sabre3 & as standards training for aerospace suppliers 8d problem solving 2-day programme...
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SABRe3 & AS Standards Training for Aerospace Suppliers
a division of GP Strategies Limited
8D Problem Solving AS13000
Design & Process FMEA AS13004
Measurement System Analysis AS13003
SABRe3 / Zero DefectsRolls-Royce
Standard
AS13006(pending)
APQP & PPAP AS9145
Process Control
The Smallpeice global training team work closely with Rolls-Royce and the aerospace supply chain to
support specialist training that is aligned to the latest industry quality standards & requirements.
Our experience as a professional training provider stretches over 50 years, and we provide an extensive
curriculum focused on Zero Defects. Problem Solving & Quality Tools, Our practical training and
coaching that is focused on implementing change, transferring knowledge and supporting clients to
ensure business improvement success.
We offer a programme of open enrolment courses, plus in-company group training that can be linked to
company examples and supported with coaching to embed best practice.
Providing global training programmes across
US, Europe & APAC. Clients include:
Aerospace Training Solutions
In-Company & Open Enrolment
Visit the aero training website Please visit our aerospace website to
view the calendar and booking process
www.aerospacesuppliertraining.com
Or contact usTo discuss requirements,
please contact us on:
• T: +44 (0)1926 336423
• www.smallpeice.com
Design & Process FMEA2-Day Programme
Introduction to FMEA
• FMEA background and
history
• What is a risk?
• Types of risk management
• Risk management phases
(identify, assess, control)
• FMEA structure
• The FMEA seven step
method
• FMEA types and timing
• The DFMEA team
Design FMEA
• Introduction to DFMEA
• The Design FMEA method
• Identify
– Product definition and
defining functional
requirements
– Failure Mode
identification &
specification
• Assess
– Design effects
identification & grading
(severity)
– Identifying potential
design causes
– Design prevention
controls identification &
grading of causes
(occurrence)
– Design detection
control identification &
grading (detection)
– Calculating the Risk
Priority Number (RPN)
• Control
– Agreeing priorities for
improving the design
– Actions management
– Future risk review
• Special characteristic
management
• Common DFMEA pitfalls
• DFMEA management
Process FMEA
• Introduction to process
risk assessment
• Linking the PFMEA with
the DFMEA
• Review of the FMEA
Aerospace standard
• Identify
– Process requirements
definition through
process mapping The
characteristic matrix
– Failure Mode
identification &
specification
– Failure modes as
product non
conformances
• Assess
– Design and Process
effects identification &
grading (severity)
– Identifying potential
process causes
– Prevention controls
identification & grading
of causes (occurrence)
– process controls
identification & grading
(detection)
– Mistake Proofing
– Calculating the Risk
Priority Number
• Control
– Process improvement
actions generation
– Actions management
– Future risk review
• Common PFMEA pitfalls
• Links with other quality
tools:
– Control plans
– Measurement Studies
– Process control
techniques
• PFMEA management
Day 1 Day 2
Overview
FMEA is a mandatory
requirement for many companies
- providing a process for
categorising failures in order to
prioritise items of risk. This
practical workshop will step
delegates though a case study
based workshop – learning how
to analyse the product functions
in terms of risk, identify failure
modes and effects, and
understanding how to set
priorities using the severity rating
scale.
Objectives
• Introduce the concept and
types of risk management
• Practise the design and
process FMEA methods
• Understand the links between
the FMEA types
• Know how special
characteristics are managed
• Understand how FMEA links
with other quality tools
• Recognise what is best
practice in FMEA management
Visit www.aerospacesuppliertraining.com for public course dates &in-company training options. Or email [email protected] with your enquiry
8D Problem Solving2-Day Programme
Overview
This workshop provides a
detailed understanding of the 8D
Problem Solving requirements for
suppliers in line with Aerospace
Standards AS13000. Participants
will learn through the practical
application of the 8D problem
solving process which is applied
to a case study exercise that runs
throughout the workshop.
