Archive for Courses

AIAG-VDA FMEA-MSRs (Coming November 2019)

AIAG-VDA FMEA-MSR Training

Course Outline
Course Objectives

Intended Audience

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

Time To Complete

4 hours (0.4 CEUs)

Print Course Info

AIAG-VDA FMEA-MSR Online Training

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

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

This course is still in development. The anticipated release is November 2019. In the meantime, to get a solid understanding of the new AIAG-VDA FMEA process, we recommend our Introduction to AIAG-VDA FMEAs.

Compare All FMEA Courses

What is AIAG-VDA Failure Mode and Effects Analysis?

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

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

Learn more about FMEA in our FMEA Resource Center.

This Training Enables Learners To…

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

Features of All Courses

Recommended Prerequisites

  • None.

You May Also Be Interested In…

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

Pricing Info

AIAG-VDA FMEA-MSRs Tentative Course Outline

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

Challenge

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

AIAG-VDA FMEA-MSRs Training Course Objectives

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

AIAG-VDA Design-FMEAs

AIAG-VDA Design-FMEA Training

Course Outline
Course Objectives

Intended Audience

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

Time To Complete

6 hours (0.6 CEUs)

Print Course Info

AIAG-VDA Design-FMEAs Online Training

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

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

This course is still in development. The anticipated release is September 2019. In the meantime, to get a solid understanding of the new AIAG-VDA FMEA process, we recommend our Introduction to AIAG-VDA FMEAs.

Compare All FMEA Courses

What is AIAG-VDA Failure Mode and Effects Analysis?

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

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

Learn more about FMEA in our FMEA Resource Center.

This Training Enables Learners To…

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

Features of All Courses

Recommended Prerequisites

  • None.

You May Also Be Interested In…

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

Pricing Info

AIAG-VDA Design-FMEAs Training Course Objectives

  • Explain the value of FMEAs in reducing risk.
  • Compare and contrast the different types of FMEAs and describe the relationship between DFMEAs and PFMEAs.
  • Identify key quality standards that specify the use of FMEAs.
  • Learn how to use the 7-Step AIAG-VDA FMEA process and explain key differences between the 2019 process and FMEAs prior to the 2019 changes.
  • Define the purpose and process for conducting an FMEA-MSR.
  • Learn how to customize the S-O-D Criteria.
  • Explain the relationship between DFMEAs and FMEA-MSRs.
  • Identify limitations of FMEAs.

AIAG-VDA Design-FMEAs Tentative Course Outline

Lesson 1 | Why Conduct DFMEAs?

Lesson 2 | Brief History of FMEAs

Lesson 3 | Overview of the DFMEA Process

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

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

Lesson 6 | Communication (Step 7)

Lesson 7 | Conducting FMEA-MSRs

Lesson 8 | Helpful Hints

Challenge

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

AIAG-VDA Process-FMEAs

AIAG-VDA Process-FMEA Training

Course Outline
Course Objectives

Intended Audience

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

Time To Complete

5 hours (0.5 CEUs)

Print Course Info

AIAG-VDA Process-FMEAs Online Training

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

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

Compare All FMEA Courses

What is AIAG-VDA Failure Mode and Effects Analysis?

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

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

This Training Enables Learners To…

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

Features of All Courses

Recommended Prerequisites

  • None.

You May Also Be Interested In…

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

Pricing Info

AIAG-VDA Process-FMEAs Training Course Objectives

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

AIAG-VDA Process-FMEAs TENTATIVE Course Outline

Lesson 1 | Why Conduct PFMEAs?

Lesson 2 | Brief History of FMEAs

Lesson 3 | Overview of the PFMEA Process

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

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

Lesson 6 | Communication (Step 7)

Lesson 7 | Helpful Tips

Challenge

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

Introduction to AIAG-VDA FMEAs

Introduction to AIAG-VDA FMEAs

Course Outline
Course Objectives

Intended Audience

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

Time To Complete

3 hours (0.3 CEUs)

Print Course Info

Introduction to AIAG-VDA FMEAs Online Training

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

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

What is AIAG-VDA Failure Mode and Effects Analysis?

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

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

Learn more about FMEA in our FMEA Resource Center.

This Training Enables Learners To…

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

Features of All Courses

Recommended Prerequisites

  • None.

You May Also Be Interested In…

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

Pricing Info

Introduction to AIAG-VDA FMEAs Course Outline

Lesson 1 | What is an FMEA?

