Archive for Courses

Internal Auditing for IATF 16949

Internal Auditing for IATF 16949

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

Internal Auditing for IATF 16949 Training Online

IATF 16949:2016 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 audit team for IATF 16949 internal audits

This course, Internal Auditing for IATF 16949, prepares in-house personnel to serve on internal teams auditing against the IATF 16949 standard.  Participants not only 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…

  • 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.

5S’s Training

5S training online from QualityTrainingPortal.com

Intended Audience

All employees in manufacturing and non-manufacturing environments.

Time To Complete

5 hours (0.5 CEUs)

5S Training Online

With the 5S training course online, employees will learn the fundamental concepts of the 5S’s that will improve quality and productivity. The 5S training includes step-by-step guidelines for achieving the 5S’s as well as a roadmap to implement the 5S’s throughout the entire organization. Many examples of 5S success stories are included throughout the training.

With this 5S training, participants will be able to go through each of the 5S’s on their own or as part of a team. They will transform their workspace from a cluttered, cramped area to a clean and highly functional space. Beginning with Sorting, learners who complete this training will be able to use the 48-hour rule to remove clutter and distracting items from the immediate work area and then create designated locations for everything based on how often it is used in the Set in Order step. The Shine step will focus the participant on not only an initial deep cleaning of the space, but will help them develop a strategy for keeping the area clean in the future. The last two steps, Standardize and Sustain will help expand the 5S’s throughout your organization.

 


For an introduction to the terminology and process of the 5S’s, please see Introduction to the 5S’s.

What are the 5S’s?

Instituting the 5S’s is usually one of the first step companies take in implementing Lean Six Sigma. The 5S’s (Sort, Set in Order, Shine, Standardize, and Sustain) are rough translations from the original Japanese terms referring to a process to optimize workplace organization. The premise for the 5S’s is that a lot of improvements and inefficiencies can be made by having a clean, organized and efficient workplace.

Learn more about the 5S’s in our 5S Resource Center.

5S Training Enables Learners To…

  • Understand each of the five S’s and how each “S” builds upon the previous “S.”
  • Apply the 5S’s to their work area.
  • Develop (or participate in the development of) a 5S Implementation Roadmap.

Features of All Courses

Recommended Prerequisites

  • Learners should have the ability/authority to make improvements in their work area.

You May Also Be Interested In…

  • Lean Manufacturing – Online training that provides learners with a comprehensive understanding of how Lean Manufacturing works in a manufacturing environment.
  • Lean for Business Processes – Online training that provides learners with a comprehensive understanding of how Lean Manufacturing works in a transaction-based/non-manufacturing business or job function.
  • 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.

Pricing Info

5S’s Workplace Organization Course Outline

Unit 1 The 5S’s Step-by-Step

Lesson 1 | What is 5S All About?

  • An overview of the 5S’s.
  • The benefits and operational impact of implementing the 5S’s.

Lesson 2 | Sort: Clearing the Work Area

  • How to organize the work area for efficiency and effectiveness and use the “48-Hour Rule.”
  • A stepwise approach to clear the work area.

Lesson 3 | Set in Order: Designated Locations

  • How to designate “a place for everything” and ensure “everything is in its place.”
  • Considerations for establishing locations for storing items including: storage rationale, storage options, location-specific tips, storage don’ts, using signs and labels and documenting the plan.

Lesson 4 | Shine: Cleanliness and Workplace Appearance

  • The three aspects of Shine: getting the workplace clean, maintaining its appearance, and using preventive measures to keep it clean.

Lesson 5 | Standardize: Everyone Doing Things the Same Way

  • How to design systems that helps ensure that everyone does things the same way with full involvement, standardized training, and a “copy exactly” mindset.

Lesson 6 | Sustain: Ingrain It in the Culture

  • How to implement techniques to prevent backsliding to sustain and ingrain workplace organization

Unit 1 Challenge

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

Unit 2 5S Implementation

Lesson 1 | An Organization-Wide 5S Effort

  • How to plan and implement a 5S initiative.
  • An 8-point roadmap to implement the 5S’s: 1: Leadership Team; 2: Infrastructure; 3: Communications; 4: Training; 5: 5S Pilots; 6: Best Practices; 7: Full Roll-Out Plan; 8: Evaluate and Adjust.

Lesson 2 | Tackling 5S’s on Your Own

  • How to implement the 5S’s in a work area if an organization-wide initiative is not supported.

Lesson 3 | Success Stories: Sorts

  • Examples of “Sort Successes” showing both the before-state and the after-state with the impact (savings) explained.
  • Checklist to help achieve successful Sorts.

Lesson 4 | Success Stories: Set in Order

  • Examples of “Set in Order Successes” showing both the before-state and the after-state complete with the impact on the organization.
  • Set in Order Checklists.

Lesson 5 | Success Stories: Shine, Standardize and Sustain

  • Examples of successful approaches for the Shine, Standardize and Sustain phases of a 5S program

Unit 2 Challenge

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

5S’s Workplace Organization Course Objectives

Unit 1 | The 5S’s Step-by-Step

In this unit learners will be introduced to the five core components of the 5S’s:

  • Sort: Sort out items not needed in the work area and disposition those items to be removed.
  • Set in Order: Select the best locations and ways to store items used in the work area using a structured rationale and knowledge of storage options.
  • Shine: Get the workplace clean; then maintain the appearance of the workplace and institute preventive measures to ensure it stays clean.
  • Standardize: Design systems in place to ensure everyone does things the same way, implement techniques to ingrain a “copy exactly” mind set, and leverage Best Practices.
  • Sustain: Learn how to prevent backsliding and build the 5S’s into the culture of the organization.

