Engineering Process Courses

Beginning Statistical Process Control (SPC)

Beginning SPC covers the following topics: SPC definition and theory; Understanding normal distribution; Causes of Variation; Description of common SPC applications; X bar and R charts—generating and interpreting; Attribute charts—generating and interpreting; Causes of out-of-control conditions—common and special.

You need SPC training if
  • You are required to participate in the generation of PPAPs
  • You need to chart inspections on the shop floor
  • You need to communicate with customers regarding new part
  • You need to discuss part issues with customers on an ongoing basis
  • You have responsibility for employee training
Course Outcomes
  • Understand statistical process control in the manufacturing environment
  • Identify instances of practical application for SPC
  • Understand how to apply SPC to your processes
  • Learn the necessary skills to develop and maintain SPC on a day-to-day basis
  • Identify out-of-control instances and take the appropriate steps to minimize instances of non-conforming products
  • Increase awareness of importance of maintaining process control

 

Advanced Product Quality Planning (APQP)

APQP is a quality framework used for developing new products in the auto industry. The APQP process can be applied to any industry. This course leads participants through each phase of the APQP process utilizing case studies and exercises. Students will participate in an APQP role play that includes each phase of the actual process.

Control plan generation is studied in depth, and each participant will develop a control plan from the scenario presented in the classroom. Students will understand the importance of ensuring the control plan is an active document and that it is accurate and current at all times.

You need APQP training if
  • You are an automotive parts or service supplier;
  • You quote new work for the automotive industry;
  • You participate in new product launch;
  • You are part of the engineering change process for existing products supplied to the automotive industry;
  • You have not participated in formal APQP or PPAP training in the past 3 years;
  • You have had you APQP submissions rejected by our customers.
Course Outcomes
  • Learn the role of each department in the APQP process and how to be an effective participant in the APQP team
  • Able to recognize missing information through various scenarios
  • Understand the importance of communicating information that is correct, current and complete to appropriately and the importance of cross-functional participation in a successful project / project launch

 

Protection Part Approval Process (PPAP)

PPAP defines requirements for production part approval, including production and bulk materials. The purpose of PPAP is to determine if customer engineering design and specification requirements are properly understood by the supplier and that the process has the potential to produce product consistently meeting these requirements at the quoted production rate.

You need PPAP training if
  • You are an automotive parts or service supplier;
  • You quote new work for the automotive industry;
  • You participate in new product launch;
  • There have been instances of misunderstanding of customer part requirements;
  • You are part of the engineering change process for existing products supplied to the automotive industry;
  • You have not participated in for PPAP training in the past 3 years;
  • You have had you PPAP submissions rejected by your customers.
Course Outcomes
  • Understand the different levels of PPAP submission and the requirements for maintaining PPAP documents.
  • Learn methods to ensure customer specific requirements are met
  • Learn to develop PPAP that is complete and meets customer requirements.

 

Failure Mode Effects Analysis (FMEA)

This course introduces the basics of FMEA and gives the attendee an overview of FMEA and how it can be applied on development projects and process studies. This FMEA training will result in a clear understanding of the concepts of FMEA, interpretation of FMEA chart, understanding concepts of RPN, applying FMEA on real projects and presenting the results.

You need FMEA training if
  • You are involved in new product launches
  • You are responsible for design and development of products
  • Corrective Actions for existing products/processes do not carry over to new product introductions
  • You believe you are spending too much time detecting problems and not enough time preventing them
Course Outcomes
  • Reduced development time and cost to Initially design any system, product, or process
  • Improved the quality, reliability, and safety of any system, product, or process
  • Anticipated quality problems, and actions taken to minimize risks
  • Prevention of recurrence of problems surfaced though problem solving and Corrective Action Reports
  • Prioritized risk reduction efforts
  • Improved customer satisfaction

 

Basic Metrology

The fundamentals of dimensional metrology are paramount to the integrity of a measurement system. This training course uses linear measurement as a basis. Students will also learn the history and role of metrology in society and its importance in the manufacturing world today.

The majority of the course will focus on rudimentary techniques for using different measurement tools (micrometer, caliper, dial indicator, steel rules and bore gages.) Time is spent using these instruments to perform basic product layouts. Students are given the opportunity to use a simple drawing that includes dimensions and tolerances. Each student will learn to select the appropriate inspection equipment and perform a layout.

