Core Tools

  • Advanced product quality planning (APQP)
  • Production Part Approval Process (PPAP)
  • Failure Mode and Effects Analysis (FMEA)
  • Control Plans
  • Statistical Process Control (SPC)
  • Other Process Control Tools
  • Root Cause Analysis


Quality Essentials

  • Plan Do Check Act (PDCA)
  • Quality Gates
  • Quality Philosophies and Foundations
  • The Quality Management System (QMS)
  • Quality Standards – ISO 9001/14001 
  • Fundamentals of passing an audit
  • Concentration on the internal auditing process
  • Quality Audits
  • Types of audits - Roles and responsibilities in audits - Audit planning and implementation - Audit reporting and follow up
  • Within this training show client different forms of effective dock audits, e.g. (3-way match etc.), and process audits
  • Introduce Layered Process Audits as these have been found to be quite effective tying them into corrective action root cause prevent recurrence items (rather than having e.g. 30,60,90-day reviews of CA’s)
  • Cost of Quality (COQ)
  • Establish / Offer advice as to which metrics to measure, how and sustainment of improvements
  • Put in place and follow through
  • ISO 9001/14001 Audit Assistance
  • Hill Standard Works has experience with working with clients and assisting in surveillance audits as well as full ISO 9001/14001 implementation. Hill Standard Works performs an ISO Gap Analysis in preparation for client surveillance audit.

Quality Leadership

  • Problem Solving Tools
  • Design of Experiments
  • Supplier Management
  • RMA Process
  • How to have communications with clients, e.g. RMA’s
  • How to have chargeback requirements established
  • Supplier Visits and Supplier Audits
  • Focus on how to deal with internal company suppliers and both parties understanding the other requirements
  • Supplier Audit Assistance 
  • Hill Standard Works has experience with working with client’s suppliers and conducting supplier quality audits for our clients. We can assist with this process and take care of supplier audits, findings and track and follow up on any issues to completion.
  • Material Control
  • Material identification, status, and traceability - Material segregation - Classification of defects
  • Material review board (MRB)
  • How and when to conduct them and how MRB ties into Quality Gates
  • Acceptance Sampling
  • Sampling concepts
  • Sampling standards and plans; sampling integrity


Other Items for the Program

  • Prevention (audits) + Capture (alert and action) + Close (ensure prevent recurrence)
  • Documentation (Vital few from the many), e.g. how to follow up and track the work after capture
  • Follow Up, Follow Up, Follow Up – quality engineers must have the skill of follow up
  • Review means in relation to how to police
  • Elements of The Change Process for Continuous Improvement should be brought into the program as this focuses on internal as well as external customer relations and requirements.