Objectives
• Support attendees to meet the
standards of AS13000 by
developing the required
competencies, and preparing a
practical action plan for
implementation of 8D
• Provide practical hands-on
training in the 8D structured
problem solving approach for
establishing root cause and
permanent solutions in line
with AS13000 requirements
• Enable participants to select
and use the appropriate tools
to solve problems and prevent
reoccurrence
• Develop the role of 8D
Practitioner able to facilitate
problem solving activities
Introduction
• Background to AS13000
and the drive towards a
standardised structured
approach to problem
solving within the
Aerospace industry
• Overview the 8D
methodology
D0 - Implement emergency
actions and preparing to
launch the 8D process
• Define and implement
emergency actions
• Identify & notify
stakeholders
D1 - Forming the Team
• Getting a GRIP of your
team (power & influence;
skill & experience;
synergy)
• Establishing Goals Roles,
Interpersonal
relationships, Processes
D2 - Define the Problem
• Define the non-
conformance to customer
requirements by
identifying and describing
the problem in
quantifiable terms
• Identify the impact in
terms of quality, reliability
and productivity
D3 - Develop Containment
Actions
• Selecting effective
methods of containment
• confirm containment
measure effectiveness
D4 - Identify & Verify Root
Causes
• Key quality tools to identify
root causes
• Identify where the problem
occurs/escape points
• Leading and facilitating
root cause activities –
planning and preparing for
successful outcomes
D5 - Identify Corrective
Actions
• Generating permanent
corrective actions
• Generating alternate
solutions
• Assessing the risk of the
corrective action on other
processes
D6 - Implement Corrective
Action
• Creating and delivering a
successful
implementation plan
• Gaining commitment
• Methods to validate the
effectiveness of the
permanent solution
• Ensuring appropriate
documentation is updated
to support the new
standard
D7 - Preventing Recurrence
• Taking systemic action to
prevent the problem
recurring
• Identifying opportunities
to replicate corrective
actions on other
processes
• Sharing lessons learnt to
ensure value is taken
from the problem solving
activity
D8 - Recognise the Team
• How to effectively close
the problem solving
activity & recognise the
achievements of the team
• Documenting the lessons
learnt for reference in
future programmes
Day 1 Day 2
Visit www.aerospacesuppliertraining.com for public course dates &in-company training options. Or email [email protected] with your enquiry
Measurement System Analysis2-Day Programme
Overview
Manufacturers are becoming
increasingly aware of the need to
obtain adequate confidence in
their measurement systems. This
is important for process control,
for the assurance of quality, and
for process improvement. This
highly practical course will enable
delegates to assess the
performance of new and existing
measurement systems, and
considers how improvements can
be introduced when they are
found to be necessary.
Objectives
• Understand how to conduct a
measurement system analysis
for continuous and attribute
data
• Show how to interpret the
results of measurement
studies to make improvements
to the measurement system
• Understand the links between
measurement system analysis
and additional quality tools
• Discuss the cultural
challenges in performing
measurement studies and how
to overcome them
Introduction to MSA
• Importance of MSA
• Measurement uncertainty
and the effect on product
and process decisions
• Sources of measurement
error & how to overcome
• Preventative maintenance
• Importance of calibration
• Checking the equipment
resolution
• Environmental
requirements
• Basic capability charts and
equipment selection
• Measurement equipment
general guidelines
• Common standards,
reference guides
• Linking MSA to additional
quality tools (FMEA, Control
Plans, Process Control, 8D)
Types of Measurement
Studies
• Introduction to the
different types of
measurement studies
available
• Types of data
• Statistical concepts of
MSA
• Common vs. special
causes of error
• Value vs feasibility of
collecting data
• Exercise: barriers to data
collection
• Introduction to Minitab
statistical software
Location Variation
• Types of studies available
• Bias, stability, linearity
• Case study examples
• Interpreting the results
Continuous Data Studies –
Type 1 Studies
• Uses for type 1 studies
• Setting up the study
• Interpreting the results
• Capability indices (Cg, Cgk)
Continuous Data studies –
Gauge R&R
• Repeatability and
reproducibility
• Types of studies available
(Average and Range vs
ANOVA)
• Setting up the study
• Interpreting the results -
graphical tools
• Interpreting discrimination
• Destructive measurement
systems
• Actions for improvement
• Re-evaluating the
measurement system
Attribute Data Studies
• Introduction to attribute
MSA
• Uses for attribute studies
• Setting up the study
• Interpreting the results
• Human factors influencing
attribute studies
• Case studies & examples
Day 1:
Measurement System Analysis –
Introduction and Location Variation
Day 2:
Measurement System Analysis –
Continuous and Attribute Studies
Visit www.aerospacesuppliertraining.com for public course dates &in-company training options. Or email [email protected] with your enquiry
Process Control2-Day Programme
Overview
This workshop introduces SPC as
a key tool which can be used to
achieve quality improvements by
providing a structured approach
to monitoring and improving
process control. Participants will
learn how to construct and
interpret control charts, and
develop their understanding of
why the control chart is the best
tool to keep a process under
control. The course also covers
the link from SPC to process
capability and, again, covers the
‘how to do it’ and ‘how does it
work’ aspects of the subject.
