how an FMEA is conducted on a conceptual basis.

Lesson 2 | Brief History of FMEAs

  • To gain an appreciation of the historical evolution of FMEAs, the types of FMEAs that are used and the industries that use them.

Lesson 3 | Overview of the PFMEA Process

  • To understand the scope and scale of the seven-step PFMEA process.

Lesson 4 | System Analysis (Steps 1, 2 & 3)

  • To appreciate how to charter and start-up a PFMEA team.
  • To understand how to analyze the structure of the process under study.
  • To learn how to identify the functions of each process step.

Lesson 5 | Failure Analysis and Risk Mitigation (Steps 4, 5 & 6)

  • To understand the concept of a Failure Chain.
  • To use the Failure Chain model to identify failure modes, failure effects and failure causes for each process step.
  • To realize how to use Evaluation Criteria to rate the Severity, Occurrence and Detection for each failure.
  • To understand how to create custom Evaluation Criteria.
  • To learn how to use the Action Priority Tables to assign AP Levels.
  • To use common problem-solving tools to develop risk mitigation plans.

Lesson 6 | Communication (Step 7)

  • To know how to document and communicate PFMEA results.

Lesson 7 | Helpful Tips

  • To be aware of approaches that can help teams conduct PFMEAs more effectively and efficiently.

Challenge

  • An assessment of the learner’s progress in this course.

Introduction to AIAG-VDA FMEAs

Introduction to AIAG-VDA FMEAs

Course Outline
Course Objectives

Intended Audience

Quality Professionals, Engineers and Managers in the automotive sector who need to understand the 2019 AIAG-VDA FMEA Process.

Time To Complete

3 hours (0.3 CEUs)

Print Course Info

Introduction to AIAG-VDA FMEAs Online Training

This online training introduces learners to the 2019 AIAG-VDA FMEA Process. Participants will complete the course with an understanding of the new FMEA methodology including the 7-step FMEA process and Action Priority Tables.

IMPORTANT NOTE: While the Introduction to AIAG-VDA FMEAs is in line with the AIAG-VDA FMEA Handbook, it is not intended as a replacement for thorough training or the source Handbook.  We recommend that this course be used in conjunction with the official Handbook.  For practitioners participating on FMEA teams, we offer more in-depth training in our AIAG-VDA Process-FMEAs and AIAG-VDA Design-FMEAs courses.

What is AIAG-VDA Failure Mode and Effects Analysis?

Failure Mode and Effects Analysis (FMEA) techniques have been used for over 70 (yes, SEVENTY!) years.  In recent years, use of FMEAs has gained popularity as a quality improvement tool.  Most industries are now using FMEA techniques as part of their risk assessment and risk mitigation strategies. Unlike many quality improvement tools, FMEAs do not require complicated statistics.  FMEA studies can yield significant savings for a company as well as reduce potential risks and associated liabilities of a product or process that does not perform as intended.

In 2019, AIAG (Automotive Industry Action Group, www.aiag.org) and VDA (Verband der Automobilindustrie, www.vda.de), two of the leading automotive trade associations, unveiled a major revision to FMEA methodology with the release of the AIAG-VDA FMEA Handbook.

Learn more about FMEA in our FMEA Resource Center.

This Training Enables Learners To…

  • Understand the systematic approach that FMEAs take to identify and reduce risks.
  • Learn the steps for conducting an AIAG-VDA FMEA at a conceptual level.
  • Know what the Five T’s are and how they are used to ensure successful FMEA team start-ups.
  • Define six best practices for conducting FMEAs.

Features of All Courses

Recommended Prerequisites

  • None.

You May Also Be Interested In…

  • Mistake-Proofing Training – Comprehensive online training in poka yoke/mistake-proofing techniques for manufacturing operations.
  • 8D Problem-Solving – Step-by-step training in how to work on a problem-solving team follow the 8D methodology including tools and techniques that are used in each step.
  • Root Cause Analysis with Corrective Action – Leads the learner through a four-step process to get to the root cause (source) of problems to eliminated problems for good.

Pricing Info

Introduction to AIAG-VDA FMEAs Course Outline

Lesson 1 | What is an FMEA?

  • Know what an FMEA is and why an FMEA is used.
  • Understand how an FMEA is conducted on a conceptual basis.

Lesson  2 | Purposes of FMEAs

  • Understand how the systematic FMEA approach gets us to dig into the details of the design or process under study to identify potential risks.
  • Realize how an FMEA helps identify risks, prioritizes the risks relative to one another and focuses efforts on an action plan to reduce the risks.

Lesson 3 | Adding Value with FMEAs

  • To gain an appreciation for how FMEAs add value to the organization.

Lesson 4 | Types of FMEAs

  • Explain the differences between a DFMEA (Design-FMEA) and a PFMEA (Process-FMEA).
  • Recognize that alternative types of FMEAs do exist and understand the reasons for their use as well as the differences in the tactics used to conduct them.

Lesson 5 | The FMEA Process

  • Be familiar with the 7 steps used to conduct an FMEA.
  • Understand how Failure Chains work.
  • Understand how evaluation criteria is used to rate the levels of Severity, Occurrence and Detection.
  • Become aware of how Action Priority Tables establish Action Priority (AP) levels for potential risks.

Lesson 6 | Assembling an FMEA Team

  • Understand how to assemble an effective Core Team for conducting FMEAs.
  • Recognize how an Extended Team complements the Core Team
  • Appreciate the role of Subject Matter Experts when conducting an FMEA.
  • Be aware of how the Five T’s are used to ensure successful team start-ups.