Unit 2 | 5S Implementation

In this unit, learners explore approaches to implement the 5S’s in their organization (or work area); examples of successes for each 5S phase are included.

  • Organization-Wide Implementation: Work though an 8-point checklist to plan an organization-wide implementation of the 5S’s.
  • Work Area Implementation: Use a 6-point checklist to plan your work area 5S effort if a site-wide 5S implementation is not supported.
  • Sort Successes: Explore examples of “Sort Successes” to trigger ideas for your 5S effort.
  • Set in Order Successes: Use lessons learned from “Set in Order Successes” to fuel your 5S effort.
  • Shine, Standardize, & Sustain Successes: Adopt the examples discussed to build success factors into your Shine, Standardize, and Sustain efforts.

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.

Basic SPC Training

Course Outline
Course Objectives

Intended Audience

Operators, engineers, supervisors, and managers who will be using control charts in their jobs.

Time To Complete

6 hours (0.6 CEUs)

Print Course Info

What is Statistical Process Control (SPC)?

SPC or statistical process control is a statistically-based family of tools used to monitor, control, and improve processes. Statistical Process Control (SPC) training can be time consuming and frustrating because of the complex nature of the statistics underlying SPC control charts. Basic SPC is a comprehensive online SPC training course for engineers, operators, and technicians that makes understanding and applying statistical process control (SPC) concepts easy.

Basic SPC Online Training

With Basic SPC online SPC training, you can eliminate or substantially reduce the need for classroom training. In addition to providing a solid understanding of variation and the statistics upon which control charts are based, this course covers use of the most common variable and attributes control charts including x-bar & R-charts, moving average charts, p-charts, u-charts, np charts, and c charts. Extensive training includes collecting sample subgroups, plotting points on control charts, and interpreting SPC charts. This online basic SPC training course also features a conceptual overview of process capability including Cp, Cr, and Cpk to provide learners is a well-rounded and thorough understanding of how to use statistical process control in their jobs. This training is ideal for Six Sigma green belt training or for lean manufacturing training.

Looking for Advanced SPC Training?

This Training Enables Learners To…

  • Better understand variation in manufacturing processes including patterns and measures of variation.
  • Monitor and control variation with variable and attribute control charts.
  • Describe basic process capability concepts and the importance of capability when using control charts.

Recommended Prerequisites

  • Basic math skills.

You May Also Be Interested In…

  • Advanced SPC Training – Comprehensive training in how to implement statistical process control including setting up control charts and conducting process capability studies.
  • 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.

Basic SPC Course Outline

Unit 1 Statistics Primer

Lesson 1 | Introduction to Variation

  • What variation is and why it’s a problem in manufacturing.

Lesson 2 | Measuring Variation

  • Using a histogram to measure the variation in a process.

Lesson 3 | Patterns of Variation

  • Types of patterns of variation, what they tell you, and what to do about them.

Lesson 4 | Measures of Variation

  • Statistical measures of variation: Mean, range, and standard deviation.

Lesson 5 | Normal Curve

  • Properties of the normal curve and the 68, 95, 99.7 rule.

Lesson 6 | Stability

  • The importance of a stable process in manufacturing.

Unit Challenge

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

Unit 2 Using Control Charts

Lesson 1 | What are Control Charts

  • What control charts are and why they are used.

Lesson 2 | What a Control Chart Looks Like

  • Common elements of all control charts.

Lesson 3 | Interpreting Control Charts & Taking Action

  • Out-of-control patterns and what to do when they occur.

Lesson 4 | Types of Control Charts

  • Variable and attribute control charts: Which do you use when?

Lesson 5 | Using Variable Control Charts

  • Calculating and plotting data on variable control charts and interpreting the chart.

Lesson 6 | Using Attribute Control Charts

  • Calculating and plotting data on attribute control charts and interpreting the chart.

Unit Challenge

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

Unit 3 Process Capability Basics

Lesson 1 | What is Process Capability

  • What process capability means and why it’s important.

Lesson 2 | Measuring Process Capability

  • The capability ratio, process capability index, and Cpk.

Unit Challenge

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

Basic SPC Course Objectives

Unit 1 | Statistics Primer

  • Explain what variation in a work process is and why it is bad.
  • Describe key techniques for measuring variation – visual display and mathematical.
  • Identify key patterns of variation and explain what causes them.

Unit 2 | Using Control Chart

  • Understand the purpose of a control chart.
  • Identify key parts of a control chart.
  • Know how to collect and plot data on a control chart.
  • Be able to interpret and take action using a control chart.

Unit 3 | Process Capability Basics

  • Describe what is meant by a capable process.
  • Contrast the difference between an “in-spec” process and a “capable process.”
  • Identify and explain the three main measures of process capability.

Measurement Systems Analysis Training

Course Outline
Course Objectives

Intended Audience

Engineers, quality professionals, supervisors, metrology technicians.

Time To Complete

7 hours (0.7 CEUs)

Print Course Info

What is Measurement Systems Analysis?

Not every organization is aware of the importance of understanding and quantifying the variation in measurement systems. Without a good measurement system, there is no real way of knowing what the output of a process really is! We may think that we are producing good parts based on measurements made 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.

GR&R Studies are the most widely accepted techniques for evaluating the level of variation in a measurement system and determining if the evaluated measurement system is acceptable for use. And, once a measurement system is found acceptable, it is equally important to institute a formal system to manage the measurement system to ensure that it continues to be reliable and dependable.

Measurement Systems Analysis Online Training

MSA (Measurement Systems Analysis) online training includes detailed tutorials on many measurement system analysis techniques including how to conduct and analyze GR&R (Gage Repeatability and Reproducibility) Studies. A GR&R is the accepted technique for evaluating the level of variation in a measurement system and determining if the measurement system is acceptable for use. Measurement System Analysis covers techniques for analyzing the variation within a measurement system, determining its suitability for use, and ways to improve measurement systems. The GR&R analysis techniques used in the MSA online training program are in compliance with IAFT 16949/AIAG methods.

