Archive for Courses

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)

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.

The 5S Training

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.

This 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.

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.

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 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.

Gage Training

Course Outline
Course Objectives

Intended Audience

Front-line operators and quality professionals who use dimensional gages in their jobs.

Time To Complete

9 hours (0.9 CEUs)

Why is Gage Training Needed?

Metrology and gage techniques used to be learned on the job. But as measuring equipment (even micrometers and calipers) becomes more discriminating and dimensional requirements tighter more formal metrology training is necessary.

Gage Training Online Training

Gage Training provides metrology, gage, and GD&T training designed for operators and technicians who use dimensional gages in their jobs to make measurements. Gage Training starts with basic dimensional metrology terminology, coversthe importance of measurement standards and the difference between precision and accuracy. Next, the learner is introduced to geometric dimensioning and tolerancing (GD&T) and the fundamentals of surface finishes. Gage Training also covers how to take measurements with the most frequently used instruments including calipers, micrometers, height and depth gages, fixed gages, and gage blocks and surface plates and helps the learner understand the best way to measure various types of dimensions such as roundness and hole position.

This Training Enables Learners To…

  • Describe good measurement principles and practices including basic GD&T concepts.
  • Take accurate measures using hand gages including calipers, micrometers, fixed gages, dial indicators.
  • Avoid the most common misapplications and complications in measuring.
  • Take certain types of measurements including those for linearity, circularity, roundness, etc.

Recommended Prerequisites

  • Basic math skills.

You May Also Be Interested In…

  • Measurement Systems Analysis – Comprehensive training in how to statistically measure the accuracy and reliability of measurement systems.

Gage Training Course Outline

Unit 1 – Gage Primer

Lesson 1 – Why Measure?

  • Understand the three main reasons why parts are measured.
  • Explain the five critical aspects of measuring.

Lesson 2 – Language of Measurement

  • Use the language of dimensional measurement.
  • Convert English to SI (metric) units of measure and SI to English units.
  • Understand basic terminology used on drawings and blueprint.

Lesson 3 – Measurement Standards

  • Explain the role of standards in the dimensional measurement field.
  • Follow the traceability trail of calibration standards.

Lesson 4 – Precision and Accuracy

  • Explain common sources of measurement error.
  • Understand the impact of the five categories of measurement error: accuracy, repeatability, reproducibility, stability, and linearity.

Lesson 5 – Datums

  • Use a datum to locate the position of part features.
  • Identify datum planes, datum points, and datum axis.

Lesson 6 – Introduction to GD&T

  • Explain the differences between coordinate tolerancing and geometric dimensioning and tolerancing.
  • Interpret feature control frames.
  • Use the 14 geometric characteristic controls.
  • Identify GD&T modifying symbols.

Lesson 7 – Surface Finishes

  • Characterize the finish of a surface.
  • Identify the five most common types of surface deviations.
  • Use surface symbols to communicate machining instructions.

Lesson 8 – Math for Measuring

  • Add and subtract fractions.
  • Convert fractions to decimals.
  • Calculate the perimeter and area of rectangular shapes and the circumference and area of circular shapes.

Unit Test Challenge

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

Unit 2 – Using Gages

Lesson 1 – Types of Gages

  • Explain the differences between direct and transfer measurement gages.
  • Identify the line of measurement.
  • Apply the 10-times rule of measurement.

Lesson 2 – Calipers

  • Use a vernier scale.
  • Use a caliper to take measurements.
  • Explain the pros and cons of vernier, dial, and digital calipers.

Lesson 3 – Micrometers

  • Use a micrometer to take measurements.
  • Read precision micrometer scales.
  • Identify applications for inside and outside micrometers.

Lesson 4 – Height and Depth Gages

  • Use height gages with a surface plate to take direct or comparative measurements.
  • Identify height gage accessories used for specialty measuring applications.
  • Use depth gages to measure the depth of features.

Lesson 5 – Fixed Gages

  • Explain the pros and cons of fixed and variable gages.
  • Identify measurement applications for fixed gages.