Lesson 7 | Best Practices for Conducting FMEAs

  • To become familiar with six (of the) best practices for conducting FMEAs.

Challenge

  • An assessment of the learner’s progress in this course.

Introduction to AIAG-VDA FMEAs Training Course Objectives

  • Understand the systematic approach that FMEAs take to identify and reduce risks.
  • Describe the differences between Design and Process FMEAs.
  • Learn the steps for conducting an AIAG-VDA FMEA at a conceptual level.
  • Describe the “Failure Chain” concept in FMEAs.
  • Understand how evaluation criteria is used to rate the levels of Severity, Occurrence and Detection.
  • Become aware of how Action Priority Tables establish Action Priority (AP) levels for potential risks.
  • Know what the Five T’s are and how they are used to ensure successful FMEA team start-ups.
  • Define the six best practices for conducting FMEAs.

Internal Auditing for IATF 16949

IATF 16949 Internal Auditor Training Online

Internal Audit training is a master course from QualityTrainingPortal.com

Course Outline
Course Objectives

Intended Audience

Quality professionals, engineers, managers and others responsible for conducting Internal Audits of IATF 16949.

Time To Complete

6 hours (0.6 CEUs)

Print Course Info

IATF 16949 Internal Auditor Training Online

IATF 16949 defines the requirements of a quality management system for organizations in the automotive industry.  The goal of this International Standard is the development of a quality management system that:

  • Provides for continual improvement,
  • Emphasizes defect prevention,
  • Includes specific requirements and tools from automotive industry,
  • Promotes reduction of variation and waste in the supply chain.

With the move away from a standard of shalls and shall nots to a requirement for a more comprehensive approach to quality, the nature of internal audits shifted as well.  Classic internal audits are clause-based, where internal audits to the IATF 16949 standard need to be process-based, assessing a full system with the intention to measure and improve process performance. By taking this approach, organizations unlock the potential to improve overall business systems instead of focusing on correcting shortcomings found with individual procedures.

Learn More about our “classic” Internal Audit Training Course.

Prepare your IATF 16949 Internal Auditors

This course, Internal Auditing for IATF 16949, prepares in-house personnel to serve as IATF 16949 Internal Auditors evaluating existing quality systems against the IATF 16949 standard.  Participants learn the details of each of the six steps of conducting an internal audit, but specifically how to use a process focus as required by the IATF 16949 standard.  The course includes training to help auditors dig deep into processes, studying the outcomes and results (the performance) of the system so they can make informed suggestions for improvement. Trainees also learn how to assess the organizations use of risk-based thinking to identify threats and opportunities as well as the effective use of the Core Tools (APQP, FMEA, MSA, SPC and PPAP).

Upon successful completion of this training, participants will have a solid understanding of the purpose, objectives and benefits of Internal Audits for IATF 16949. They will know the purpose and process for each of the six steps for conducting Internal Audits and will be able to plan and prepare for audits, participate in the audit itself collecting and evaluating evidence, write a final report and conduct a closing meeting.

Clause-Based vs. Process-Based Internal Audits

Traditional auditing can be called “clause-based” auditing since the audit is focused on compliance to a “clause” such as a procedure, policy or standard. IATF 16949 specifically calls for the use of “process-based” auditing. A process approach to auditing is different because it involves assessing a full process with the intention to measure and improve process performance. Both the clause-based and process-based internal auditing approaches are valid auditing practices. However, when auditing for IATF 16949, always use the process-based approach.

Both approaches, clause-based and process-based auditing can be used to identify issues or noncompliances (if they exist) and initiate corrective action. But the process-based approach has the potential of improving a full process or even a series of integrated processes. When using a process-based approach, the organization is essentially using an holistic methodology to assess their business systems. With an holistic approach, organizations view processes and policies as a continuum rather than as separate components.

The upside to process-based auditing (required with IATF 16949) is that the approach opens the opportunity to make dramatic improvements for overall business systems. The downside is that process-based audits take more time, experience and skill than clause-based auditing.

This Training Enables Learners To…

  • Serve as IATF 16949 Internal Auditors.
  • Define the five supplemental areas beyond “conventional” internal auditor qualifications that those auditing for IATF 16949 must be proficient in.
  • Highlight the differences between “clause-based” and “process-based” auditing and explain the benefits to the process-based approach to auditing.
  • Describe how Risk-Based Thinking and Core Tools are used in IATF 16949 Internal Audits.
  • Appreciate the role Customer Specific Requirements (CSRs) play in strengthening the overall supply chain.
  • Explain the relationship between IATF 16949 and ISO 9001 and the impact the two standards in tandem have on auditing practices.
  • Describe the purpose, objectives and benefits of Internal Audits.
  • Identify each of the six steps of the internal audit process, explain the key components of each step as well as the importance of that step on the overall success of the audit.

Features of All Courses

Recommended Prerequisites

  • None.

You May Also Be Interested In…

  • Risk-Based Thinking – Training in how to develop and conduct a risk management process.
  • Core Tools Training – Five courses that can be offered as a curriculum for comprehensive training in the core tools (APQP, FMEA, MSA, SPC, PPAP).
  • Internal Audit Training – Focused on the six steps of a clause-based internal audit process.

Pricing Info

Internal Auditing for IATF 16949 Course Outline

Unit 1: Requirements for Auditing IATF 16949

Lesson 1 | IATF 16949 Auditing Requirements

  • Be aware of the five supplemental areas (beyond “conventional” internal auditor qualifications) that those auditing IATF 16949 must have proficiency.