Once a measurement system is found to be acceptable, it is equally important to institute a formal system to manage the measurement system to ensure that it continues to be reliable and dependable. MSA explores approaches to managing measurement systems to ensure that they can be depended upon.

This Training Enables Learners To…

  • To explain various sources of measurement system uncertainty.
  • To conduct measurement system studies including assessment of linearity, stability, repeatability, and reproducibility.
  • To define ways to improve measurement systems.
  • To understand and implement a gage management and calibration system.

Recommended Prerequisites

  • A solid understanding of statistical measures of variation covered in Basic SPC and Advanced SPC or the equivalent.
  • Experience with basic measuring concepts and an understanding of sources of variation in measurement systems such as what is covered in Gage Training or the equivalent.

You May Also Be Interested In…

  • DOE: Screening Experiments – Comprehensive training in one of the most powerful families of Designs of Experiments – Screening Experiments.  Includes training in both Plackett-Burman designs and Taguchi techniques.
  • Advanced SPC Training – Comprehensive training in how to implement statistical process control including setting up control charts and conducting process capability studies.
  • 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 Course Outline

Unit 1 Analyzing Measurement System Variation

Lesson 1 | Variation in Measurement Systems

  • A review of sources of measurement system variation.
  • An explanation of Type A and Type B evaluations of measurement uncertainty.
  • Exploration of the effects of too much variation on measurements.

Lesson 2 | Measurement System Linearity

  • How to measure gage/instrument linearity (both graphically and mathematically) to determine if a gage (or instrument) has linearity problems.
  • Taking action to deal with linearity problems.

Lesson 3 | Measurement System Stability

  • How to evaluate gage/instrument stability using a control chart. Taking action to deal with stability problems.

Lesson 4 | Repeatability & Reproducibility

  • How to conduct a GR&R study.
  • R&R analysis for non-destructive measurements.
  • Use of ANOVA for GR&Rs.
  • R&R analysis for destructive measurements.
  • R&R analysis for attribute measurements.
  • Graphical techniques to analyze R&R.

Lesson 5 | Improving Measurement Systems

  • Using a problem-solving approach to find the root causes of repeatability and reproducibility problems.
  • Using the GR&R data to help direct the problem-solving effort.
  • A description of some basic causes to investigate if gage/instrument repeatability is high.
  • A description of some basic causes to investigate if appraiser reproducibility is high.

Lesson 6 | MSA Software Considerations

  • Suggested selection criteria for features of software programs for analyzing GR&R studies.
  • An overview of some of the advanced measurement system analysis tools that a GR&R software package may have.

Unit 1 Challenge

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

Unit 2 Managing Measurement Systems

Lesson 1 | Formal Instruments Management

  • Why a gage/instrument calibration program is so important and makes good business sense.
  • Why a gage/instrument may not be accurate.
  • The components of a gage/instrument management system.

Lesson 2 | Sources of Measurement Error

  • Measurement errors due to gage/instrument calibration deficiencies.
  • Measurement error related to gage/instrument usage or damage.
  • Errors of judgment resulting in measurement errors.
  • GR&R issues and measurement error.

Lesson 3 | Calibration Practices

  • A discussion of common calibration practices.
  • Key elements of a calibration system as defined by ISO 10012-1.
  • Gage/instrument identification techniques.
  • Sources for calibration procedures and independent calibration laboratories.
  • Methods for determining intervals of calibration.

Lesson 4 | Calibration Standards & Tools

  • Traceability of calibration standards from primary national standards to working standards.
  • The role of transfer standards and working standards.
  • Measurement uncertainty and the calibration system.

Lesson 5 | Calibration Pitfalls

  • Common instrument management system pitfalls.
  • Proactive techniques to steer your organization clear of these pitfalls.

Lesson 6 | Records & Audits

  • Different types of records needed for a comprehensive instrument management system.
  • The role of audits to ensure your instrument management system is working.

Lesson 7 | Calibration Software Considerations

  • Benefits of using instrument management software.
  • Suggested selection criteria of software features for an instrument management software program.

Unit 2 Challenge

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

Measurement Systems Analysis Course Objectives

Unit 1 | Analyzing Measurement System Variation

In this unit, you will cover the techniques for analyzing the variation contained within a measurement system itself. After completing this Unit, you should be able to:

  • Know the common sources of measurement system variation.
  • Understand both Type A and Type B evaluations of measurement uncertainty.
  • Use both graphical and mathematical techniques to evaluate gage or instrument linearity and stability, and initiate action to address linearity or stability issues.
  • Know how to plan and conduct a GR&R study.
  • Perform R&R analysis for non-destructive measurements, for destructive measurements, and for attribute measurements.
  • Use ANOVA and graphical techniques for the R&R analysis.
  • Use the GR&R data to initiate action to improve the measurement device’s repeatability and reproducibility.

Unit 2 | Managing Measurement Systems

In this unit you will learn about the importance of measurement device calibration management. Upon completion of this unit you will be able 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 your requirements for measurement instrument management software, if you choose to computerize your records.

Fundamentals of APQP Training

APQP Training online from QualityTrainingPortal.com

Course Outline
Course Objectives

Intended Audience

Product design engineers, product development professionals, quality engineers.

Time To Complete

6 hours (0.6 CEUs)

Print Course Info

What is APQP?

