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Homepage > training offer > Open training > Core Tools (Quality Management Tools) – Overview / for First- and Second-Party Auditors
Core Tools (Quality Management Tools) – Overview / for First- and Second-Party Auditors

Core Tools (Quality Management Tools) – Overview / for First- and Second-Party Auditors

Participants of the training will learn about the scope of application of individual Core Tools and how they are interconnected. The Core Tools training is focused on gaining practical knowledge through numerous exercises and case studies conducted with participants (whenever possible, we work on real company data).

The training can also be delivered in an extended version for auditors, focused on the practical auditing of Core Tools methods and tools. In this variant, particular emphasis is placed on evaluating their effectiveness, analysing documentation consistency, and properly documenting nonconformities during internal (first-party) and supplier (second-party) audits.

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Open training

Join a group of participants from different companies and discover industry best practices.

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IN-COMPANY TRAINING

Order a training tailored to the needs of your organization.

3 days / 24 training hours
Stationary / On-line
The day may be established
Individual pricing
Request a quote

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TRAINING PROGRAM

For in-company training, the proposed program is a preliminary suggestion and can be freely adapted to the individual needs of the company.

The following program is indicative (the division into days is arbitrary) and the trainer adapts the course of the training to the specific characteristics of the group. Individual topics may be discussed at a different time or in a different form than indicated in the plan.

Module 1

PRODUCT QUALITY DEVELOPMENT – FROM PLANNING TO SERIAL PRODUCTION

Contents:

  • Presentation of the 5 project phases (including those in accordance with APQP)
  • Objectives and activities to be carried out at each stage of product planning

Module 2

RISK ANALYSIS AT THE DESIGN AND PRODUCTION STAGES (FMEA)

Contents:

  • Types of FMEA (D, P, L, M, MSR, S)
  • Scope of analysis for DFMEA and PFMEA and their interrelationships – practical cases
  • PFMEA analysis – detailed review of the steps:
    • defining the scope of PFMEA analysis (in the context of LFMEA and MFMEA)
    • building the PFMEA structure
    • identifying functions, followed by failures, effects, and causes
    • describing and evaluating prevention and detection controls
    • risk analysis using AP, RPN, and matrices
    • planning improvement actions
  • FMEA standards: AIAG ed. 4, AIAG & VDA, SAE J1739, and selected customer-specific requirements (CSR)

Exercises:

PFMEA for a sample process

Risk analysis based on S, O, and D ratings and improvement planning

Module 3

ZAWARTOŚĆ:

ĆWICZENIA:

Module 4

ZAWARTOŚĆ:

ĆWICZENIA:

Module 1

PROCESS CONTROL USING STATISTICAL METHODS (SPC)

Contents:

  • Types of statistical tools used within SPC
  • Control charts for variable and attribute data – overview
  • The significance of the normal distribution in SPC
  • X̄-R control chart – principles of process control
  • Pp/Ppk and Cp/Cpk indices – calculation methods and application
  • SPC standards: ISO standards, AIAG and VDA standards, and selected customer-specific requirements (CSR)

Exercises:

Analysis of process behavior based on histograms – case studies

Determining process stability limits and analyzing special causes for sample data

Determining and analyzing process capability using Cp and Cpk

Module 2

MEASUREMENT SYSTEM ANALYSIS (MSA)

Contents:

  • Scope of MSA application – measurement systems and instruments
  • Classification of MSA methods and their alignment with specific measurement systems
  • Overview of principles applied within Procedures 1, 2, and 3
  • MSA analysis using the ARM method (%GRR and ndc determination) – case study
  • MSA for attribute inspection – principles and indicators
  • MSA standards: AIAG and VDA standards (VDA 5) and selected customer-specific requirements (CSR)

Exercises:

Analysis of MSA results – case study

Determination of %GRR and ndc for sample measurement data

Analysis of attribute inspection (including visual inspection) using the KAPPA index and evaluation of MISS and FALSE errors

Module 1

CONTROL PLANS AT THE DESIGN AND PRODUCTION STAGES

Contents:

  • Description of the process flow using a PFD (Process Flow Diagram) – requirements and practical principles
  • Process and product characteristics – differentiation and inclusion in the control plan
  • Control plan in relation to PTF, PFMEA, and DFMEA
  • PTC characteristics – principles of application
  • Control plan forms (including the AIAG 2024 form) – content and usage options
  • Error-proofing and mistake-proofing – supervision responsibilities
  • Monitoring and development of control plans using Reversed PFMEA and LPA audits
  • Standards related to control plans: AIAG and VDA standards, as well as selected customer-specific requirements (CSR)

