Resources to Diagnose Your Quality Challenges

Do you have a specific automotive manufacturing question that you're looking for a solution on? From APQP and PPAP, to IATF 16949 and everything in between, AIAG offers publications, training, and certification in quality manufacturing, engineering, and purchasing. Check out our self-diagnostic resource to get started

Diagnostics for Manufacturing

Production Part Approval Process (PPAP) is the industry standard that ensures engineering design and product specification requirements are met. Through the PPAP guideline, suppliers and customers understand the requirements to obtain part approval of supplier manufactured parts. Applicable to all parts and commodities, application of these principles reduces delays and non-conformances during part approval.

Benefits of PPAP

  • Consistent part approval process
  • Assurance parts conform to customer requirements
  • Evidence of process stability
  • Controls product and process change process, providing an approval outlet for all changes to ensure conformance to the next level assembly/process

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Advanced Product Quality Planning (APQP) and Control Plans reduce the complexity of product quality planning for customers and suppliers by allowing customers to easily communicate their product quality planning requirements to their suppliers. Suppliers gain an understanding of basic industry requirements for achieving part approval from their customer. Control Plans summarize the identified process and product parameters required to maintain product conformity. These tools are applicable throughout the supply base in all customer/supplier relationships.

Benefits of APQP

  • Up-front planning
  • Guidelines to produce a product quality plan
  • Consistent process for product launch
  • Planned product launches
  • Established benchmarks for achieving customer satisfaction
  • Controlled operations
  • Completion of all process documentation
  • Control plans provide a summary of all process and product parameters that require control and the design limits of these parameters with reaction plans
  • Ensures linkage between process and design documentation (DFMEA, flow chart, PFMEA, control plan, etc.)

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Measurement data monitors nearly every process. As data quality improves, decision quality improves. The MSA guide helps you assess the quality of your measurement systems, providing a basis for identifying where improvements can be made and recognizing the impact of improvement activities. MSA is the core tool for ensuring your measurement system provides accurate and adequate data.

Benefits of MSA

  • Assurance that measurement systems function properly
  • Identifies areas of measurement variation
  • Identifies non-conforming measurement devices
  • Standardization between measurement systems
  • Assurance of shipping conforming measured product

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Statistical Process Control (SPC) is the core tool for measuring process performance. This guide describes several basic and advanced statistical methods to ensure your process improvements are more effective, resulting in products and services that improve value to both you and your customer.

Benefits of SPC

  • Monitoring process trends
  • Process control
  • Measuring and quantifying process improvement
  • Statistical data for process monitoring and for customer sharing
  • Process conformance

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Product and process failure is costly, but identification and countermeasure of potential failure modes significantly reduces those costs. Potential Failure Mode & Effects Analysis (FMEA) is a tool used to identify and address failure modes in products and processes, allowing a company to identify and address risks in their product and process streams. FMEA(s) are living documents that are updated as processes and products are improved, allowing the document to serve as a lessons learned tool. This guide answers questions concerning the technical development of both Design and Process FMEAs.

Benefits of FMEA

  • Analytical, cross-functional process
  • Identification of potential areas of failure
  • Analysis of risk and direction for areas requiring action plans
  • Identification of preventive and detective measures
  • Applicable to processes and product design
  • Tool for tracking lessons learned and process improvements
  • Tool that allows and tracks improvement replication in similar processes/products
  • Improves communication, logs history of error proofing

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IATF 16949:2016, coupled with the applicable customer-specific requirements, defines the quality management system requirements for automotive production, service and/or accessory parts. IATF 16949 is an autonomous QMS standard that is fully aligned with the structure and requirements of ISO 9001. It is not a stand-alone document, but is implemented as a supplement to, and in conjunction with, ISO 9001.

Benefits of IATF 16949

  • Ensures consistent processes
  • Identifies prioritizes and plans for risk
  • Improves employee and leadership involvement
  • Identification of preventive and detective measures
  • Establishes organizational goals and identification of core processes to achieve these goals

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Now in its 5th Edition, the document commonly referred to as "Rules 5th” includes the criteria for certification body recognition, the certification body audit process, certification body auditor qualifications, and IATF 16949 certification. This document replaces "Rules 4th" and encompasses previous Sanctioned Interpretations and Rules related Frequently Asked Questions (FAQs) issued by the IATF prior to the release of this document.

Benefits of IATF 16949 Rules 5th

  • Ensures understanding of the rules for achieving IATF 16949 Certification
  • Improve audit and auditor planning
  • Understand the audit process
  • IATF 16949 Rules 5thResources

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