Advanced Product Quality Planning, or APQP for short, creates a roadmap for developing new products complete with time-based milestones and decision points along the way. A major objective of APQP is to provide a vehicle for suppliers and customers to work together when developing a new product. This helps assure that the product is delivered on time and with the highest added-value. New Product Introductions (NPIs) have a greater success rate when the principles of the APQP approach are followed.

APQP has five formal phases. Each phase is connected to and triggers the next. APQP is not a “use what I like and ignore the rest” approach. It represents a continuum in which each phase builds upon the next. Some organizations precede the “official” five phases with a “Phase 0” that includes forming a team, defining the scope of the project, conducting an initial assessment of the projects’ feasibility and establishing documentation and communication protocols.

Fundamentals of APQP Training Online

The Fundamentals of APQP training online walks learners through all phases of the APQP process beginning at Phase 0 and ends with a lesson on Control Plans.  Throughout the training there are exercises and upon completion of the content, learners complete the Fundamentals of APQP Challenge that tests their understanding of the material.

This APQP Training is designed for employees who are responsible for conducting or participating in the APQP process.  We also offer an Overview of APQP course for managers and personnel responsible to overseeing departments responsible for conducting APQPs but who are not intimately involved in conducting them.

This APQP Training Enables Learners To…

  • Work through the five phases of the APQP process.
  • Create a Design Verification Plan and Report.
  • Use Control Plans from Prototype to Pre-Launch to Production Phases.
  • Describe the Production Part Approval Process.

Recommended Prerequisites

  • Mistake-Proofing or Error-Proofing or the equivalent understanding of the difference between fixing problems after they happen and preventing problems from happening in the first place.

You May Also Be Interested In…

  • PPAP Training – A Targeted Training Course on the Production Part Approval Process.
  • Advanced SPC Training – Comprehensive training in how to implement statistical process control including setting up control charts and conducting process capability studies.
  • 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.
  • Measurement Systems Analysis – Comprehensive training in how to statistically measure the accuracy and reliability of measurement systems.

Fundamentals of APQP Course Outline

Lesson 0 | Overview of APQP

  • Overview of the five phases of the APQP Process.

Lesson 1 | Phase 1: Plan and Define the Program

  • Information and data are compiled to build a business case.
  • The output of this phase defines specifically what product will be studied.

Lesson 2 | Phase 2: Product Design and Development

  • The design of the product is fleshed out.
  • After the design is verified, a prototype is built, specifications developed and inputs for the process design are generated.

Lesson 3 | Phase 3: Process Design and Development

  • The manufacturing process for the product is designed.
  • Major outcomes include development of the process flow and layout.
  • Additionally, a Characteristics Matrix, PFMEA, Pre-Launch Control Plan and Process Instructions are developed.

Lesson 4 | Phase 4: Product and Process Validation

  • The process and the product design are validated.
  • The output product from the production run is used to evaluate the measurement system and check the process capability.

Lesson 5 | Phase 5: Feedback Assessment & Corrective Action

  • Start the cycle of continuous improvement.
  • Control charts can be used to identify special causes of variation, capability studies and the use of design of experiments can help reduce common cause variation.
  • Work to ensure the product fully meets customer’s needs.

Lesson 6 | (Unofficial) Phase 6: Control Plans

  • Identify control factors, control points and control methods for the product and its corresponding manufacturing process.
  • Develop a comprehensive Control Plan.

Challenge

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

Fundamentals of APQP Course Objectives

  • Explain the purpose of the APQP process.
  • Describe the five phases of the APQP process.
  • List the steps necessary to prepare for an APQP effort.
  • Be aware of techniques used to identify the VOC (Voice of the Customer.)
  • Understand how Design-FMEAs can help reduce risks in the design phase and Process-FMEAs can help reduce process related risks.
  • Be familiar with a Design Verification Plan and Report.
  • Understand the sequential progress of Control Plans from Prototype to Pre-Launch to Production Phases.
  • Understand how Engineering Change Requests generate vital documentation.
  • Be familiar with a Team Feasibility Checklist (to conclude Phase 2.)
  • Select appropriate flowcharting and process mapping techniques to aid in design of the process.
  • Be familiar with a Characteristics Matrix to plot the relationship between product parameters and operational steps of the process.
  • Know the importance of Measurement System Analyses and a Preliminary Process Capability studies in evaluating the process and product output.
  • Be familiar with the Production Part Approval Process.
  • Be acquainted with a Quality Planning Sign-Off (that confirms completion of Phases 1 through 4.)
  • Know about tools and techniques that are used to continuously improve both the product its corresponding process.

Value Stream Mapping Training

Course Outline
Course Objectives

Intended Audience

Quality professionals, engineers, marketing, managers and supervisors.

Time To Complete

2 hours (0.2 CEUs)

What Is Value Stream Mapping?

A value stream is another term for a process that has inputs, performs work on those inputs, and generates an output that has added value. The basic premise of a value stream is that value is added as goods or services stream through the process. Unfortunately, some actions, task, and activities continued within most all value streams do not add value; those non-value-adding task or activities represent waste in the process or value stream.

Mapping the value stream creates a visual representation of the value stream that helps point out the waste contained within the process flow. A value stream represents all of the activities and tasks needed to produce a product. Value streams start with the source of raw materials, flow through the internal processes and continue with the delivery of the product to customers.

Value Stream Mapping Online Training

In this targeted online training, learners will gain an understanding of the purpose of conducting a value stream analysis and what a value stream map is.  Steps to streamline a value stream from current state to future state are presented.

This Training Enables Learners To…

  • Describe the purpose of a Value Stream Map.
  • Identify the key components of a Value Stream Map.
  • Explain the key steps in developing the Future State Map.
  • Work as a productive member of a team tasked with conducting a value stream analysis.

Recommended Prerequisites

  • None.