Objectives
• Understand how to use SPC
controls charts for continuous
and attribute data
• Show how to conduct and
interpret the results of
capability studies
• Understand the links between
process control techniques
and additional quality tools
• Discuss the cultural
challenges in performing
process control studies and
how to overcome them
Introduction to SPC
• Key objectives of SPC
• Prevention vs detection
• The importance of
process centring
• Using data for continuous
process improvement
• The limitations of
specification-based
systems
• Sources, causes and
types of variation
Pre-requisites to SPC
• Planning data collection
and checking the
measurement system
• Frequency distributions
and normal distribution
• Introduction to Minitab
Control Techniques
• Overview of mistake
proofing
• Pre-control charts
• Reduced and sample
inspection
Control Charts and their
Applications
• The concepts of control
limits
• Overview of the types of
statistical signals
• Control charts for
variables (I-MR, X-Bar R, X
-Bar s)
• I-MR charts and how to
use them
• Examples and case
studies
• X-Bar R, X -Bar s charts
and how to use them
• Examples and case
studies
• SPC techniques for
special situations - Short
Run SPC
• Links to additional quality
tools (FMEA, Control
Plans, MSA, 8D)
SPC Techniques for Special
Situations
• Short run SPC
• Handling more than one
characteristic
• Examples and case
studies
Control Charts for Attributes
(P, NP, C, U)
• P and NP charts
• Setting up the charts
• Interpreting results
• Examples and case
studies
• C and U charts
• Setting up the charts
• Interpreting results
• Examples and Case
Studies
Evaluating Process
Capability
• Capability analysis of
variables data
(Cp,Cpk,Pp,Ppk)
• Dealing with non-normal
data
• Single sided tolerances
• Capability analysis for
Attribute data (PPM,
DPMO)
• Implementing SPC and
process capability in the
workplace
• Case study examples
Day 1:
Introduction to SPC & Continuous Data Studies
Day 2:
Attribute Charts & Process Capability
Visit www.aerospacesuppliertraining.com for public course dates &in-company training options. Or email [email protected] with your enquiry
SABRe3 Essentials1-Day Programme
Overview
This 1-day course provides a
detailed explanation and
understanding of the content and
clauses contained within
SABRe3, and the alignment with
the related AS standards and
ISO9001. The training focuses
on the essential requirements
within SABRe3 and highlights the
changes from the previous
SABRe2 standard. Guidance will
also be provided in the use of the
Self Assessment tool and the
process for achieving
certification.
Objectives
To enable participants to:
• obtain a working knowledge of
all essential requirements
within SABRe3
• understand the links with AS /
ISO standards
• use the Self Assessment tool
& criteria for 3 compliance
• identify good practices within
existing processes and be able
to identify areas for
improvement
• recognise where greater
technical knowledge will assist
and facilitate development
plans
Introduction to SABRe3
• Background to the update of SABRe2 to SABRe3
• The benefits the purpose, scope and applicability of
SABRe3
• The structure of SABRe3 and alignment to other ISO and
AS standards
• Overview of the key differences between SABRe2 &
SABRe3
• Implementation and supporting documents
Section 1 of SABRe3:
Quality Management System Requirements
• Scope, applicability and review of the new and/or
modified requirements Structure of the sub-clauses and
their links to ISO9001 and AS9100
• Detailed review of the specific Rolls-Royce requirements
• Scope, normative references, terms & definitions
• Context of the organisation
• Leadership / Planning / Support
• Operation / Performance evaluation
• Improvement & Best practice examples
• Guidance on using the Self Assessment Tool
Workshop Programme
Section 2 of SABRe3:
APQP & PPAP
• Scope and applicability of Section 2 of SABRe3
• Links to the AS APQP and PPAP standard
• Detailed review of the specific Rolls-Royce
requirements
– Objectives of the intent and goals of PPAP
deployment
– Applicability of PPAP and what PPAP provides
– Process improvement techniques
– Product and process risk assessment and control
planning
– Process variation management
– Review of the PPAP submission levels
– Review of the required standard templates
– The roles and responsibilities of the PPAP
Co-ordinator
Course Summary
• Next steps for your role & responsibility
• Guidance on assessing and achieving certification
• Additional training support
Visit www.aerospacesuppliertraining.com for public course dates &in-company training options. Or email [email protected] with your enquiry
SABRe3 Tools & the AS Standards1-Day Programme
Overview
The ‘SABRe3 Tools & AS
Standards’ is designed as an
optional follow-on from the ‘SABRe
Essentials’ training. This module
will provide a practical overview to
the suite of AS standards which
are an intrinsic part of SABRe3 and
which include FMEA, 8D, MSA,
Process Capability, APQP/PPAP
(AS13000 / AS13003 / AS13004
/ AS13006).