Lesson  2 | Process Approach to Auditing

  • Understand what is involved with a process approach to auditing.
  • Describe how to use process mapping to understand a process.
  • Identify which elements impact process performance and determine measures that can be used to monitor and improve the performance of the process.

Lesson 3 | Role of Risk-Based Thinking

  • Realize that risk-based thinking fosters a proactive culture of prevention and improvement.
  • Recognize that risks can refer to either a threat or an opportunity.
  • Be aware of tools and techniques for identifying both threats and opportunities.

Lesson 4 | Focus on Customer Requirements

  • Recognize the importance of Customer Specific Requirements (CSRs).
  • Understand the role that CSRs play in strengthening the integrity of the overall supply chain.

Lesson 5 | Audit Perspective of Related Standards

  • Know that IATF 16949:2016 is implemented in conjunction with ISO 9001:2015.
  • Be aware of significant changes to IATF 16969:2016 and ISO 9001:2015 that impact auditing practices.

Lesson 6 | Role of Core Tools

  • Identify the five Core Tools.
  • Understand how the Core Tools are integrated and interconnected.
  • Realize how to get the “most” out of the Core Tools.

Challenge

  • An assessment of the learner’s progress in this course.

Unit 2: Internal Auditing Practices

Lesson 1 | The Audit Process

  • Understand the purpose, objectives and benefits of Internal Audits.
  • Preview six steps for conducting Internal Audits.

Lesson 2 | Step 1: Preparation and Planning

  • Recognize that the bounds of the audit scope must be tightly defined and that staying within these bounds improves results.
  • Understand how to prepare for an effective audit.
  • Be aware of how important it is for all audit participants to remain objective.

Lesson 3 | Step 2: The Opening Meeting

  • Appreciate the importance of a comprehensive Opening Meeting.
  • Know what agenda topics should be covered during the Opening Meeting.

Lesson 4 | Step 3: Collect Evidence

  • Recognize viable sources of evidence.
  • Sort through the evidence to hone in on meaningful data that leads to valid conclusions.
  • Realize when there is enough data gathered.

Lesson 5 | Step 4: Evaluate the Evidence

  • Consolidate evidence gathered.
  • Generate a composite picture of how well the organization’s performance conforms to Standards and documented procedures.
  • Separate and itemize nonconformities.
  • Rate nonconformities against a simple, relative priority scale.
  • Provide substantiated evidence of each nonconformity found.

Lesson 6 | Step 5: The Closing Meeting

  • Appreciate the purpose and importance of the Closing Meeting.
  • Understand how to prepare the Audit Report.
  • Know how to prepare for and lead the Closing Meeting.

Lesson 7 | Step 6: Audit Follow-Up

  • Recognize the need to confirm that changes made (at least for Critical and Major Nonconformities) have actually been made.
  • Be aware of the need to verify that the changes made are the right changes.
  • Know what to look for to ensure changes made are sustainable.

Lesson 8 | Auditing Tips

  • Be aware of tips and techniques that can lead to more effective audits and efficient outcomes.

Challenge

  • An assessment of the learner’s progress in this course.

Internal Auditing for IATF 16949 Training Course Objectives

  • Define the five supplemental areas beyond “conventional” internal auditor qualifications that those auditing for IATF 16949 must be proficient in.
  • Highlight the differences between “clause-based” and “process-based” auditing and explain the benefits to the process-based approach to auditing.
  • Describe how Risk-Based Thinking and Core Tools are used in IATF 16949 Internal Audits.
  • Appreciate the role Customer Specific Requirements (CSRs) play in strengthening the overall supply chain.
  • Explain the relationship between IATF 16949 and ISO 9001 and the impact the two standards in tandem have on auditing practices.
  • Describe the purpose, objectives and benefits of Internal Audits.
  • Identify each of the six steps of the internal audit process, explain the key components of each step as well as the importance of that step on the overall success of the audit.

Features of All QualityTrainingPortal Courses

Easy reporting for ISO 9001 and IATF 16949 records.

Powerful learning management and administration.

Media-rich presentation enhances the training.

Exercises reinforce concepts and keep learners engaged.

Printable PDF Reference Guide for future use.

Solid technical content developed by experts.

Learners progress through the training at their own pace.

Bookmarking so learners can start and stop the training as time allows.

Certificate of Completion that can be easily printed or saved.

CEUs awarded to fulfill continuing education requirements.

Risk-Based Thinking Training

Risk-based thinking training online from QualityTrainingPortal.com

Course Outline
Course Objectives

Intended Audience

Managers, supervisors, process owners, engineers who participate in developing business plans and improving operations.

Time To Complete

4 hours (0.4 CEUs)

What is Risk-Based Thinking?

Both industry-wide and industry-specific standards have incorporated risk-based thinking into their requirements. Some standards call for assessing risk levels and taking action to deal with risks that are identified, others call for organizations to define risk management protocols. But, in all cases, the underlying premise of risk-based thinking is that organizations should always factor in risks as they develop plans, review business results and take corrective action. The intent is for the organization to identify the risk, decide what (if any) action is required and then act.

Risk-Based Thinking Training Online

Risk-Based Thinking training teaches learners how to develop and conduct a risk management process in seven lessons. The initial lesson highlights industry standards that now incorporate risk-based thinking. The next five lessons lead learners through the five phases of risk-based thinking.  The final lesson in the course explores a sample risk management process complete with forms to track and document risks identified and mitigated (if they are unacceptable threats) or identified and capitalized upon (if they are worthwhile opportunities).

