26. IATF 16949 Five Core Tools Introduction

Quality core tools are across all different industry. But in the automobile industry, there are 5 primary core tools applied towards area such as New Product Introduction, Process Development, Process Control, Risk Analysis and many more.

In this particular section, the five core tools listed below will be briefly introduced and give a general outline for when and how to apply for it.

For detailed explanation on each core tool, please click the respective tool name for detailed explanation.

APQP ensures the automobile OEMs or customer requirement can be realized by breaking down different segments of requirement during the product realization phase. APQP can be applied for New Product Introduction or existing product modification whether it’s from design improvement or modification.

It can summarize the timeline schedule from development stage and product realization along with required timing for trial execution before mass production.

PPAP can be considered as a bundled approval packaged for verified parts. The verification include but not limited to information such as product design drawing (specification included), Risk Analysis Evidence (preferably FMEA), General Process Flow Diagram, Production Trial Results, Process Capability Report, Measurement System Analysis, Documented Production Process and Respective Record.

Failure Mode & Effect Analysis are used for analyzing potential failure mode occurred at product realization phase. The most common ones are applied in design and production processes (DFMEA and PFMEA respectively).

 

FMEA’s purpose is to help stakeholder identify what are the critical elements and implement appropriate control to prevent potential high risk elements. FMEA’s score is generally scored by the level of severity, occurrence and detection frequency before prioritizing critical element in design/production phase. 

Statistical Process Control helps to identify and plot process data for monitoring purposes. It could be either applied with control chart or scattered diagram to check correlation between the process input and output. This tool can help process engineers or management team to identify the trend earlier to bring the process back to normal standard.

 

For detailed introduction, please refer to the SPC Introduction Link

Measurement System Analysis is used to evaluate whether the inspection measurement system is sufficient to control the production process, meanwhile verifying the inspection system’s effectiveness based on the design specification. 

 

For detailed introduction, please  refer to the MSA introduction link.

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