Objectives
• Understand the benefits of the
new standards and the drivers
for change
• Identify good practices that
enable compliance and be able
to identify areas for
improvement
• Learn the critical success
factors of the key quality tools
for Product Defect Prevention
and the links between them in
three main areas (Quality
Planning, Process Control,
Problem Solving)
• Review of real examples of
current practice
• Enable technical team working
cross functionally to review
‘where are with the maturity of
the tools’ and ‘what do we need
to do to improve’
Introduction to SABRe3
• Introduction to SABRe3
• Introduction to the concepts of Zero Defects
• Overview of the essential SABBe3 and Zero
Defects toolkit
• The structure alignment to other ISO and AS
standards
Design and Process FMEA (AS13004)
• The need for FMEA – objectives/ benefits and
types of FMEA
• Introduction to DFMEA
• Strategies to improving the risk profile (RPNs)
• PFMEA and the advanced quality planning system
• Constructing a PFMEA and control plan
• Leadership deployment considerations,
management of FMEA
Measurement Systems Analysis (AS13006)
• Benefits of improved measurement capability
• Deciding what to measure / measures of location
and spread
• Continuous data gauge R&R studies / attribute
data studies
Workshop Programme
Introduction to Process Capability and Statistical
Process Control
• Introduction to the concepts of process control
• Introduction to process capability calculations
• How to use capability calculations effectively to
support the drive to Zero Defects
• Introduction to SPC control charts and prerequisites
required
• Types of control charts and how to implement SPC
effectively to reduce variation and target set
processes
• Overview of mistake proofing techniques
Structured Problem Solving (AS13000)
• 8D and the drive towards a standardised structured
approach to problem solving
• Overview the 8D methodology
Course Summary
• Next steps & further training support
Visit www.aerospacesuppliertraining.com for public course dates &in-company training options. Or email [email protected] with your enquiry
Zero Defects Leadership 3-Day Programme
Introduction
• Zero Defects philosophy & benefits
• The Paradigm Shift – reactive vs
proactive problem solving
• The 4 absolutes of quality
• Core defect prevention tools
• The Journey ahead: Deploying the
Philosophy / Technical Capability /
Supplier Management /
Organisational
• Alignment with AS standards
Advanced Product Quality Planning
• The Design FMEA process
• Improving Risk Profile (RPNs)
• Deployment of FMEA
• Process FMEA & Advanced Quality
Planning System
• Constructing a PFMEA & Control
Plan
• Common mistakes & best practice
Guidance
Day 1:
Zero Defect Philosophy,
& Advanced Product Quality
Planning tools
Measurement Systems Analysis
(MSA)
• Benefits of improved measurement
capability
• Deciding what to measure
• Measures of location/spread
• Continuous & Attribute Data
studies and acceptable quality
levels
• Successful deployment of MSA
Establishing Process Capability
• The link between process capability
and Zero Defects
• Capability calculations (Cp/Cpk,
Pp/Ppk, DPMO, PPM, Sigma levels)
• Introduction to APQP & PPAP
Process Control
• Process Control Strategies,
including Mistake Proofing and SPC
Day 2:
Quality Planning Tools (cont’d)
& Process Control
Coaching for Zero Defects
• High performance culture
behaviours and links to the zero
defects approach
• Zero defects as way of thinking and
creating the right ‘mind-set’
Problem Solving
• Overview of 8D and the need to
effectively engage teams in
supporting the 8D process
• Getting to the root cause and
developing corrective actions
Deployment Planning
• Group feedbacks – what are we
doing well opportunities for
improvement?
