SABRe3 & AS Standards Training for Aerospace Suppliers 8D Problem Solving 2-Day Programme Overview This workshop provides a detailed understanding of the 8D Problem Solving requirements

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

• [email protected]

• 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


of causes (occurrence)

– process controls


(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


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


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


• Capability indices (Cg, Cgk)

Continuous Data studies –

Gauge R&R

• Repeatability and

reproducibility

• Types of studies available

(Average and Range vs

ANOVA)


• 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



• 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


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


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


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


studies

Control Charts for Attributes

(P, NP, C, U)

• P and NP charts

• Setting up the charts

• Interpreting results


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


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


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


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


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

E: [email protected]

W: www.smallpeice.com

V2-Aug18

Documents

SABRe3 & AS Standards Training for Aerospace Suppliers 8D Problem Solving 2-Day Programme Overview This workshop provides a detailed understanding of the 8D Problem Solving requirements