Automotive Quality Core Tools (APQP, FMEA, SPC, MSA, PPAP)
The five automotive core tools in one programme: APQP, FMEA (AIAG-VDA), SPC, MSA and PPAP. Participants learn what IATF 16949 customers expect from each tool and practise them on case studies, so the tools work together as one product-quality system.
At a glance
- 5 days
Who it's for
- Quality, manufacturing & supplier quality engineers
- Production managers
- Tier 1 / Tier 2 automotive suppliers
- Staff working toward IATF 16949 compliance
Learning objectives
- Understand IATF 16949 and the role of the AIAG core tools
- Run Design and Process FMEA using the AIAG- VDA 7-step approach
- Monitor processes with SPC and capability indices
- Evaluate measurement systems (MSA)
- Prepare PPAP submissions
- Integrate the tools into daily quality work
Detailed content
- Why quality matters in automotive
- IATF 16949 & customer-specific requirements
- APQP phases & Control Plan
- AIAG-VDA FMEA (7-step approach)
- Design FMEA & Process FMEA
- Failure modes, causes & effects
- Action Priority (AP) – replaces RPN
- Action planning
- Variation & stability
- Control charts, histograms
- Cp, Cpk, Pp, Ppk
- Interpreting control charts
- Reducing variability
- Measurement variation
- Gage R&R, bias, linearity, stability
- Attribute agreement analysis
- When PPAP is required
- The 18 PPAP elements
- Submission levels 1–5
- Part Submission Warrant & approval
- Hands-on FMEA, control chart and Gage R&R exercises
- Integrating tools in daily work
Day-by-day agenda
A typical schedule. In-company versions are tailored to your processes, data and timing.
- Automotive Quality & IATF 16949
- FMEA
- SPC
- MSA
- PPAP
- Case Studies & Application
- Case study, action plans and course assessment
Practice, tools and assessment
Hands-on practice
- Build and interpret X-bar/R, I-MR and p-charts from plant data
- Run a capability study (Cp, Cpk, Pp, Ppk) and set improvement targets
- Software lab: the same analysis in Minitab and Excel
- Variable Gage R&R study with three appraisers
Tools and templates you keep
- SPC chart selection guide
- Capability and sample-size calculators
- Gage R&R data sheet and decision guide
- Calibration record template
How learning is assessed
- Pre- and post-course knowledge check
- Assessment of practical exercises by the trainer
- Action plan reviewed at the end of the course
Built on these standards and bodies of knowledge
- AIAG SPC manual (2nd ed.)
- ISO 7870 (control charts) and ISO 22514 (capability)
- AIAG MSA manual (4th ed.)
How it is delivered
- Public courses in Cairo, in-company programs and live online training
- Practical exercises, case studies and examples from your sector
- Can also run as Train & Stay in Sharm El Sheikh, Hurghada or Cairo
Part of these career paths
- Automotive & Manufacturing Quality · Practitioner
Frequently asked questions
How long is Automotive Quality Core Tools (APQP, FMEA, SPC, MSA, PPAP)?
The program runs 5 days. In-company versions can be adapted to your needs.
Is the course taught in Arabic or English?
Sessions are usually delivered in Arabic with English technical terms and materials. Full English delivery is available for in-company groups.
Can you run it inside our company?
Yes. In-company programs use exercises built on your own processes. Tell us the group size and preferred timing and we will send a proposal.
Will I receive a certificate?
Participants who complete the program and its assessment receive a certificate from The Excellence Center, which can be verified online.
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Get dates, fees and the full outline.
Tell us whether you are joining as an individual or planning a program for your team.