Our Risk-Based Thinking training course is a cost-effective and flexible way to get your entire team up to speed on Risk-Based Thinking without time-consuming off-site seminars or expensive in-house training.  Learners take the training when it fits into their schedule and everyone learns the same concepts and terminology in the same way.  When you purchase one of our subscriptions, you have full administration of your training and can assign courses, monitor results and use our follow-up reminders to assure everyone completes the training on time.  Reports and certificates provide the documentation of training completed that is often needed for audits.

This Training Enables Learners To…

  • Identify, assess and evaluate potential risks (whether they are threats or opportunities).
  • Develop action plans for high priority targets.
  • Measure and track the effectiveness and progress of action taken.
  • Establish a comprehensive risk management process.

Recommended Prerequisites

  • None.

You May Also Be Interested In…

  • Mistake-Proofing Training – Comprehensive online training in poka yoke/mistake-proofing techniques for manufacturing operations.
  • 8D Problem-Solving – Step-by-step training in how to work on a problem-solving team follow the 8D methodology including tools and techniques that are used in each step.
  • Root Cause Analysis with Corrective Action – Leads the learner through a four-step process to get to the root cause (source) of problems to eliminated problems for good.

Risk-Based Thinking Course Outline

Lesson 1 | Risks and Quality Standards

  • Understand that some standards have been revised and now incorporate risk-based thinking into their requirements.
  • Be exposed to several industry-wide and industry-specific standards that call for risk-based thinking.

Lesson 2 | Identify Risks

  • Recognize potential risks that signal threats.
  • Realize that a potential risk may be an opportunity, not a threat.
  • Be familiar with common tools to identify threats and opportunities.

Lesson 3 | Analyze Risks

  • Know how to analyze the Likelihood of a potential threat or opportunity.
  • Rate the Impact of an event.
  • Plot the Likelihood versus the Impact on a 2-D Matrix.

Lesson 4 | Evaluate & Prioritize Risks

  • Calculate the Risk Index using the ratings for Likelihood and Impact from the “Analyze Risks” phase.
  • Use the Risk Index to set priorities for action plans to reduce the risk from threats and capitalize on favorable opportunities.

Lesson 5 | Mitigation or Capitalization

  • Understand how to mitigate unacceptable threats.
  • Be aware of strategies to capitalize on worthwhile opportunities.

Lesson 6 | Control Risks

  • Be familiar with some common measures and control mechanisms that help ensure that risk mitigation continues to work as planned and that gains made are sustained.

Lesson 7 | Risk Management

  • Realize that Risk-Based Thinking can lead to a comprehensive Risk Management Process.
  • Be aware of forms that can support the methodology needed for a Risk Management Process.
  • Understand how the Summary Worksheet serves as both an historical document and a communication tool.

Challenge

  • An assessment of the learner’s progress in this course.

Risk-Based Thinking Course Objectives

  • Identify, assess and evaluate potential risks (whether they are threats or  opportunities).
  • Prioritize potential targets.
  • Gain insight on how to develop action plans for high priority targets.
  • Measure and track the effectiveness and progress of action taken.
  • Initiate control plans to curb similar risks in the future.
  • Establish a comprehensive risk management process.

PPAP Training

PPAP Training Online Courses

Course Outline
Course Objectives

Intended Audience

Product design engineers, product development professionals, quality engineers.

Time To Complete

2 hours (0.2 CEUs)

What is PPAP?

PPAP stands for Production Part Approval Process. It was developed by AIAG (the Automotive Industry Action Group) and it is an important part of their comprehensive Advanced Product Quality Planning (APQP) approach. APQP was originated to provide a common, standardized process for planning, developing and communicating the requirements and status of new products and services between suppliers and their customers. There are five phases to APQP; PPAP is triggered in Phase 4, Product & Process Validation.

On the surface, PPAP can appear to be complicated and even overwhelming. Once it is understood, it becomes apparent that PPAP requirements represent the culmination and reporting of activities that any “good” supplier already does. The PPAP Process merely helps put the reporting of activities and their results into a structured and consistent format.

PPAP Online Training

This PPAP Training online course teaches learners what PPAP’s are, why they are important and how to conduct a PPAP by fulfilling all 18 elements of the PPAP Package.

This Training Enables Learners To…

  • Understand what PPAP is, why it should be used and when it should be used.
  • Know how to complete PPAP documentation requirements.
  • Interpret when specific PPAP requirements apply and when they don’t.

Recommended Prerequisites

  • Fundamentals of APQP – To have an in-depth understanding of the overall APQP process and how PPAP fits into that process.

You May Also Be Interested In…

  • FMEA Training – Complete online training in how to conduct Design and Process FMEAs and to reduce high Risk Priority Numbers, how to customize FMEAs for a specific business and how to maintain improved processes using a control plan.
  • Advanced SPC Training – Comprehensive training in how to implement statistical process control including setting up control charts and conducting process capability studies.

PPAP Training Course Outline

Lesson 1 | PPAP Overview

  • Explains what the PPAP Process is.
  • Explores why a PPAP should be used.
  • Discusses when PPAP is needed.
  • Introduces how the PPAP Process is conducted.

Lesson 2 | Documentation Requirements

  • Explores each of the 18 Elements of the PPAP Documentation Package.
  • Explains “Reasons for PPAP Submission.”
  • Describes PPAP “Submission Levels.”

Lesson 3 | Reviewing the PPAP Process

  • Clarifies PPAP requirements.
  • Reinforces how the PPAP Process fosters customer-supplier trust.
  • Confirms that PPAP documentation is based on data.
  • Reviews documentation requirements for Bulk Materials.
  • Discusses customer-supplier negotiations.
  • Recaps requirements for part submission, retaining documentation, Master Samples and shipment samples.

