AIAG Core Tools (APQP, PPAP, FMEA, MSA, SPC) Training

Lesson 1 • Overview of the Five Core Tools

Introduces APQP, FMEA, MSA, SPC, and PPAP as an integrated toolkit. Learners map each tool to its phase in the product lifecycle.

Lesson 2 • Interrelationships Among Core Tools

Explains how outputs from one tool feed inputs to another. Learners construct a dependency map linking all five tools.

Lesson 3 • Roles and Responsibilities in Core Tools

Defines cross-functional team roles required to execute core tools effectively. Learners assign responsibilities using a RACI model.

Lesson 1 • Voice of the Customer and Design Inputs

Translates customer requirements into measurable design inputs using QFD and benchmarking. Outputs feed directly into FMEA and control plans.

Lesson 2 • APQP Structure and Phase Gates

Breaks down the five APQP phases and their entry and exit criteria. Learners sequence deliverables across the product development timeline.

Lesson 3 • Control Plan Development in APQP

Guides creation of prototype, pre-launch, and production control plans. Learners align control plan columns with FMEA outputs and process flow.

Lesson 4 • Design Verification and Validation Planning

Covers DVP&R construction to confirm design intent before production. Learners link test methods to specific customer and regulatory requirements.

Lesson 1 • Risk Priority Number and Action Priority

Explains RPN calculation and the newer action priority method for ranking risk. Learners apply both approaches and understand their limitations.

Lesson 2 • FMEA Review, Update, and Governance

Establishes cadence for FMEA review triggered by design changes or field failures. Learners implement a governance process to keep FMEAs current.

Lesson 3 • Design FMEA Execution

Walks through DFMEA column-by-column using a structured function-based approach. Learners complete a DFMEA for a sample product subsystem.

Lesson 4 • Process FMEA Execution

Applies PFMEA methodology to a process flow diagram to identify process risks. Learners link PFMEA outputs to control plans and operator instructions.

Lesson 1 • Attribute MSA and Agreement Studies

Applies attribute agreement analysis to pass-fail and visual inspection systems. Learners calculate kappa statistics and interpret appraiser consistency.

Lesson 2 • Measurement System Concepts

Defines accuracy, precision, bias, linearity, stability, and resolution in measurement. Learners identify sources of measurement variation in a system.

Lesson 3 • MSA Acceptance Criteria and Decision Rules

Defines industry-standard acceptance thresholds for Gage R&R and attribute studies. Learners apply decision rules to accept, conditionally accept, or reject a gage.

Lesson 4 • MSA for Destructive and Complex Gages

Addresses MSA challenges when parts are destroyed during measurement or gages are automated. Learners adapt standard methods to non-standard measurement scenarios.

Lesson 1 • Process Capability Indices

Calculates Cp, Cpk, Pp, and Ppk and interprets their meaning relative to specifications. Learners distinguish short-term from long-term capability and set improvement targets.

Lesson 2 • Control Chart Interpretation Rules

Applies Western Electric and Nelson rules to detect out-of-control signals. Learners practice identifying patterns that indicate process shifts or trends.

Lesson 3 • Attribute Control Charts

Introduces p, np, c, and u charts for count and proportion defect data. Learners select the correct attribute chart based on subgroup size and defect type.

Lesson 4 • Variable Control Charts

Covers X-bar and R, X-bar and S, and individuals and moving range charts. Learners calculate control limits and plot charts from raw process data.

Lesson 1 • Capability Improvement Strategies

Links low capability indices to root causes and selects targeted improvement actions. Learners use designed experiments and process centering to raise Cpk.

Lesson 2 • Multivariate and Regression-Based SPC

Introduces T-squared charts and regression control charts for correlated variables. Learners identify when multivariate methods outperform univariate charts.

Lesson 3 • Reaction Plans and Out-of-Control Response

Designs structured reaction plans triggered by control chart signals. Learners integrate reaction plans into control plans and operator work instructions.

Lesson 4 • SPC Software and Real-Time Monitoring

Evaluates SPC software features for data collection, charting, and alerting. Learners configure automated monitoring rules and dashboard reporting.

Lesson 1 • Process and Quality Documentation

Assembles process flow diagrams, PFMEAs, control plans, and work instructions for PPAP. Learners ensure alignment and traceability across all process documents.

Lesson 2 • Dimensional and Material Results

Compiles dimensional layout results and material and performance test reports. Learners interpret results against drawing requirements and flag nonconformances.

Lesson 3 • Part Submission Warrant and Approval

Completes the Part Submission Warrant and manages the customer approval workflow. Learners respond to conditional approvals and manage resubmission requirements.

Lesson 4 • PPAP Requirements and Submission Levels

Defines the five PPAP submission levels and the 18 required elements. Learners match submission level to customer requirements and risk level.

Lesson 1 • Cross-Tool Traceability and Alignment

Establishes traceability from customer requirements through FMEA, control plans, and PPAP. Learners audit a quality package for gaps and inconsistencies.

Lesson 2 • Continuous Improvement Using Core Tools

Uses SPC signals, FMEA updates, and field data to drive ongoing process improvement. Learners close the feedback loop from production data back to APQP planning.

Lesson 3 • End-to-End Launch Simulation

Simulates a full product launch using APQP as the governing framework. Learners execute each core tool in sequence and transfer outputs between tools.

Lesson 4 • Managing Changes After PPAP Approval

Defines change management triggers that require PPAP resubmission or FMEA updates. Learners apply a change impact assessment to determine required actions.