• Reflections on Zero Defect Action
Planning in your Company.
• What are the key actions you will
take when you are back in your
business?
Day 3:
Coaching for ZD,
Problem Solving, ZD Reflections
& Planning
Overview
In line with the aerospace
industry focus on zero defects,
this leadership level programme
reviews the strategy and enablers
required for successful zero
defects deployment.
The training is based around
case study applications and
practise to discuss and highlight
the opportunities for change.
Alongside a practical introduction
to the zero defects toolkit, the
programme emphasises the
importance of the leadership role
in championing and driving a zero
defects culture change.
Objectives
• Provide context Zero Defects
• Demonstrate the key Zero
Defects tools - Design &
Process FMEA, Inspection
Capability, Process Control,
Problem Solving and
Continuous Improvement
• Enable leaders to ask the right
questions to establish the
current state and build the
business case for quality
• Commit to leading the Zero
Defect programme and lead by
example Visit www.aerospacesuppliertraining.com for public course dates &
in-company training options. Or email [email protected] with your enquiry
APQP & PPAP1-Day Programme
Overview
Advanced Product Quality
Planning (APQP), has been
adopted by the aerospace
industry under AS9145 as the
framework for new product or
process introduction.
This 1-day workshop covers the 5
phases of APQP– making links to
links to the support tools of
Statistical Process Control,
Measurement Systems Analysis,
Failure Modes Effects Analysis,
Control Plans and Product Part
Approval Process.
Objectives
• To enable gap analysis of each
of the 5 phases between the
APQP/PPAP requirements &
current practice
• To provide a clear roadmap n
the tools and techniques that
underpin the APQP framework
for product development.
Introduction
• Quality planning: why / who / how?
• Introduction & background to AS9145
• Product Quality Planning Timing Chart
APQP Phase I: Plan & Define Programme
• Project planning and definition
• Project scope, resources & timings
APQP Phase II: Product Design & Development
• (Design) FMEA, design review
• Control Plan, Cause & Effect Diagram
APQP Phase III: Process Design & Development
• Process flow
• Process FMEA
• Pre-Control Plan
Workshop Programme
APQP Phase IV: Product & Process Validation
• Customer approval via PPAP
Part Approval: PPAP
• PPAP manual
• Reporting requirements
• Submission, records
APQP Phase V: Feedback, Assessment, Corrective Action
• Continual improvement of product and process
focusing on improvements in
• Improvement focus on safety, quality, delivery and
cost
Summary
• Gap analysis on current use of tools
• Developing the action plan
Visit www.aerospacesuppliertraining.com for public course dates &in-company training options. Or email [email protected] with your enquiry
Smallpeice Feedback &
Sample of Our Client Base
Smallpeice training is designed to be inspirational, enjoyable and effective. You will work with expert
facilitators who are experienced in working across different business sectors.
Great training! I can’t
wait to go back and
start applying the new
techniques into my day.
The course was
highly enjoyable.
The modelling exercises
really hammer home
the point of Lean
working.
Informative, to the
point, and delivered
in a way that can be
related to.
Looking forward to
implementing the
tools within the team,
sharing knowledge and
hopefully formulating
a process to improve
efficiency.
Really pleased with
the course – would
recommend to
colleagues. Good
trainer with great
knowledge and
excellent practical
examples.
I found the whole
course incredibly
useful and delivered
by an extremely
knowledgeable and
well-versed trainer.
Great consideration for
how techniques can be
applied within my
company’s processes.
Everyone should be
educated
on this culture. The
skills and tools are
relevant to all areas of
the business.
Fabulous course and
extremely enjoyable.
Great mix of content
and exercises.
Great class & really
good to see how the
requirements are
aligned to industry
standards.
Thought provoking,
and provided a
methodical approach.
Lots of ideas to apply
to ongoing issues
within my department.
a division of GP Strategies Limited
For more information on training
courses and options, please contact:
Smallpeice Enterprises
T: +44 (0)1926 336423
W: www.smallpeice.com
V2-Aug18