Challenge

  • An assessment of the learner’s progress in this course.

PPAP Training Course Objectives

  • Understand what PPAP is, why it should be used and when it should be used.
  • Know how to complete PPAP documentation requirements.
  • Interpret when specific PPAP requirements apply and when they don’t.

A3 Problem-Solving Training Course Objectives

  • Understand how the A3 approach and the PDCA cycle are linked.
  • Learn how to use the A3 model to solve problems.
  • Apply the appropriate problem-solving tools throughout the problem-solving process.
  • Know how to effectively use the visual reporting and communication aspects of the A3 approach.

A3 Problem-Solving Course Outline

Lesson 1 | A3 & PDCA

  • Realize that the A3 Problem-Solving is based on the PDCA cycle.
  • Understand the similarities and differences between the A3, 8D and DMAIC problem-solving approaches.
  • Recognize how the A3 reporting structure provides a compelling visual means of tracking and communicating the progress of addressing a problem.

Lesson 2 | Plan: A3 Steps 1-6

  • Know how to clarify and validate the problem.
  • Be able to use data to identify the performance shortfall and where in the process is it falling short.
  • Understand how to contain “harm” and stabilize the process for the short-term.
  • Recognize how to establish a target for the future state.
  • Appreciate how to use tools and techniques to identify the root cause.
  • Understand how to develop countermeasures to the root cause.

Lesson 3 | Do: A3 Step 7

  • Understand how to develop Action Plans using either Simple or Complex Action Plans formats.
  • Learn how to use Project Management tools such as Activity Plans, PERT Charts and Gantt Charts to develop Action Plans to manage and track execution of the countermeasure.

Lesson 4 | Check: A3 Step 8

  • Confirm that the countermeasure will do what it was intended to do under all reasonable conditions.
  • Use techniques to ensure the problem does not recur.
  • Remove unnecessary “Contain & Stabilize” measures.

Lesson 5 | Act: A3 Step 9

  • Know which associated documents and systems to update.
  • Recognize how powerful it can be to share Lessons Learned Remove candidates that are not practical, feasible or cost-effective from consideration.

Lesson 6 | Helpful Tips

  • To be aware of ten tips that can help A3 Teams be effective and efficient when conducting A3 Projects.

Challenge

  • An assessment of the learner's progress in this course.

Features of All QualityTrainingPortal Courses

Easy reporting for ISO 9001 and IATF 16949 records.

Powerful learning management and administration.

Media-rich presentation enhances the training.

Exercises reinforce concepts and keep learners engaged.

Printable PDF Reference Guide for future use.

Solid technical content developed by experts.

Learners progress through the training at their own pace.

Bookmarking so learners can start and stop the training as time allows.

Certificate of Completion that can be easily printed or saved.

CEUs awarded to fulfill continuing education requirements.

This training is a Master Course; our most comprehensive, "how-to" offering. It provides in-depth training that enables learners to use the skills gained in the training both on the job and in team projects.

QualityTrainingPortal Master courses are comprehensive and in-depth.

Pricing for Credits start at $69/credit for individuals, with quantity discounts for Team or Corporate Subscriptions.

More on Pricing

Layered Process Audits Course Outline

Lesson 1 | Explaining Layered Process Audits

  • Provide an overview of what Layered Process Audits are and how they work.
  • Preview the benefits of conducting Layered Process Audits.

Lesson 2 | Planning a Layered Process Audit

  • Become aware of a proven 10-step plan to develop an LPA program.
  • Understand the roles of the LPA Planning Team the Overall Process Owner and Local Process Owners.

Lesson 3 | Preparing to Rollout LPAs

  • Help Process Owners comprehend their role and how to carry it out.
  • Understand how to develop questions for a Layered Process Audit.
  • Realize what is involved in a Rollout of the LPA approach.

Lesson 4 | Conducting a Layered Process Audit

  • Know how to establish the frequency of audits and set the audit frequency for each Layer.
  • Realize the role of preformatted LPA Check Sheets.
  • Recognize the value of visual data displays of audit results.
  • Understand the periodic reviews and adjustments necessary to retain the viability of the program.

Lesson 5 | Helpful Tips for LPAs

  • Be aware of tips and techniques that can lead to more effective Layered Process Audits and successful outcomes.

Challenge

  • An assessment of the learner's progress in this course.

Layered Process Audits Training Course Objectives

  • Understand what a Layered Process Audit is and recognize the benefits it can bring to an organization.
  • Be aware of a proven 10 step approach to plan, develop and rollout LPAs.
  • Know how to select audit teams of all layers and get them up to speed.
  • Realize how to monitor results, track progress, and make adjustment to the LPA program.

Managing Calibration Programs Course Outline

Lesson 1 | Formal Instrument Management

  • Identify the components of a good calibration program.
  • Explain why many industry standards require formal measurement device management programs.

Lesson 2 | Sources of Measurement Error

  • Explain the four major categories of measurement error: calibration, usage or handling damage, errors of judgment, measurement system variation.
  • Know what to do about sources of measurement error.

Lesson 3 | Calibration Practices

  • Understand the requirements of a measurement calibration system as defined by ISO 10012.
  • Establish calibration procedures to check the calibration of a measurement device.

Lesson 4 | Calibration Standards & Tools

  • Understand the traceability route of measurement standard back to primary national standards and ISO.
  • Select measurement standards appropriate for the measuring device.

Lesson 5 | Calibration Pitfalls

  • Become familiar with the 7 most common calibration pitfalls.
  • Overcome calibration pitfalls.