Exercises:

Defining PTC characteristics, product characteristics, and process characteristics for a described process

Developing a control plan for a sample process

Analyzing the interrelationships between the control plan and PFMEA

Module 2

PART APPROVAL ACCORDING TO PPAP – FUNDAMENTALS

Contents:

  • PPAP objectives in the context of customer requirements
  • Types of documentation required for PPAP submission
  • Preparation of Part Submission Warrant (PSW) – principles and required documentation
  • Application of Core Tools within PPAP
  • PPAP standards: AIAG and VDA standards, as well as selected customer-specific requirements (CSR)

Exercises:

Developing a section of a control plan for a selected topic

Assessing histogram compliance in terms of capability and normality

Analyzing process stability (control charts)

Analyzing process capability (Cp/Cpk)

Module 3

ADDITIONAL TOOLS IN QUALITY MANAGEMENT

Contents:

  • QFD analysis – from VOC to the process control plan
  • 8D – principles of application within corrective actions
  • DOE – fundamentals of Design of Experiments (also as input for PFMEA and control plans)
  • Reliability analysis using the Weibull distribution – fundamentals of reliability testing

ADDITIONAL INFORMATION

We ensure that a significant part of the training is dedicated to exercises and practical workshops, making it easier for participants to retain new information.

During this training, practical work includes tasks such as:

  • Developing a section of DFMEA and PFMEA for a selected topic
  • Analyzing MSA and SPC results for process control
  • Reviewing actual control plans – case study
  • Developing a new control plan based on PFMEA and PFD

The detailed scope of the training will be agreed upon after further analysis of training needs.

After completing the training, each participant will receive a certificate confirming their attendance.

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    Sylwia Konsewicz
    Training Specialist – RONAL Polska Sp. z o.o.
  • Training sessions conducted by PROQUAL are characterized by an excellent lecturer–participant relationship. Gaining knowledge during lectures and exercises is an enjoyable experience combined with the expected results. The sessions were organized in a clear and effective manner.
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    BURY Sp. z o.o.
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    Kinga Krystek
    Guillin Polska Sp. z o.o.
  • Training on quality management and specific customer requirements delivered by PROQUAL Management Institute met our expectations. The trainers present deep theoretical and practical knowledge, skillfully adapting the content to specific needs, which significantly increases the effectiveness of the training. We recommend PROQUAL Management Institute as a reliable partner in raising quality standards in the automotive industry.
    Marcin Zieliński
    HR Manager – Merit Poland Sp. z o.o.
  • PROQUAL conducted training for us in SPC and PFMEA, which stood out for the trainer's engagement and knowledge. The material was supported by many interesting industry examples, allowing participants to better understand the issues. We can wholeheartedly recommend working with PROQUAL
    Paweł Chodnik
    Manufacturing Engineering Manager – Electrolux Poland Sp. z o.o.
  • The training sessions were conducted very professionally. The topics were tailored to the participants’ level of knowledge and skills, which allowed for proper understanding of the issues. This was reflected in the evaluation surveys completed by participants, where the PROQUAL expert received very high scores.
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    Head of Quality Assurance Department
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What are Core Tools?

Core Tools are a set of key, standardized tools supporting quality management throughout the entire product lifecycle — from the planning phase, through serial production, to service parts delivery.

The Core Tools set includes five fundamental tools developed and published by AIAG: APQP, PPAP, FMEA, SPC, and MSA. These methods help organizations plan quality, assess risks, control processes, and confirm production capability to meet customer requirements. As such, they form the foundation of quality management systems and support companies in maintaining stable, repeatable, and compliant processes.

Participation in a Core Tools course enables a better understanding of the interrelationships between these tools and their practical application in daily operations.

TRAINING DATES – FLEXIBLE REGISTRATION OPTION

Pay less and let us invite you to a date that suits you and fits into our training schedule. The perfect solution if you can be flexible – we’ll take care of the rest!

THE FLEXIBLE DATE OPTION IS FOR YOU IF:

You are flexible regarding the date and form of participation in the training

You need to use your budget now and want to optimize costs

You want to save money and take advantage of the lowest price option

HOW DOES IT WORK?
  • After receiving your registration, we will propose a training date within a maximum of 180 days (unless the client decides otherwise).
  • At least one week before the training, we will inform you about the possibility of participating and about the available formats – on-site or online (depending on the number of spots).
  • The price of such training is PLN 200 lower than the price of the online version.
    The current price of this training in the flexible form is given in the registration form below.

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