You need training in Metrology if
  • You have turnover of manufacturing staff that uses inspection equipment to accept or reject product
  • You hear staff say that you and I can measure the same part and get different results
  • There is no defined system to train new employees on how to use gages
  • Gages are left laying around machines and/or the shop floor or they are dirty
  • Staff is sometimes unsure which gage is most appropriate to take a particular measurement
Course Outcomes
  • An expanded knowledge of modern measurement terms and language;
  • Clear definition of measurement error types and systematic methods to prevent such errors;
  • An ability to identify dimensional tolerances and select the best suited inspection equipment;
  • Learn proper care and handling of inspection equipment.

 

Advanced Metrology

Advanced metrology is a continuation of the concepts introduced in the Basic Metrology Class. Additional time is spent determining appropriate inspection equipment for use with specific measurements.
The metric system is introduced and its fundamental purpose is presented. Students practice conversions between the English and the Metric system.

Additionally, time is spent learning how to perform a Gage R&R, as outlined in the AIAG MSA Manual. The calculations used in this statistical technique are presented and practiced by the class. Each student participates in a Gage R&R during the class time using steel rules, calipers and/or micrometers. Students are also introduced to bias, stability and linearity.

Length: 1/2 dayLocation: E&M Design Solutions
Cost: $99.00

You need Advanced Metrology Training if
  • Your staff has participated in Basic Metrology training
  • You are responsible for or participate in Gage R & R studies
Course Outcomes
  • Extensive ability to select the appropriate inspection equipment based on blue print specifications;
  • An aptitude to perform conversions between Metric and English systems;
  • Conduct a Gage R&R study;
  • Understanding of Bias, Stability and Linearity calculations.

 

Calibration System Development

A hands-on course that will lead you through the steps necessary to develop a calibration system which meets the requirements of ISO9001-2008 and other published QMS Standards. The course addresses the content of element 7.6 and utilizes ISO 10012. Participants are introduced to the fundamental principles of metrology as the foundation to the integrity of a calibration system.

You need Calibration System Development training if
  • There are returned products from customers when you have inspected the product and believe the parts conform to requirements;
  • Have had nonconformance’s cited by internal or external audit in the area of calibration;
  • You believe you are spending too much money on the existing calibration system;
  • You are unable to keep up with the calibration schedule as the intervals of calibration are short;
  • You are not sure if your system of calibration will be adequate to pass an ISO or ISO/TS audit;
  • Staff does not understand the importance of gage calibration.
Course Outcomes

After completing this course you will understand:

  • The requirements of an ISO9001, ISO/TS 16949, AS9100 or ISO 13485 compliant calibration system;
  • The steps required to develop a solid calibration system;
  • How to write a calibration procedure;
  • Calibration certificate record requirements;
  • When to adjust intervals of calibration.
  • What information is required on a purchase order for calibration services;

Lean Manufacturing

This course introduces and explains the concept of Lean manufacturing. Concepts presented include: The origin and principles of Lean; Identifying the goals of Lean production; The 5S system studied in depth; Total Production Maintenance; Value Stream Mapping; Poka-yoke; Muda; KanBan.

You need training in Lean Manufacturing if
  • Your customers are asking you to lower or freeze your prices;
  • Your shop floor appears sloppy and unorganized;
  • You have excess finished goods inventory;
  • Your manufacturing staff spends time looking for the tools or materials they need to do their jobs;
  • Defects that occur in one of the first processes are often not identified until the end of the process;
  • Customers occasionally receive defective product;
  • On time shipment is jeopardized by not having the needed raw material and components at the “right” times.
Course Outcomes
  • Develop a thorough understanding of the principles behind the presented concepts;
  • Acquire an effective means for utilizing suitable lean principles within one’s facility;
  • Development of an accurate, case-specific concept of the affect that application of lean principles will have on the organization.

 


Shop Math

This course is intended to provide a working knowledge of shop-related mathematics for entry level students and serve as a refresher course for those students having prior mathematics training.

The mathematical concepts covered in this course include:

  • Review of decimals
  • Review of fractions
  • Addition / Subtraction
  • Multiplication / Division
  • Equations
  • Graphing / Charting Practices
  • XBar and R Charts
  • Attribute Charts
  • Mean, Median, Mode
  • Standard Deviation
  • Normal Distribution
  • Use of Calculators—basic functions
  • Angular measurement
  • Deg. Min. Sec. Deg. Decimal Conversions
  • Metric system
  • Metric / English conversion
  • Place value