Lesson 6 | Records & Audits

  • Establish comprehensive records needed to document the management of measurement devices.
  • Develop an audit system to ensure the measurement management system is being used correctly.

Lesson 7 | Calibration Software Considerations

  • Explore common options of measurement management software.
  • Evaluate measurement management software to select the software program that best fits the needs of your organization.

Challenge

  • An assessment of the learner's progress in this course.

Managing Calibration Programs Training Course Objectives

  • Explain the importance of calibration and management.
  • Describe the primary sources of measurement error.
  • Show how the calibration of a measurement device is tied to ISO standards.
  • Specify requirements for measurement instrument management software, if you choose to computerize your records.

AIAG-VDA FMEA-MSRs Course Outline

Lesson 1 | Why Conduct FMEA-MSRs and How They Fit with DFMEAs
Lesson 2 | Overview of the FMEA-MSR Process
Lesson 3 | System Analysis (Steps 1, 2 & 3)
Lesson 4 | Failure Analysis and Risk Mitigation (Steps 4, 5 & 6)
Lesson 5 | Communication (Step 7)
Lesson 6 | Helpful Tips

Challenge

  • An assessment of the learner's progress in this course.

AIAG-VDA FMEA-MSRs Training Course Objectives

  • Explain the purpose of conducting an FMEA-MSR and how it is related to a DFMEA.
  • Explain the methodology of the AIAG-VDA FMEA-MSR process.
  • Use the 5 T’s to plan and prepare for an FMEA-MSR study.
  • Work though each step of the 7 steps for conducting an FMEA-MSR.
  • Use the FMEA-MSR Analysis Worksheet to document the results of the study.
  • Customize the Severity, Frequency and Monitoring/System-Response Ranking Scales.
  • Use the results of an FMEA-MSR to continue to reduce risk.

AIAG-VDA Design-FMEAs Course Outline

Lesson 1 | Why Conduct DFMEAs?

  • Know what a DFMEA is and why a DFMEA is used.
  • Understand how a DFMEA is conducted on a conceptual basis.

Lesson 2 | Brief History of FMEAs

  • To gain an appreciation of the historical evolution of FMEAs, the types of FMEAs that are used and the industries that use them.

Lesson 3 | Overview of the DFMEA Process

  • To understand the scope and scale of the seven-step DFMEA process.

Lesson 4 | System Analysis (Steps 1, 2 & 3)

  • To appreciate how to charter and start-up a DFMEA team.
  • To understand how to analyze the structure of the design under study.
  • To learn how to identify the functions of each design component.

Lesson 5 | Failure Analysis and Risk Mitigation (Steps 4, 5 & 6)

  • To understand the concept of a Failure Chain.
  • To use the Failure Chain model to identify failure modes, failure effects and failure causes for each design element.
  • To realize how to use Evaluation Criteria to rate the Severity, Occurrence and Detection for each failure.
  • To understand how to create custom Evaluation Criteria.
  • To learn how to use the Action Priority Tables to assign AP Levels.
  • To use common problem-solving tools to develop risk mitigation plans.

Lesson 6 | Communication (Step 7)

  • To know how to document and communicate DFMEA results.

Lesson 7 | Overview of FMEA-MSRs

  • Understand what FMEA-MSRs are and how they supplement DFMEAs.

Lesson 8 | Helpful Tips

  • To be aware of approaches that can help teams conduct DFMEAs more effectively and efficiently.

Challenge

  • An assessment of the learner's progress in this course.

AIAG-VDA Design-FMEAs Training Course Objectives

  • Describe the systematic approach that FMEAs take to identify and reduce risks.
  • Compare and contrast the different types of FMEAs and describe the relationship between DFMEAs and FMEA-MSRs.
  • Define what the Five T’s are and explain how they are used to ensure successful FMEA team start-ups.
  • Learn to use the Seven-Step AIAG-VDA DFMEA process.
  • Describe the "Failure Chain" concept in FMEAs.
  • Understand how evaluation criteria is used to rate the levels of Severity, Occurrence and Detection and how the S-O-D rating is used to establish the Action Priority Level of potential failure modes.
  • Develop action plans to reduce risks and make the process more robust.
  • Understand what FMEA-MSRs are and how they supplement DFMEAs.
  • Identify key factors to improve the effectiveness of DFMEAs.

AIAG-VDA Process-FMEAs Course Outline

Lesson 1 | Why Conduct PFMEAs?

  • Know what an FMEA is and why an FMEA is used.
  • Understand how an FMEA is conducted on a conceptual basis.

Lesson 2 | Brief History of FMEAs

  • To gain an appreciation of the historical evolution of FMEAs, the types of FMEAs that are used and the industries that use them.

Lesson 3 | Overview of the PFMEA Process

  • To understand the scope and scale of the seven-step PFMEA process.

Lesson 4 | System Analysis (Steps 1, 2 & 3)

  • To appreciate how to charter and start-up a PFMEA team.
  • To understand how to analyze the structure of the process under study.
  • To learn how to identify the functions of each process step.

Lesson 5 | Failure Analysis and Risk Mitigation (Steps 4, 5 & 6)

  • To understand the concept of a Failure Chain.
  • To use the Failure Chain model to identify failure modes, failure effects and failure causes for each process step.
  • To realize how to use Evaluation Criteria to rate the Severity, Occurrence and Detection for each failure.
  • To understand how to create custom Evaluation Criteria.
  • To learn how to use the Action Priority Tables to assign AP Levels.
  • To use common problem-solving tools to develop risk mitigation plans.