You May Also Be Interested In…

  • 5S’s Workplace Organization – Comprehensive training in the concepts and application of the 5S’s (Sort, Set in Order, Shine, Standardize and Sustain) and how to apply these techniques on the job.
  • Lean for Business Processes – Online training that provides learners with a comprehensive understanding of how Lean Manufacturing works in a transaction-based/non-manufacturing business or job function.
  • Mapping Office Workflows – Targeted training in various techniques to map workflows in non-manufacturing environments.

Value Stream Mapping Course Outline

Lesson 1 | Value Stream Analysis

  • Defining what the Value Stream is and why is should be mapped.
  • How to use process flow mapping symbols to show the flow of the process – both the current state and the desired future state.

Lesson 2 | Streamlining the Value Stream

  • Using the Value Stream Map to understand sources of waste and then to conduct a work analysis and then to create a macro workflow and finally a micro workflow.
  • Focus on the characteristics of a lean value stream and how to build those into the future state.

Challenge

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

Value Stream Mapping Course Objectives

  • Describe the purpose of a Value Stream Map.
  • Identify the key components of a Value Stream Map.
  • Explain the key steps in developing the Future State Map.
  • Understand the purpose of streamlining the value stream.
  • Describe the steps to streamline a workflow.
  • Identify the key characteristics of a lean value stream.
  • Compare and contrast the difference between a macro and micro workflow.
  • Describe the impact of a bottleneck on a process.

Overview of APQP Training

Course Outline
Course Objectives

Intended Audience

Product design engineers, product development professionals, quality engineers.

Time To Complete

1.5 hours (0.2 CEUs)

What is APQP?

Advanced Product Quality Planning, or APQP for short creates a roadmap for developing new products complete with time-based milestones and decision points along the way. A major objective of APQP is to provide a vehicle for suppliers and with customers to work together when developing a new product. This helps assure that the product is delivered on time and with the highest added-value. New Product Introductions (NPIs) have a greater success rate when the principles of the APQP approach are followed.

APQP has five formal phases. Each phase is connected to and triggers the next. APQP is not a “use what I like and ignore the rest” approach. It represents a continuum in which each phase builds upon the next. Some organizations precede the “official” five phases with a “Phase 0” that includes forming a team, defining the scope of the project, conducting an initial assessment of the projects’ feasibility and establishing documentation and communication protocols.

Overview of APQP Online Training

The Overview of APQP training is ideal for managers and supervisors who oversee departments responsible for Advanced Product Quality Planning.  This is a short online course intended to explain the basic approach and scope of the Advanced Product and Quality Planning (APQP) methodology.  We also offer the Fundamentals of APQP that is designed for employees who are responsible for conducting or participating in the APQP process.

This Training Enables Learners To…

  • Explain the purpose of the APQP process.
  • Describe the five phases of the APQP process.
  • List the steps necessary to prepare for an APQP.

Recommended Prerequisites

  • Mistake-Proofing or Error-Proofing or the equivalent understanding of the difference between fixing problems after they happen and preventing problems from happening in the first place such.

You May Also Be Interested In…

  • Advanced SPC Training – Comprehensive training in how to implement statistical process control including setting up control charts and conducting process capability studies.
  • 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.
  • Fundamentals of APQP – A Master Course that helps learners understand the five phases of the APQP process and apply it to the development of new products and their corresponding processes.
  • PPAP Training – A Targeted Training Course on the Production Part Approval Process.

This Course is Derived from Fundamentals of APQP

This course is a great way to learn the basic concepts and terminology of APQP.  It is taken from our comprehensive Fundamentals of APQP course.  If you have already taken the Fundamentals of APQP course, you have already seen the content covered in Overview of APQP.

Overview of APQP Course Outline

Lesson 1 | Overview of APQP

  • Overview of the five phases of the APQP Process.

Course Test Challenge

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

Overview of APQP Course Objectives

  • Explain the purpose of the APQP process.
  • Describe the five phases of the APQP process.
  • List the steps necessary to prepare for an APQP.

Mapping Office Workflows Training

Course Outline
Course Objectives

Intended Audience

All employees in a non-manufacturing environment.

Time To Complete

2 hours (0.2 CEUs)

Why Map Office Workflows?

Workflows are patterns of tasks or steps in a process that are designed to lead to an output. The intent of mapping a workflow is to improve a process by uncovering “the good, the bad and the ugly” parts of the process. “Good” steps in a process are value-adding activities. Anything that does not add value is “bad.” Process steps that lead to errors, mistakes and defects represent the “ugly.” With the bad and ugly parts of a process uncovered, it is much easier to identify opportunities for improvement. In a manufacturing environment it is fairly easy to see the physical steps in the process; in an office/service environment steps in the process can be more difficult to see because they include non-tangible items such as information, services or transactions.

Mapping Office Workflows Online Training

Mapping Office Workflows helps office workers create visual representations of processes that they work in and provides them with tools that help unveil different aspects of their workflow and see the processes they work in from different angles. By using one or more of the mapping tools covered (Brown-Paper Flow, Workflow Diagrams, Flowcharting, Value-Stream Mapping), learners will be able to identify the causes of nagging problems and take action to remedy them.

This Training Enables Learners To…

  • Define the bounds of a workflow.
  • Use a variety of process (workflow) mapping techniques.
  • Identity hand-offs, disconnects, incomplete communication and rework loops as non-value-adding components (or waste).
  • Plan improvements to workflows.
  • Consider a move from batch processing to continuous (or one-piece) flow.

Recommended Prerequisites

  • None.

