APQP & PPAP Master Class (AS9145)
The implementation of effective APQP & PPAP demands an in-depth knowledge of the essential process steps, project managements, reporting requirements and quality tools.
DFMEA (Design Failure Mode and Effects Analysis) is a methodology for identifying, assessing, and prioritizing potential risks introduced in a new or changed design of a product. Once the risks have been identified, the organization will manage a plan to minimize or eliminate the impact of negative events on the product as designed.
PFMEA (Process Failure Mode and Effects Analysis) is a methodology for identifying, assessing, and prioritizing risks of different kinds within production and assembly. Once the risks have been identified, the organization will manage a plan to minimize or eliminate the impact of negative events and create control plans which are documented descriptions of the system for controlling processes and the products they create.
Measurement Systems Analysis (MSA)
MSA is an experimental and statistical method of determining how much the variation within the measurement process contributes to overall part characteristic variability – which we are trying to measure!
Process Control Methods & SPC
No two products manufactured on the same process will ever be exactly the same! Discrepancies exists because (manufacturing) processes contain many sources of variation. Process Control Methods contain three main facets – Product Capability determination (statistical control, Cp & Cpk) and Process Control Methods (SPC charting for variable and attribute data).
8D Problem Solving Method
8D (Eight Disciplines) is a step-by-step team-orientated problem-solving methodology which identifies and corrects the root causes of events as opposed to simply addressing their symptoms –
Act rapidly to put immediate containment action in place to protect the customer
Find and fix the root cause with a permanent corrective action on all current product
Prevent the recurrence of the problem in the future by identifying and implementing preventive action anywhere possible within the organization
Formally report on progress in a customer-agreed format
Human Factors (HF) in Manufacturing
We’ve all heard the excuse: “it’s down to human error” with the assumption that there’s nothing we can do about it. Human Factors (HF) focuses on understanding why human errors occur in manufacturing operations –
selecting and using the appropriate 'model' to search for root cause(s)
finding and proving the root cause(s)
then implementing effective ‘controls’ (barriers) to prevent; using practical psychology; or mitigate the consequences of human errors to downstream operations or the customer
FOD Prevention Program in Manufacturing (AS9146)
Foreign Object Damage (FOD) is any damage attributed to alien substances or articles which could potentially degrade the product or system’s required safety and/or performance characteristics
Establishing and maintaining an effective FOD prevention program involves using a process approach and risk-based thinking that proactively addresses the events (conditions and actions) leading to FOD. Risk-based thinking ensures FOD risk is considered when establishing, implementing, and maintaining a FOD prevention program.
Counterfeit parts (CP) prevention
Counterfeit parts (CP) are parts made or modified so as to imitate or resemble an ‘approved part’ without authority or right, and with the intent to mislead, intentionally falsify or defraud by passing the imitation as original or genuine. CPs are “causal factors” in numerous aviation accidents and emergency landings.
CP avoidance demands a formal counterfeit parts prevention program with awareness training for personnel.