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

Lesson  2 | Purposes of FMEAs

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

Lesson 3 | Adding Value with FMEAs

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

Lesson 4 | Types of FMEAs

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

Lesson 5 | The FMEA Process

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

Lesson 6 | Assembling an FMEA Team

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

Lesson 7 | Best Practices for Conducting FMEAs

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

Challenge

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

Introduction to AIAG-VDA FMEAs Training Course Objectives

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

Internal Auditing for IATF 16949

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.

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.

AIAG-VDA FMEA-MSRs Tentative Course Outline

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

Challenge

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

AIAG-VDA FMEA-MSRs Training Course Objectives

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

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.

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AIAG-VDA Design-FMEAs Tentative Course Outline

Lesson 1 | Why Conduct DFMEAs?

Lesson 2 | Brief History of FMEAs

Lesson 3 | Overview of the DFMEA Process

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

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

Lesson 6 | Communication (Step 7)

Lesson 7 | Conducting FMEA-MSRs

Lesson 8 | Helpful Hints

Challenge

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

AIAG-VDA Design-FMEAs Training Course Objectives

  • Explain the value of FMEAs in reducing risk.
  • Compare and contrast the different types of FMEAs and describe the relationship between DFMEAs and PFMEAs.
  • Identify key quality standards that specify the use of FMEAs.
  • Learn how to use the 7-Step AIAG-VDA FMEA process and explain key differences between the 2019 process and FMEAs prior to the 2019 changes.
  • Define the purpose and process for conducting an FMEA-MSR.
  • Learn how to customize the S-O-D Criteria.
  • Explain the relationship between DFMEAs and FMEA-MSRs.
  • Identify limitations of FMEAs.

AIAG-VDA Process-FMEAs TENTATIVE Course Outline

Lesson 1 | Why Conduct PFMEAs?

Lesson 2 | Brief History of FMEAs

Lesson 3 | Overview of the PFMEA Process

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

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

Lesson 6 | Communication (Step 7)

Lesson 7 | Helpful Tips

Challenge

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

AIAG-VDA Process-FMEAs Training Course Objectives

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

Introduction to AIAG-VDA FMEAs Course Outline

Lesson 1 | What is an FMEA?

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

Lesson  2 | Purposes of FMEAs

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

Lesson 3 | Adding Value with FMEAs

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

Lesson 4 | Types of FMEAs

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

Lesson 5 | The FMEA Process

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

Lesson 6 | Assembling an FMEA Team

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

Lesson 7 | Best Practices for Conducting FMEAs

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

Challenge

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

Introduction to AIAG-VDA FMEAs Training Course Objectives

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

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

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

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Internal Auditing for IATF 16949 Course Outline

Unit 1: Requirements for Auditing IATF 16949

Lesson 1 | IATF 16949 Auditing Requirements

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

Lesson  2 | Process Approach to Auditing

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

Lesson 3 | Role of Risk-Based Thinking

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

Lesson 4 | Focus on Customer Requirements

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

Lesson 5 | Audit Perspective of Related Standards

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

Lesson 6 | Role of Core Tools

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

Challenge

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

Unit 2: Internal Auditing Practices

Lesson 1 | The Audit Process

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

Lesson 2 | Step 1: Preparation and Planning

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

Lesson 3 | Step 2: The Opening Meeting

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

Lesson 4 | Step 3: Collect Evidence

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

Lesson 5 | Step 4: Evaluate the Evidence

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

Lesson 6 | Step 5: The Closing Meeting

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

Lesson 7 | Step 6: Audit Follow-Up

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

Lesson 8 | Auditing Tips

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

Challenge

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

Internal Auditing for IATF 16949 Training Course Objectives

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

Risk-Based Thinking Course Outline

Lesson 1 | Risks and Quality Standards

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

Lesson 2 | Identify Risks

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

Lesson 3 | Analyze Risks

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

Lesson 4 | Evaluate & Prioritize Risks

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

Lesson 5 | Mitigation or Capitalization

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

Lesson 6 | Control Risks

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

Lesson 7 | Risk Management

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

Challenge

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

Risk-Based Thinking Course Objectives

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

PPAP Training Course Outline

Lesson 1 | PPAP Overview

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

Lesson 2 | Documentation Requirements

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

Lesson 3 | Reviewing the PPAP Process

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

Challenge

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

PPAP Training Course Objectives

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

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.

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.