You May Also Be Interested In…

  • The 5S’s: Workplace Organization – Comprehensive training in the concepts and application of the 5S’s (Sort, Set in Order, Shine, Standardize and Sustain) and how to apply these techniques on the job.
  • Lean for Business Processes – Online training that provides learners with a comprehensive understanding of how Lean Manufacturing works in a transaction-based/non-manufacturing business or job function.
  • Value Stream Mapping – Focused training in how to map a value stream from developing a current state map, analyzing the value stream and then creating a future state map.

This Course is Derived from Lean for Business Processes

This course is a great way to learn how to map workflows.  It is taken from our comprehensive Lean for Business Processes course.  If you have already taken the Lean for Business Processes course, you have already seen the content covered in Mapping Office Workflows.

Mapping Office Workflows Course Outline

Lesson 1 | Overview of Workflows

  • Overview on what a workflow map is and how they can help improve processes.
  • Discussion on the types of maps and the value of each in the mapping process.

Lesson 2 | Brown Paper Workflows

  • Introduction to the Brown-Paper Flow as the place to start with mapping processes.
  • Step-by-step instructions on how to construct a brown-paper flow and how to use it to identify problems with a work process.

Lesson 3 | Workflow Diagrams

  • How to construct a workflow diagram to understand the physical flow of a process.
  • Using a workflow diagram to combine or eliminate steps, move sequential steps closer together, reduce the number of hand-offs and to convert to a continuous process.

Lesson 4 | Flowcharting

  • How to use flowcharts to document the details of a process including activities, decision points, wait periods, feedback loops and rework loops.
  • Four of the most common families of flowcharts are explored along with the pros and cons of each.

Lesson 5 | Value Stream Mapping

  • How to use a value-stream map to evaluate workflows and identify waste in a process.
  • Developing both a current state and future state map.

Challenge

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

Mapping Office Workflows Course Objectives

  • Define the bounds of a workflow.
  • Use a variety of process (workflow) mapping techniques.
  • Identity hand-offs, disconnects, incomplete communication and rework loops as non-value-adding components (or waste.)
  • Plan improvements to workflows.
  • Consider a move from batch processing to continuous (or one-piece) flow.

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.

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

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.

5S's Workplace Organization Course Outline

Unit 1 The 5S’s Step-by-Step

Lesson 1 | What is 5S All About?

  • An overview of the 5S's.
  • The benefits and operational impact of implementing the 5S's.

Lesson 2 | Sort: Clearing the Work Area

  • How to organize the work area for efficiency and effectiveness and use the "48-Hour Rule."
  • A stepwise approach to clear the work area.

Lesson 3 | Set in Order: Designated Locations

  • How to designate "a place for everything" and ensure "everything is in its place."
  • Considerations for establishing locations for storing items including: storage rationale, storage options, location-specific tips, storage don'ts, using signs and labels and documenting the plan.

Lesson 4 | Shine: Cleanliness and Workplace Appearance

  • The three aspects of Shine: getting the workplace clean, maintaining its appearance, and using preventive measures to keep it clean.

Lesson 5 | Standardize: Everyone Doing Things the Same Way

  • How to design systems that helps ensure that everyone does things the same way with full involvement, standardized training, and a "copy exactly" mindset.

Lesson 6 | Sustain: Ingrain It in the Culture

  • How to implement techniques to prevent backsliding to sustain and ingrain workplace organization

Unit 1 Challenge

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

Unit 2 5S Implementation

Lesson 1 | An Organization-Wide 5S Effort

  • How to plan and implement a 5S initiative.
  • An 8-point roadmap to implement the 5S's: 1: Leadership Team; 2: Infrastructure; 3: Communications; 4: Training; 5: 5S Pilots; 6: Best Practices; 7: Full Roll-Out Plan; 8: Evaluate and Adjust.

Lesson 2 | Tackling 5S's on Your Own

  • How to implement the 5S's in a work area if an organization-wide initiative is not supported.

Lesson 3 | Success Stories: Sorts

  • Examples of "Sort Successes" showing both the before-state and the after-state with the impact (savings) explained.
  • Checklist to help achieve successful Sorts.

Lesson 4 | Success Stories: Set in Order

  • Examples of "Set in Order Successes" showing both the before-state and the after-state complete with the impact on the organization.
  • Set in Order Checklists.

Lesson 5 | Success Stories: Shine, Standardize and Sustain

  • Examples of successful approaches for the Shine, Standardize and Sustain phases of a 5S program

Unit 2 Challenge

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

5S's Workplace Organization Course Objectives

Unit 1 | The 5S's Step-by-Step

In this unit learners will be introduced to the five core components of the 5S's:

  • Sort: Sort out items not needed in the work area and disposition those items to be removed.
  • Set in Order: Select the best locations and ways to store items used in the work area using a structured rationale and knowledge of storage options.
  • Shine: Get the workplace clean; then maintain the appearance of the workplace and institute preventive measures to ensure it stays clean.
  • Standardize: Design systems in place to ensure everyone does things the same way, implement techniques to ingrain a "copy exactly" mind set, and leverage Best Practices.
  • Sustain: Learn how to prevent backsliding and build the 5S's into the culture of the organization.

Unit 2 | 5S Implementation

In this unit, learners explore approaches to implement the 5S's in their organization (or work area); examples of successes for each 5S phase are included.

  • Organization-Wide Implementation: Work though an 8-point checklist to plan an organization-wide implementation of the 5S's.
  • Work Area Implementation: Use a 6-point checklist to plan your work area 5S effort if a site-wide 5S implementation is not supported.
  • Sort Successes: Explore examples of "Sort Successes" to trigger ideas for your 5S effort.
  • Set in Order Successes: Use lessons learned from "Set in Order Successes" to fuel your 5S effort.
  • Shine, Standardize, & Sustain Successes: Adopt the examples discussed to build success factors into your Shine, Standardize, and Sustain efforts.

