The 6 Core Tools + Automotive QMS

Over 30 years ago, North America's Automotive Industry Action Group (AIAG) created and published a common set of quality tools and methodology which became to be known as "core tools". These tools were created to compliment the purpose of international quality management system standards by providing a framework for how to comply with specific requirements. Core tools provide organizations with advanced methods to improve opportunities to meet customer requirements, launch production correctly the first time, identify and control risks and potential failures, ultimately leading to improvements to the bottom-line.

Core Tools “7-pack”

**APQP** - Advanced Product Quality Planning (NEW 2024)
**FMEA** - Failure Mode & Effects Analysis (NEW 2019)
CP - Control Plan (NEW 2024)
**MSA** - Measurement System Analysis
**SPC** - Statistical Process Control
**PPAP** - Production Part Approval Process

Core tools are the fundamental building blocks of an effective quality management system (QMS); most commonly used within the automotive supply chain. Since their creation, various other sectors such as aerospace and medical device manufacturing have incorporated their use in improving internal and supply chain performance.

The core tools, guidance documents and associated standard are ever-changing. In the illustration above, you’ll see that the IATF 16949 automotive QMS standard is included, the FMEA manual has been jointly released by AIAG and VDA (German automotive equivalent), and the Control Plan manual has parted ways from the APQP manual. Since 2019, 3 of the now 6 core tools have been updated and re-released as new editions.

The linkages between the 5 core tools & requirements in IATF 16949

The illustration above is from our course materials for AIAG Core Tools training (see below for details). This shows the general linkage and interaction between the 5 core tools and their purpose. Ultimately, these tools are meant to ensure you are clearly defining and producing what the customer wants while continuously improving your production processes.

AIAG Core Tools Training (40hrs)

Course Description: Core tools are the fundamental building blocks of an effective quality management system (QMS); most commonly used within the automotive supply chain. Since their creation, various other sectors such as aerospace, medical devices, etc. have incorporated their use in improving internal and supply chain performance. Each course day, as well as individual module, can be offered ala carte either onsite or remotely. Courses can be configured to meet your specific needs. Each 8-hour class is worth 0.8 CEUs.

Download Course Syllabus

Day 1

The history & purpose of AIAG Core Tools
Connection to IATF 16949:2016 requirements
APQP - Advanced Product Quality Planning
Overview of APQP and connection to PPAP
Connecting APQP to the Control Plan
Exercises & quizzes (optional)

Day 2

FMEA - Failure Mode & Effects Analysis
Overview of FMEA and connection to CP
Creating PFDs to map major process steps
DFMEA (product DESIGN) vs PFMEA (manufacturing PROCESS)
Process Flow Diagram (PFD) > FMEA
Exercises & quizzes (optional)

Day 3

CP - Control Plan
Overview of CP and connection to operations
Connecting the PFD > FMEA > CP
Prototype vs pre-production vs production control plans
Comparing controls to actual operations
Exercises & quizzes (optional)

Day 4

MSA - Measurement System Analysis
Overview of measurement systems
Measurement bias simulation or in practice
Connecting MSA studies to operational controls & methods
SPC - Statistical Process Control
Exercises & quizzes (optional)

Day 5

Connecting SPC to operational controls & methods
PPAP - Production Part Approval Process
Overview of PPAP and the Part Submission Warrant (PSW)
Tips for achieving customer approval the first time
Course material review, Q&A, lessons learned
Final Exam

OPTIONAL ADD-ON: Assessment Workshop

FMEA > Control plan assessment
Summary & presentation of findings
Planning of next steps for sustainability

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How can we improve your business through core tools?

What makes us different is the decades of implementation of management systems and core tools for our employers and clients within the automotive sector. The majority of our working hours have been spent studying and implementing the demands and precision required to survive in the advanced manufacturing world of the automotive industry. Time and time again, the teachings and deployment of core tools has been at the heart of our service to the most demanding customers in the world. That is why they choose us as their partner.

Training & Workshop Options

Core Tools Overview (2-8hrs)
Core Tools In-Depth (24-40hrs)
Core Tools Training + assessment and implementation workshop (40-80hrs)

Delivery methods

Public Training: traditional in-person classroom style with open enrollment to accommodate students from various companies in a collaborative setting
Remote Training: remote live training using conferencing solutions like Zoom, Microsoft Teams or Google Meet to accommodate students from all over the world
Onsite Training: our instructor(s) come to you and your team on your terms
One-on-One: coach and mentor style training great for students who need in-depth, hands on learning or busy executives with specific focus areas
Self-Paced: online, mobile-friend learning that can be consumed at your own pace including reading, recorded lectures, exercises, collaborative discussion forums, quizzes, testing and assignment submissions
Do-It-Yourself: the most scalable option for those trainers and facilitators using our material and online learning management system (LMS) to teach others in-house

Contact us today to find out which training and methodology is right for you!

Want to test your current level of competency?

Upon completion, you will receive your confidential scores for each Core Tool, allowing you to measure your competencies and monitor individual improvement. Best of all, it’s FREE.

AIAG Self Assessment