Lesson 6 | Communication (Step 7)

  • To know how to document and communicate PFMEA results.

Lesson 7 | Helpful Tips

  • To be aware of approaches that can help teams conduct PFMEAs more effectively and efficiently.

Challenge

  • An assessment of the learner's progress in this course.

AIAG-VDA Process-FMEAs Training Course Objectives

  • Describe the systematic approach that FMEAs take to identify and reduce risks.
  • Compare and contrast the different types of FMEAs and describe the relationship between DFMEAs and PFMEAs.
  • Define what the Five T’s are and explain how they are used to ensure successful FMEA team start-ups.
  • Learn to use the Seven-Step AIAG-VDA PFMEA process.
  • Describe the "Failure Chain" concept in FMEAs.
  • Understand how evaluation criteria is used to rate the levels of Severity, Occurrence and Detection and how the S-O-D rating is used to establish the Action Priority Level of potential failure modes.
  • Develop action plans to reduce risks and make the process more robust.
  • Explain the relationship between PFMEAs and Control Plans.
  • Identify key factors to improve the effectiveness of PFMEAs.

Introduction to AIAG-VDA FMEAs Course Outline

Lesson 1 | What is an FMEA?

  • Know what an FMEA is and why an FMEA is used.
  • Understand how an FMEA is conducted on a conceptual basis.

Lesson  2 | Purposes of FMEAs

  • Understand how the systematic FMEA approach gets us to dig into the details of the design or process under study to identify potential risks.
  • Realize how an FMEA helps identify risks, prioritizes the risks relative to one another and focuses efforts on an action plan to reduce the risks.

Lesson 3 | Adding Value with FMEAs

  • To gain an appreciation for how FMEAs add value to the organization.

Lesson 4 | Types of FMEAs

  • Explain the differences between a DFMEA (Design-FMEA) and a PFMEA (Process-FMEA).
  • Recognize that alternative types of FMEAs do exist and understand the reasons for their use as well as the differences in the tactics used to conduct them.

Lesson 5 | The FMEA Process

  • Be familiar with the 7 steps used to conduct an FMEA.
  • Understand how Failure Chains work.
  • Understand how evaluation criteria is used to rate the levels of Severity, Occurrence and Detection.
  • Become aware of how Action Priority Tables establish Action Priority (AP) levels for potential risks.

Lesson 6 | Assembling an FMEA Team

  • Understand how to assemble an effective Core Team for conducting FMEAs.
  • Recognize how an Extended Team complements the Core Team
  • Appreciate the role of Subject Matter Experts when conducting an FMEA.
  • Be aware of how the Five T’s are used to ensure successful team start-ups.

Lesson 7 | Best Practices for Conducting FMEAs

  • To become familiar with six (of the) best practices for conducting FMEAs.

Challenge

  • An assessment of the learner's progress in this course.

Introduction to AIAG-VDA FMEAs Training Course Objectives

  • Understand the systematic approach that FMEAs take to identify and reduce risks.
  • Describe the differences between Design and Process FMEAs.
  • Learn the steps for conducting an AIAG-VDA FMEA at a conceptual level.
  • Describe the "Failure Chain" concept in FMEAs.
  • Understand how evaluation criteria is used to rate the levels of Severity, Occurrence and Detection.
  • Become aware of how Action Priority Tables establish Action Priority (AP) levels for potential risks.
  • Know what the Five T’s are and how they are used to ensure successful FMEA team start-ups.
  • Define the six best practices for conducting FMEAs.

This training is an Overview Course. These short courses, that are typically 2 hours or less, provide a high-level introduction to the topic and terminology. This training is perfect for managers or others who need to understand the concepts, but who will not actually be using the tools or process in their everyday activities.

Pricing for Credits start at $69/credit or$39/half-credit for individuals, with quantity discounts for Team or Corporate Subscriptions.

More on Pricing

Internal Auditing for IATF 16949 Course Outline

Unit 1: Requirements for Auditing IATF 16949

Lesson 1 | IATF 16949 Auditing Requirements

  • Be aware of the five supplemental areas (beyond “conventional” internal auditor qualifications) that those auditing IATF 16949 must have proficiency.

Lesson  2 | Process Approach to Auditing

  • Understand what is involved with a process approach to auditing.
  • Describe how to use process mapping to understand a process.
  • Identify which elements impact process performance and determine measures that can be used to monitor and improve the performance of the process.

Lesson 3 | Role of Risk-Based Thinking

  • Realize that risk-based thinking fosters a proactive culture of prevention and improvement.
  • Recognize that risks can refer to either a threat or an opportunity.
  • Be aware of tools and techniques for identifying both threats and opportunities.

Lesson 4 | Focus on Customer Requirements

  • Recognize the importance of Customer Specific Requirements (CSRs).
  • Understand the role that CSRs play in strengthening the integrity of the overall supply chain.

Lesson 5 | Audit Perspective of Related Standards

  • Know that IATF 16949:2016 is implemented in conjunction with ISO 9001:2015.
  • Be aware of significant changes to IATF 16969:2016 and ISO 9001:2015 that impact auditing practices.

Lesson 6 | Role of Core Tools

  • Identify the five Core Tools.
  • Understand how the Core Tools are integrated and interconnected.
  • Realize how to get the “most” out of the Core Tools.

Challenge

  • An assessment of the learner's progress in this course.

Unit 2: Internal Auditing Practices

Lesson 1 | The Audit Process

  • Understand the purpose, objectives and benefits of Internal Audits.
  • Preview six steps for conducting Internal Audits.