Lesson 6 – Test Indicators and Dial Indicators

  • Use both test indicators and dial/digital indicator for comparative length measurements.
  • Select indicator contact points types and test stands to specific measurement applications.

Lesson 7 – Gage Blocks and Surface Plates

  • Wring and stack gage blocks.
  • Use gage blocks to calibrate variable gages, check the validity of fixed limit ages, and to set comparative-length indicators.
  • Use gage blocks with surface plates to make comparative measurements.

Unit Test Challenge

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

Unit 3 – Gaging Applications

Lesson 1 – Application Overview

  • Understand that some dimensional instruments are appropriate and some are not for a specific measuring application.
  • Realize that there are common errors and misapplications in measuring and that they can be avoided.

Lesson 2 – Linear Measurements

  • Select the appropriate type of gages for common linear measurement applications.
  • Measure the position of a hole.
  • Measure the differential height between two lands.

Lesson 3 – Roundness and Circularity

  • Use two-point contact gages to measure out-of-roundness.
  • Recognize limitations of two-point contact gages for shapes that are oval, egg-shaped, irregular or lobed.
  • Be exposed to three-point contact gages and sophisticated gages to measure out-of-roundness.

Lesson 4 – Common Misapplications

  • 12 common measuring mistakes and misapplications.
  • What to look out for and how to prevent these mistakes from happening.

Lesson 5 – Measuring Complications

  • 10 systemic problems that can lead to measuring complications.
  • An exploration of why each complication may occur with suggested remedies to combat the complication and make the system more robust.

Lesson 6 – Care of Gages

  • Apply universal practices to take care of gages.
  • Review tips for cleaning and caring for specific instruments.

Unit Test Challenge

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

Gage Training Course Objectives

Unit 1 | Gage Primer

The purpose of this unit is to develop a fundamental understanding of basic gaging concepts. The rest of the training program builds on these concepts. Upon completion of this unit you will be able to:

  • Describe the purpose of measuring and the importance of precise and accurate measurements.
  • Define key metrology terms.
  • Explain the source of measurement standards and why they are so important.
  • Read and interpret basic engineering drawing symbols.
  • Understand GD&T terminology and symbols.
  • Identify and classify flaws in the finish of a surface.
  • Use basic geometry to describe part dimensions.

Unit 2 | Using Gages

In this unit you will learn the proper way to use a variety of dimensional measurement instruments. Upon completion of this unit you will be able to:

  • Use calipers, vernier calipers, micrometers, and vernier micrometers and interpret readings taken with those instruments.
  • Measure parts with both height and depth gages.
  • Use fixed limit gages and describe the advantages and disadvantages of them.
  • Perform measurements with comparative length devices such as test indicators and dial indicators.
  • Use gage blocks for establishing dimensional standards as well as describe their qualities and grades.
  • Explain the purpose and qualities of surface plates.

Unit 3 | Gaging Applications

In this unit you will learn how to select the best gage to use for particular measuring situations. Upon completion of this unit you will be able to:

  • Specify the best gage to use for a variety of different measuring applications.
  • Identify the best way to measure linearity, roundness, and circularity.
  • Make sure you don’t make any of the most common measuring mistakes.
  • Design a measurement process that eliminates or reduces potential measuring complications.
  • Properly care for and maintain gages and measuring instruments.

Overview of Root Cause Analysis Training

Overview of Root Cause Analysis Training from QualityTrainingPortal.com

Course Outline
Course Objectives

Intended Audience

Managers and supervisors who need to have a basic understanding of RCA and CA principles.

Time To Complete

2 hours (0.2 CEUs)

What is Root Cause Analysis (RCA)?

