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

Lesson 1 • Roles and Responsibilities in Core Tools

Identifies cross-functional team roles required to execute each tool effectively. Clarifies accountability structures used throughout the course.

Lesson 2 • Interrelationship of the Five Tools

Maps how APQP, PPAP, FMEA, MSA, and SPC feed into one another across the product lifecycle. Builds a mental model for integrated quality planning.

Lesson 3 • Quality Planning Terminology

Defines key terms used across all five tools to ensure consistent language. Eliminates ambiguity before technical content begins.

Lesson 1 • Phase 5: Feedback and Continuous Improvement

Establishes post-launch monitoring, lessons-learned capture, and corrective action loops. Closes the APQP cycle and feeds future programmes.

Lesson 2 • Phase 4: Product and Process Validation

Covers production trial runs, measurement system evaluation, and capability studies. Validates that the process consistently meets customer specifications.

Lesson 3 • APQP Timing Plan and Deliverables

Builds a complete APQP timing chart with all required deliverables and owners. Enables professionals to manage launch readiness reviews.

Lesson 4 • Phase 1: Plan and Define Programme

Covers voice-of-customer inputs, design goals, and preliminary bill of materials. Connects customer needs to measurable product requirements.

Lesson 5 • APQP Purpose and Scope

Defines APQP objectives, applicable product types, and launch timing requirements. Sets the stage for phase-by-phase execution.

Lesson 1 • DFMEA Specific Application

Applies FMEA methodology to design functions, interfaces, and design verification activities. Connects DFMEA outputs to design records and DVP&R.

Lesson 2 • Steps 5 and 6: Risk Assessment and Optimisation

Covers occurrence and detection ratings, Action Priority determination, and corrective action planning. Drives risk reduction through targeted prevention and detection controls.

Lesson 3 • FMEA Fundamentals and AIAG-VDA Approach

Introduces the seven-step AIAG-VDA FMEA methodology and its differences from legacy RPN-based approaches. Establishes the foundation for both DFMEA and PFMEA.

Lesson 4 • Steps 1 and 2: Planning and Structure

Covers FMEA scope definition, boundary diagrams, and structure trees for design and process. Ensures the analysis is properly bounded before failure modes are identified.

Lesson 5 • PFMEA Specific Application

Applies FMEA methodology to manufacturing process steps, equipment, and operator interactions. Links PFMEA outputs to control plans and process controls.

Lesson 1 • Design and Engineering Documentation Elements

Covers design records, engineering change documents, and customer engineering approvals. Ensures design intent is fully documented before submission.

Lesson 2 • Process and Quality System Elements

Addresses PFMEA, control plan, process flow, and measurement system analysis within PPAP. Links process planning documents to submission evidence.

Lesson 3 • Capability Studies and Appearance Approval

Addresses initial process capability indices and appearance approval reports for visual parts. Connects statistical evidence to customer acceptance criteria.

Lesson 4 • Part Submission Warrant and PPAP Disposition

Covers PSW completion, bulk material requirements, and customer disposition outcomes. Prepares professionals to manage approval, interim approval, and rejection.

Lesson 5 • PPAP Purpose and Submission Levels

Explains why PPAP exists, when it is triggered, and the five submission levels. Establishes the scope of evidence required at each level.

Lesson 1 • Gage R&R: Variable Data Studies

Teaches crossed and nested Gage R&R study design, data collection, and ANOVA-based analysis. Quantifies repeatability and reproducibility for variable measurement systems.

Lesson 2 • Measurement System Fundamentals

Defines measurement system components, sources of variation, and the impact of measurement error on decisions. Establishes why MSA is required before process data is trusted.

Lesson 3 • Bias, Linearity, and Stability Studies

Covers methods to evaluate systematic measurement error across the operating range and over time. Identifies gage calibration and drift issues before production use.

Lesson 4 • Attribute Gage Studies

Covers attribute agreement analysis and signal detection methods for go/no-go and visual inspection systems. Evaluates consistency of attribute decisions across operators.

Lesson 1 • SPC Foundations and Variation Concepts

Introduces common and special cause variation, the normal distribution, and the statistical basis of control charts. Builds the conceptual foundation for all SPC methods.

Lesson 2 • Process Capability Analysis

Covers Cp, Cpk, Pp, and Ppk indices, their calculation, and customer acceptance thresholds. Links capability results to PPAP submission and APQP validation.

Lesson 3 • Individuals and Moving Range Charts

Teaches I-MR chart construction for processes where subgrouping is impractical. Addresses assumptions, limitations, and appropriate use cases.

Lesson 4 • Variable Control Charts: X-bar and R/S

Covers subgroup sampling, control limit calculation, and chart interpretation for X-bar and R or S charts. Applies to continuous measurement data in production.

Lesson 5 • SPC Implementation and Sustainment

Addresses control plan integration, operator training, reaction plans, and SPC system auditing. Ensures SPC transitions from a study tool to a sustained production system.

Lesson 1 • Control Method and Reaction Plan Design

Addresses selection of control methods, sample plans, and operator reaction instructions for each characteristic. Converts FMEA detection controls into actionable production steps.

Lesson 2 • Characteristic Classification and Selection

Covers methods for identifying and classifying special and significant characteristics for control. Ensures the highest-risk features receive appropriate monitoring intensity.

Lesson 3 • Control Plan Purpose and Structure

Defines the control plan's role in linking FMEA, process flow, and SPC into a single document. Introduces the three types: prototype, pre-launch, and production.

Lesson 1 • Simulated Product Launch Case Study

Applies all five tools to a single product scenario from concept through PPAP submission. Reinforces integration by requiring outputs from each tool to feed subsequent steps.

Lesson 2 • Cross-Functional Team Facilitation

Covers techniques for leading APQP reviews, FMEA sessions, and PPAP readiness meetings. Builds facilitation skills needed to drive team alignment across functions.

Lesson 3 • Integrated Launch Planning Workflow

Maps the sequence of core tool deliverables across a complete product launch timeline. Demonstrates how outputs from one tool become inputs to the next.

Lesson 4 • Launch Readiness Review and Customer Approval

Covers the structure and content of a launch readiness review and customer approval process. Prepares professionals to present and defend core tool outputs to customers.