Lesson 1Process 3: Production (shop floor) — purpose, inputs/outputs, roles, in-process inspections and first-article checksThis lesson describes the production process on the shop floor, defining purpose, inputs, outputs, roles, and key controls, including first-article checks and in-process inspections, to ensure stable, capable production of metal components.
Defining production process scope and flowInputs, outputs, and work order informationRoles of operators, leaders, and engineersFirst-article inspection and approval stepsIn-process inspection and reaction plansControl of rework, scrap, and traceabilityLesson 2Process 1: Sales order handling — purpose, inputs/outputs, roles, two practical quality checksThis lesson details the sales order handling process, from inquiry to confirmed order, defining purpose, inputs, outputs, roles, and two practical quality checks to ensure requirements are clear, feasible, and correctly communicated to operations.
Capturing customer inquiries and RFQsReviewing technical and quality requirementsFeasibility review and risk assessmentOrder confirmation and contract reviewTwo key order quality verification checksHandover of order data to planning and productionLesson 3Process documentation: simple SOPs, process maps, RACI matrices, and control plansThis lesson explains documenting processes using simple SOPs, process maps, RACI matrices, and control plans, showing how each tool supports ISO 9001, improves clarity, and helps manage risks, handovers, and quality controls on the shop floor.
When to use simple SOPs and work instructionsBuilding clear process maps and swimlanesCreating practical RACI responsibility matricesLinking control plans to process stepsVersion control and document approval rulesKeeping documentation lean yet compliantLesson 4Process 5: Maintenance and equipment management — purpose, inputs/outputs, roles, preventive maintenance checksThis lesson defines the maintenance and equipment management process, covering purpose, inputs, outputs, roles, and preventive maintenance checks, linking equipment reliability to product conformity, safety, and ISO 9001 risk-based thinking.
Purpose and scope of maintenance processMaintenance inputs, outputs, and recordsRoles of operators, technicians, and plannersPreventive maintenance planning and checklistsSpare parts, tools, and calibration interfacesKPIs for downtime, breakdowns, and backlogLesson 5Process 4: Quality control and inspection — purpose, inputs/outputs, roles, incoming and final inspection controlsThis lesson defines the quality control and inspection process, clarifying purpose, inputs, outputs, roles, and controls for incoming, in-process, and final inspection, ensuring objective evidence of conformity and effective feedback to operations.
Purpose and scope of inspection activitiesInspection inputs, outputs, and recordsRoles of inspectors and production staffIncoming inspection and sampling decisionsFinal inspection, release, and labellingFeedback loops and nonconformity triggersLesson 6Process 6: Nonconformity and corrective action handling — purpose, inputs/outputs, roles, containment and root-cause verificationThis lesson explains the nonconformity and corrective action process, covering purpose, inputs, outputs, roles, containment, root-cause analysis, verification of actions, and links to risk-based thinking and continual improvement in ISO 9001.
Defining nonconformity types and sourcesImmediate containment and segregation stepsRoot-cause analysis tools and evidenceCorrective action planning and ownershipVerification of effectiveness and closureTrend analysis and lessons learned sharingLesson 7Selecting core processes for an automotive metal components manufacturerThis lesson guides selection of core processes for an automotive metal components manufacturer, linking customer, statutory, and IATF-style needs to process scope, showing how to prioritise, group, and name processes for a coherent process map.
Understanding customer and regulatory driversIdentifying value-adding and support processesCriteria for defining a process as coreGrouping processes into a logical process mapExample core process set for metal partsReviewing and updating the process listLesson 8Process 2: Purchasing and supplier control — purpose, inputs/outputs, roles, two supplier quality controlsThis lesson defines the purchasing and supplier control process, clarifying purpose, scope, inputs, and outputs, detailing roles, approval criteria, and two practical supplier quality controls aligned with ISO 9001 and automotive expectations.
Purpose and scope of purchasing processKey inputs, outputs, and process interfacesRoles, responsibilities, and authoritiesSupplier selection and approval criteriaIncoming material and certificate checksSupplier performance and escalation rules