Root cause analysis (RCA) involves searching backwards from an undesirable effect (or problem) to its cause(s) and addressing those causes. While the term “Root Cause” implies that there is a single cause for a problem, often multiple causes interact and work together to trigger the problem. The root cause analysis task is to identify potential causes, determine which cause or causes are root causes and address those root causes to ensure the effect (the problem) does not recur. RCA is important because if a problem has occurred once, it most likely will occur again. However, if the root cause is found and addressed, future occurrences of the same problem CAN BE PREVENTED!

Root cause analysis and corrective action is the key to preventing future problems.

Overview of Root Cause Analysis Online Training

Overview of Root Cause Analysis online training provides the learner with a basic understanding of the principles and techniques of Root Cause Analysis and Corrective Action.  The course is ideal for managers and supervisors who need to understand the terminology and process of RCA without needing to know the specific “how to” details.  For more detailed training on how to conduct root cause analysis, please see Root Cause Analysis with Correction Action.

This Training Enables Learners To…

  • Understand the importance of getting to the root cause of a problem to assure that it is eliminated for good.
  • Recognize common barriers to root cause analysis and apply techniques to overcome those barriers.

Recommended Prerequisites

  • Because this is an overview course, no prior experience is necessary.

You May Also Be Interested In…

  • Introduction to Mistake-Proofing – Online training is designed to introduce learners to the prevention-focused mindset that is the cornerstone of mistake-proofing and to familiarize learners with the concepts, tools, techniques and terminology used to formulate (and evaluate) mistake-proofing solutions.
  • 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.

Overview of Root Cause Analysis Course Outline

Root Cause Analysis Overview

  • What is Root Cause Analysis and why is it important in solving problems.
  • The five steps to Root Cause Analysis with Corrective Action.

Challenge

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

Overview of Root Cause Analysis Course Objectives

  • Understand the importance of getting to the root cause of a problem to assure that it is eliminated for good.
  • Recognize common barriers to root cause analysis and apply techniques to overcome those barriers.

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.

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.

Gage Training Course Outline

Unit 1 - Gage Primer

Lesson 1 - Why Measure?

  • Understand the three main reasons why parts are measured.
  • Explain the five critical aspects of measuring.

Lesson 2 - Language of Measurement

  • Use the language of dimensional measurement.
  • Convert English to SI (metric) units of measure and SI to English units.
  • Understand basic terminology used on drawings and blueprint.

Lesson 3 - Measurement Standards

  • Explain the role of standards in the dimensional measurement field.
  • Follow the traceability trail of calibration standards.

Lesson 4 - Precision and Accuracy

  • Explain common sources of measurement error.
  • Understand the impact of the five categories of measurement error: accuracy, repeatability, reproducibility, stability, and linearity.

Lesson 5 - Datums

  • Use a datum to locate the position of part features.
  • Identify datum planes, datum points, and datum axis.

Lesson 6 - Introduction to GD&T

  • Explain the differences between coordinate tolerancing and geometric dimensioning and tolerancing.
  • Interpret feature control frames.
  • Use the 14 geometric characteristic controls.
  • Identify GD&T modifying symbols.

Lesson 7 - Surface Finishes

  • Characterize the finish of a surface.
  • Identify the five most common types of surface deviations.
  • Use surface symbols to communicate machining instructions.

Lesson 8 - Math for Measuring

  • Add and subtract fractions.
  • Convert fractions to decimals.
  • Calculate the perimeter and area of rectangular shapes and the circumference and area of circular shapes.

Unit Test Challenge

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

Unit 2 - Using Gages

Lesson 1 - Types of Gages

  • Explain the differences between direct and transfer measurement gages.
  • Identify the line of measurement.
  • Apply the 10-times rule of measurement.

Lesson 2 - Calipers

  • Use a vernier scale.
  • Use a caliper to take measurements.
  • Explain the pros and cons of vernier, dial, and digital calipers.

Lesson 3 - Micrometers

  • Use a micrometer to take measurements.
  • Read precision micrometer scales.
  • Identify applications for inside and outside micrometers.

Lesson 4 - Height and Depth Gages

  • Use height gages with a surface plate to take direct or comparative measurements.
  • Identify height gage accessories used for specialty measuring applications.
  • Use depth gages to measure the depth of features.