Basic SPC Course Outline

Unit 1 Statistics Primer

Lesson 1 | Introduction to Variation

  • What variation is and why it's a problem in manufacturing.

Lesson 2 | Measuring Variation

  • Using a histogram to measure the variation in a process.

Lesson 3 | Patterns of Variation

  • Types of patterns of variation, what they tell you, and what to do about them.

Lesson 4 | Measures of Variation

  • Statistical measures of variation: Mean, range, and standard deviation.

Lesson 5 | Normal Curve

  • Properties of the normal curve and the 68, 95, 99.7 rule.

Lesson 6 | Stability

  • The importance of a stable process in manufacturing.

Unit Challenge

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

Unit 2 Using Control Charts

Lesson 1 | What are Control Charts

  • What control charts are and why they are used.

Lesson 2 | What a Control Chart Looks Like

  • Common elements of all control charts.

Lesson 3 | Interpreting Control Charts & Taking Action

  • Out-of-control patterns and what to do when they occur.

Lesson 4 | Types of Control Charts

  • Variable and attribute control charts: Which do you use when?

Lesson 5 | Using Variable Control Charts

  • Calculating and plotting data on variable control charts and interpreting the chart.

Lesson 6 | Using Attribute Control Charts

  • Calculating and plotting data on attribute control charts and interpreting the chart.

Unit Challenge

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

Unit 3 Process Capability Basics

Lesson 1 | What is Process Capability

  • What process capability means and why it's important.

Lesson 2 | Measuring Process Capability

  • The capability ratio, process capability index, and Cpk.

Unit Challenge

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

Basic SPC Course Objectives

Unit 1 | Statistics Primer

  • Explain what variation in a work process is and why it is bad.
  • Describe key techniques for measuring variation - visual display and mathematical.
  • Identify key patterns of variation and explain what causes them.

Unit 2 | Using Control Chart

  • Understand the purpose of a control chart.
  • Identify key parts of a control chart.
  • Know how to collect and plot data on a control chart.
  • Be able to interpret and take action using a control chart.

Unit 3 | Process Capability Basics

  • Describe what is meant by a capable process.
  • Contrast the difference between an "in-spec" process and a "capable process."
  • Identify and explain the three main measures of process capability.

Measurement Systems Analysis Course Outline

Unit 1 Analyzing Measurement System Variation

Lesson 1 | Variation in Measurement Systems

  • A review of sources of measurement system variation.
  • An explanation of Type A and Type B evaluations of measurement uncertainty.
  • Exploration of the effects of too much variation on measurements.

Lesson 2 | Measurement System Linearity

  • How to measure gage/instrument linearity (both graphically and mathematically) to determine if a gage (or instrument) has linearity problems.
  • Taking action to deal with linearity problems.

Lesson 3 | Measurement System Stability

  • How to evaluate gage/instrument stability using a control chart. Taking action to deal with stability problems.

Lesson 4 | Repeatability & Reproducibility

  • How to conduct a GR&R study.
  • R&R analysis for non-destructive measurements.
  • Use of ANOVA for GR&Rs.
  • R&R analysis for destructive measurements.
  • R&R analysis for attribute measurements.
  • Graphical techniques to analyze R&R.

Lesson 5 | Improving Measurement Systems

  • Using a problem-solving approach to find the root causes of repeatability and reproducibility problems.
  • Using the GR&R data to help direct the problem-solving effort.
  • A description of some basic causes to investigate if gage/instrument repeatability is high.
  • A description of some basic causes to investigate if appraiser reproducibility is high.

Lesson 6 | MSA Software Considerations

  • Suggested selection criteria for features of software programs for analyzing GR&R studies.
  • An overview of some of the advanced measurement system analysis tools that a GR&R software package may have.

Unit 1 Challenge

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

Unit 2 Managing Measurement Systems

Lesson 1 | Formal Instruments Management

  • Why a gage/instrument calibration program is so important and makes good business sense.
  • Why a gage/instrument may not be accurate.
  • The components of a gage/instrument management system.

Lesson 2 | Sources of Measurement Error

  • Measurement errors due to gage/instrument calibration deficiencies.
  • Measurement error related to gage/instrument usage or damage.
  • Errors of judgment resulting in measurement errors.
  • GR&R issues and measurement error.

Lesson 3 | Calibration Practices

  • A discussion of common calibration practices.
  • Key elements of a calibration system as defined by ISO 10012-1.
  • Gage/instrument identification techniques.
  • Sources for calibration procedures and independent calibration laboratories.
  • Methods for determining intervals of calibration.

Lesson 4 | Calibration Standards & Tools

  • Traceability of calibration standards from primary national standards to working standards.
  • The role of transfer standards and working standards.
  • Measurement uncertainty and the calibration system.

Lesson 5 | Calibration Pitfalls

  • Common instrument management system pitfalls.
  • Proactive techniques to steer your organization clear of these pitfalls.

Lesson 6 | Records & Audits

  • Different types of records needed for a comprehensive instrument management system.
  • The role of audits to ensure your instrument management system is working.

Lesson 7 | Calibration Software Considerations

  • Benefits of using instrument management software.
  • Suggested selection criteria of software features for an instrument management software program.

Unit 2 Challenge

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

Measurement Systems Analysis Course Objectives

Unit 1 | Analyzing Measurement System Variation

In this unit, you will cover the techniques for analyzing the variation contained within a measurement system itself. After completing this Unit, you should be able to:

  • Know the common sources of measurement system variation.
  • Understand both Type A and Type B evaluations of measurement uncertainty.
  • Use both graphical and mathematical techniques to evaluate gage or instrument linearity and stability, and initiate action to address linearity or stability issues.
  • Know how to plan and conduct a GR&R study.
  • Perform R&R analysis for non-destructive measurements, for destructive measurements, and for attribute measurements.
  • Use ANOVA and graphical techniques for the R&R analysis.
  • Use the GR&R data to initiate action to improve the measurement device's repeatability and reproducibility.