Lesson 2 | Step 1: Preparation and Planning

  • Recognize that the bounds of the audit scope must be tightly defined and that staying within these bounds improves results.
  • Understand how to prepare for an effective audit.
  • Be aware of how important it is for all audit participants to remain objective.

Lesson 3 | Step 2: The Opening Meeting

  • Appreciate the importance of a comprehensive Opening Meeting.
  • Know what agenda topics should be covered during the Opening Meeting.

Lesson 4 | Step 3: Collect Evidence

  • Recognize viable sources of evidence.
  • Sort through the evidence to hone in on meaningful data that leads to valid conclusions.
  • Realize when there is enough data gathered.

Lesson 5 | Step 4: Evaluate the Evidence

  • Consolidate evidence gathered.
  • Generate a composite picture of how well the organization's performance conforms to Standards and documented procedures.
  • Separate and itemize nonconformities.
  • Rate nonconformities against a simple, relative priority scale.
  • Provide substantiated evidence of each nonconformity found.

Lesson 6 | Step 5: The Closing Meeting

  • Appreciate the purpose and importance of the Closing Meeting.
  • Understand how to prepare the Audit Report.
  • Know how to prepare for and lead the Closing Meeting.

Lesson 7 | Step 6: Audit Follow-Up

  • Recognize the need to confirm that changes made (at least for Critical and Major Nonconformities) have actually been made.
  • Be aware of the need to verify that the changes made are the right changes.
  • Know what to look for to ensure changes made are sustainable.

Lesson 8 | Auditing Tips

  • Be aware of tips and techniques that can lead to more effective audits and efficient outcomes.

Challenge

  • An assessment of the learner's progress in this course.

Internal Auditing for IATF 16949 Training Course Objectives

  • Define the five supplemental areas beyond "conventional" internal auditor qualifications that those auditing for IATF 16949 must be proficient in.
  • Highlight the differences between "clause-based" and "process-based" auditing and explain the benefits to the process-based approach to auditing.
  • Describe how Risk-Based Thinking and Core Tools are used in IATF 16949 Internal Audits.
  • Appreciate the role Customer Specific Requirements (CSRs) play in strengthening the overall supply chain.
  • Explain the relationship between IATF 16949 and ISO 9001 and the impact the two standards in tandem have on auditing practices.
  • Describe the purpose, objectives and benefits of Internal Audits.
  • Identify each of the six steps of the internal audit process, explain the key components of each step as well as the importance of that step on the overall success of the audit.

Risk-Based Thinking Course Outline

Lesson 1 | Risks and Quality Standards

  • Understand that some standards have been revised and now incorporate risk-based thinking into their requirements.
  • Be exposed to several industry-wide and industry-specific standards that call for risk-based thinking.

Lesson 2 | Identify Risks

  • Recognize potential risks that signal threats.
  • Realize that a potential risk may be an opportunity, not a threat.
  • Be familiar with common tools to identify threats and opportunities.

Lesson 3 | Analyze Risks

  • Know how to analyze the Likelihood of a potential threat or opportunity.
  • Rate the Impact of an event.
  • Plot the Likelihood versus the Impact on a 2-D Matrix.

Lesson 4 | Evaluate & Prioritize Risks

  • Calculate the Risk Index using the ratings for Likelihood and Impact from the “Analyze Risks” phase.
  • Use the Risk Index to set priorities for action plans to reduce the risk from threats and capitalize on favorable opportunities.

Lesson 5 | Mitigation or Capitalization

  • Understand how to mitigate unacceptable threats.
  • Be aware of strategies to capitalize on worthwhile opportunities.

Lesson 6 | Control Risks

  • Be familiar with some common measures and control mechanisms that help ensure that risk mitigation continues to work as planned and that gains made are sustained.

Lesson 7 | Risk Management

  • Realize that Risk-Based Thinking can lead to a comprehensive Risk Management Process.
  • Be aware of forms that can support the methodology needed for a Risk Management Process.
  • Understand how the Summary Worksheet serves as both an historical document and a communication tool.

Challenge

  • An assessment of the learner's progress in this course.

Risk-Based Thinking Course Objectives

  • Identify, assess and evaluate potential risks (whether they are threats or  opportunities).
  • Prioritize potential targets.
  • Gain insight on how to develop action plans for high priority targets.
  • Measure and track the effectiveness and progress of action taken.
  • Initiate control plans to curb similar risks in the future.
  • Establish a comprehensive risk management process.

PPAP Training Course Outline

Lesson 1 | PPAP Overview

  • Explains what the PPAP Process is.
  • Explores why a PPAP should be used.
  • Discusses when PPAP is needed.
  • Introduces how the PPAP Process is conducted.

Lesson 2 | Documentation Requirements

  • Explores each of the 18 Elements of the PPAP Documentation Package.
  • Explains "Reasons for PPAP Submission."
  • Describes PPAP "Submission Levels."

Lesson 3 | Reviewing the PPAP Process

  • Clarifies PPAP requirements.
  • Reinforces how the PPAP Process fosters customer-supplier trust.
  • Confirms that PPAP documentation is based on data.
  • Reviews documentation requirements for Bulk Materials.
  • Discusses customer-supplier negotiations.
  • Recaps requirements for part submission, retaining documentation, Master Samples and shipment samples.

Challenge

  • An assessment of the learner’s progress in this course.

PPAP Training Course Objectives

  • Understand what PPAP is, why it should be used and when it should be used.
  • Know how to complete PPAP documentation requirements.
  • Interpret when specific PPAP requirements apply and when they don’t.