Lesson 5 - Fixed Gages

  • Explain the pros and cons of fixed and variable gages.
  • Identify measurement applications for fixed gages.

Lesson 6 - Test Indicators and Dial Indicators

  • Use both test indicators and dial/digital indicator for comparative length measurements.
  • Select indicator contact points types and test stands to specific measurement applications.

Lesson 7 - Gage Blocks and Surface Plates

  • Wring and stack gage blocks.
  • Use gage blocks to calibrate variable gages, check the validity of fixed limit ages, and to set comparative-length indicators.
  • Use gage blocks with surface plates to make comparative measurements.

Unit Test Challenge

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

Unit 3 - Gaging Applications

Lesson 1 - Application Overview

  • Understand that some dimensional instruments are appropriate and some are not for a specific measuring application.
  • Realize that there are common errors and misapplications in measuring and that they can be avoided.

Lesson 2 - Linear Measurements

  • Select the appropriate type of gages for common linear measurement applications.
  • Measure the position of a hole.
  • Measure the differential height between two lands.

Lesson 3 - Roundness and Circularity

  • Use two-point contact gages to measure out-of-roundness.
  • Recognize limitations of two-point contact gages for shapes that are oval, egg-shaped, irregular or lobed.
  • Be exposed to three-point contact gages and sophisticated gages to measure out-of-roundness.

Lesson 4 - Common Misapplications

  • 12 common measuring mistakes and misapplications.
  • What to look out for and how to prevent these mistakes from happening.

Lesson 5 - Measuring Complications

  • 10 systemic problems that can lead to measuring complications.
  • An exploration of why each complication may occur with suggested remedies to combat the complication and make the system more robust.

Lesson 6 - Care of Gages

  • Apply universal practices to take care of gages.
  • Review tips for cleaning and caring for specific instruments.

Unit Test Challenge

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

Gage Training Course Objectives

Unit 1 | Gage Primer

The purpose of this unit is to develop a fundamental understanding of basic gaging concepts. The rest of the training program builds on these concepts. Upon completion of this unit you will be able to:

  • Describe the purpose of measuring and the importance of precise and accurate measurements.
  • Define key metrology terms.
  • Explain the source of measurement standards and why they are so important.
  • Read and interpret basic engineering drawing symbols.
  • Understand GD&T terminology and symbols.
  • Identify and classify flaws in the finish of a surface.
  • Use basic geometry to describe part dimensions.

Unit 2 | Using Gages

In this unit you will learn the proper way to use a variety of dimensional measurement instruments. Upon completion of this unit you will be able to:

  • Use calipers, vernier calipers, micrometers, and vernier micrometers and interpret readings taken with those instruments.
  • Measure parts with both height and depth gages.
  • Use fixed limit gages and describe the advantages and disadvantages of them.
  • Perform measurements with comparative length devices such as test indicators and dial indicators.
  • Use gage blocks for establishing dimensional standards as well as describe their qualities and grades.
  • Explain the purpose and qualities of surface plates.

Unit 3 | Gaging Applications

In this unit you will learn how to select the best gage to use for particular measuring situations. Upon completion of this unit you will be able to:

  • Specify the best gage to use for a variety of different measuring applications.
  • Identify the best way to measure linearity, roundness, and circularity.
  • Make sure you don't make any of the most common measuring mistakes.
  • Design a measurement process that eliminates or reduces potential measuring complications.
  • Properly care for and maintain gages and measuring instruments.

Overview of Root Cause Analysis Course Outline

Root Cause Analysis Overview

  • What is Root Cause Analysis and why is it important in solving problems.
  • The five steps to Root Cause Analysis with Corrective Action.

Challenge

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

Overview of Root Cause Analysis Course Objectives

  • Understand the importance of getting to the root cause of a problem to assure that it is eliminated for good.
  • Recognize common barriers to root cause analysis and apply techniques to overcome those barriers.

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.