Consulting and training on the 6 Core Tools in IATF 16949

1. What are the 6 Core Tools?

Core Tools are quality tools used in the automotive supply chain to support IATF 16949 implementation and meet customer requirements. The six tools complement one another in product development, risk management, measurement system evaluation, process control and product approval.

Why the term “6 Core Tools” is now used: Many earlier introductions referred to five tools because APQP and Control Plan were presented together. AIAG has separated APQP and Control Plan into two manuals, so current introductory materials should include APQP, Control Plan, PPAP, FMEA, MSA and SPC. Control Plan is not an entirely new activity. See AIAG’s information on APQP and Control Plan.

The scope, editions and implementation approach should be determined by the product, processes, design responsibility and customer-specific requirements.

2. The role of each tool

1. APQP — Advanced Product Quality Planning

Advanced Product Quality Planning. Plan activities, assign responsibilities and monitor product and process development milestones to meet customer requirements.

2. Control Plan (CP)

Control Plan. Define the characteristics to control, measurement methods, sample sizes, frequencies, responsibilities and reaction plans for abnormal conditions.

3. PPAP — Production Part Approval Process

Production Part Approval Process. Prepare evidence and customer submission records demonstrating that the product and process meet agreed requirements.

4. FMEA — Failure Mode and Effects Analysis

Failure Mode and Effects Analysis. Identify design and process risks, assess priorities and determine actions to prevent or reduce risk.

5. MSA — Measurement System Analysis

Measurement System Analysis. Assess measurement data reliability and select appropriate studies, such as repeatability, reproducibility, bias, linearity and stability.

6. SPC — Statistical Process Control

Statistical Process Control. Monitor variation, use control charts and assess process capability when the necessary analytical conditions are met.

3. Connecting the 6 Core Tools in practice

APQP organizes the product and process development plan. FMEA analyzes risks; its findings need to be reflected in the Control Plan and work instructions. MSA helps assess measurement data quality, while SPC monitors process variation. PPAP brings together the evidence needed for customer submission under agreed requirements.

For example, for a critical part dimension, the project team defines requirements through APQP, analyzes the risk of dimensional errors in the PFMEA, incorporates inspection methods and reactions into the Control Plan, evaluates the measurement system through MSA, monitors the process with SPC, and includes the relevant results in the PPAP submission.

When designs, equipment, materials or manufacturing methods change, the business needs to review and update related documents consistently.

4. ITVC consulting and training services

• Awareness and practical training on the 6 Core Tools: clarify each tool’s role, application methods and relationships with the other tools.
• Consulting on development and implementation: help businesses review their current situation, create an implementation plan and practice on suitable products and processes.
• Control Plan guidance: connect process flow diagrams, PFMEA, controlled characteristics, measurement methods and reaction plans.
• Review of records and implementation capability: identify missing or inconsistent elements for improvement before engaging with customers.

The program is suitable for quality, engineering, production, product development and supplier management personnel, as well as IATF 16949 implementation teams. Content, duration and delivery format are discussed according to current capabilities and business needs.

Request consulting and training on the 6 Core Tools →

5. Documents and related articles

AIAG’s introduction to Quality Core Tools. Articles about past training courses and projects retain the content applicable at the time they were carried out.

• How to develop a Control Plan
• Training on 5 Core Tools at Uniden Vietnam Co., Ltd.
• VDA 6.3 process audit training course
• Training to understand and apply the 6 Core Tools in IATF 16949
• IATF 16949:2016 awareness and requirements interpretation training at Federal Mogul Vietnam
• ISO 9001, ISO 14001 and IATF 16949 consulting at IRISO Vietnam Electronics Co., Ltd.
• IATF 16949:2016 consulting at Halla Electronic Vietnam
• IATF 16949:2016 consulting at YOSHINO DENKA KOGYO VIETNAM
• ISO/TS 16949 consulting at Federal Mogul Vietnam — Trang Due Industrial Park, Hai Phong
• Download the IATF 16949:2016 standard
• Download IATF 16949:2016 – Sanctioned Interpretations #1~15
• List of IATF 16949 certification bodies
• IATF 16949:2016 – Sanctioned Interpretations
• Consulting on upgrading to IATF 16949:2016
• ISO 9001:2008 consulting at Bridgestone Tire Manufacturing Co., Ltd.