Unit 2 | Managing Measurement Systems

In this unit you will learn about the importance of measurement device calibration management. Upon completion of this unit you will be able 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 your requirements for measurement instrument management software, if you choose to computerize your records.

Fundamentals of APQP Course Outline

Lesson 0 | Overview of APQP

  • Overview of the five phases of the APQP Process.

Lesson 1 | Phase 1: Plan and Define the Program

  • Information and data are compiled to build a business case.
  • The output of this phase defines specifically what product will be studied.

Lesson 2 | Phase 2: Product Design and Development

  • The design of the product is fleshed out.
  • After the design is verified, a prototype is built, specifications developed and inputs for the process design are generated.

Lesson 3 | Phase 3: Process Design and Development

  • The manufacturing process for the product is designed.
  • Major outcomes include development of the process flow and layout.
  • Additionally, a Characteristics Matrix, PFMEA, Pre-Launch Control Plan and Process Instructions are developed.

Lesson 4 | Phase 4: Product and Process Validation

  • The process and the product design are validated.
  • The output product from the production run is used to evaluate the measurement system and check the process capability.

Lesson 5 | Phase 5: Feedback Assessment & Corrective Action

  • Start the cycle of continuous improvement.
  • Control charts can be used to identify special causes of variation, capability studies and the use of design of experiments can help reduce common cause variation.
  • Work to ensure the product fully meets customer's needs.

Lesson 6 | (Unofficial) Phase 6: Control Plans

  • Identify control factors, control points and control methods for the product and its corresponding manufacturing process.
  • Develop a comprehensive Control Plan.

Challenge

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

Fundamentals of APQP Course Objectives

  • Explain the purpose of the APQP process.
  • Describe the five phases of the APQP process.
  • List the steps necessary to prepare for an APQP effort.
  • Be aware of techniques used to identify the VOC (Voice of the Customer.)
  • Understand how Design-FMEAs can help reduce risks in the design phase and Process-FMEAs can help reduce process related risks.
  • Be familiar with a Design Verification Plan and Report.
  • Understand the sequential progress of Control Plans from Prototype to Pre-Launch to Production Phases.
  • Understand how Engineering Change Requests generate vital documentation.
  • Be familiar with a Team Feasibility Checklist (to conclude Phase 2.)
  • Select appropriate flowcharting and process mapping techniques to aid in design of the process.
  • Be familiar with a Characteristics Matrix to plot the relationship between product parameters and operational steps of the process.
  • Know the importance of Measurement System Analyses and a Preliminary Process Capability studies in evaluating the process and product output.
  • Be familiar with the Production Part Approval Process.
  • Be acquainted with a Quality Planning Sign-Off (that confirms completion of Phases 1 through 4.)
  • Know about tools and techniques that are used to continuously improve both the product its corresponding process.

Value Stream Mapping Course Outline

Lesson 1 | Value Stream Analysis

  • Defining what the Value Stream is and why is should be mapped.
  • How to use process flow mapping symbols to show the flow of the process - both the current state and the desired future state.

Lesson 2 | Streamlining the Value Stream

  • Using the Value Stream Map to understand sources of waste and then to conduct a work analysis and then to create a macro workflow and finally a micro workflow.
  • Focus on the characteristics of a lean value stream and how to build those into the future state.

Challenge

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

Value Stream Mapping Course Objectives

  • Describe the purpose of a Value Stream Map.
  • Identify the key components of a Value Stream Map.
  • Explain the key steps in developing the Future State Map.
  • Understand the purpose of streamlining the value stream.
  • Describe the steps to streamline a workflow.
  • Identify the key characteristics of a lean value stream.
  • Compare and contrast the difference between a macro and micro workflow.
  • Describe the impact of a bottleneck on a process.

Overview of APQP Course Outline

Lesson 1 | Overview of APQP

  • Overview of the five phases of the APQP Process.

Course Test Challenge

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

Overview of APQP Course Objectives

  • Explain the purpose of the APQP process.
  • Describe the five phases of the APQP process.
  • List the steps necessary to prepare for an APQP.

Mapping Office Workflows Course Outline

Lesson 1 | Overview of Workflows

  • Overview on what a workflow map is and how they can help improve processes.
  • Discussion on the types of maps and the value of each in the mapping process.

Lesson 2 | Brown Paper Workflows

  • Introduction to the Brown-Paper Flow as the place to start with mapping processes.
  • Step-by-step instructions on how to construct a brown-paper flow and how to use it to identify problems with a work process.

Lesson 3 | Workflow Diagrams

  • How to construct a workflow diagram to understand the physical flow of a process.
  • Using a workflow diagram to combine or eliminate steps, move sequential steps closer together, reduce the number of hand-offs and to convert to a continuous process.

Lesson 4 | Flowcharting

  • How to use flowcharts to document the details of a process including activities, decision points, wait periods, feedback loops and rework loops.
  • Four of the most common families of flowcharts are explored along with the pros and cons of each.

Lesson 5 | Value Stream Mapping

  • How to use a value-stream map to evaluate workflows and identify waste in a process.
  • Developing both a current state and future state map.

Challenge

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

Mapping Office Workflows Course Objectives

  • Define the bounds of a workflow.
  • Use a variety of process (workflow) mapping techniques.
  • Identity hand-offs, disconnects, incomplete communication and rework loops as non-value-adding components (or waste.)
  • Plan improvements to workflows.
  • Consider a move from batch processing to continuous (or one-piece) flow.