Quality-Engineering-Skills

Assign AP table ratings (H-AP, M-AP, L-AP) in PFMEA or DFMEA — the RPN replacement from AIAG-VDA FMEA Handbook 2019. Explains H/M/L classification logic, mandatory action requirements for High Priority items, and OEM-specific thresholds. Use when assigning risk levels in PFMEA or DFMEA, or auditing FMEA documents for AP compliance.

Run quality problem zeroing, perform 双归零 (double-five zeroing), write a technical zeroing report, write a management zeroing report, or close an aerospace quality problem under GB/T 29076—2021. Covers problem reporting, emergency response, team formation, technical zeroing (定位准确、机理清楚、问题复现、 措施有效、举一反三), management zeroing (过程清楚、责任明确、措施落实、严肃处理、 完善规章), evidence gates, review, and closure. Use for aerospace or complex equipment failures, defects, accidents, repeated problems, human-responsibility problems, and issues requiring a formal closed-loop investigation.

Interactive Control Plan builder — takes PFMEA failure modes and process flow steps as input and builds a complete Control Plan row by row, with correct control methods, sample plans, and reaction plans for each characteristic. Use when building a new Control Plan, updating after a corrective action (8D D7), or converting a PFMEA into Control Plan format. Covers AIAG Control Plan reference manual and IATF 16949 §8.5.1.

Interactive PPAP completeness checker — walks through all 18 PPAP elements for a given submission level, identifies missing or incomplete items, and generates a gap report before PSW signature. Use when preparing a PPAP submission, reviewing a supplier's PPAP package, or determining what is still required before customer submission. Covers AIAG PPAP 4th Edition.

VDA 6.3 Process Audit — conduct or prepare for a process audit using the VDA 6.3 methodology, evaluate process elements P1–P7, calculate degree of fulfillment, classify findings, and generate an audit report. Use when a customer requests a VDA 6.3 audit, when auditing a supplier's manufacturing process, or when preparing for a VDA process audit visit. Covers VDA 6.3 4th edition (2023).

Measurement System Analysis (MSA) and Gauge Repeatability & Reproducibility (Gauge R&R) — plan, execute, and interpret an MSA study for variable or attribute measurement systems. Use when qualifying a gauge for a new part, validating a measurement system before PPAP, interpreting Gauge R&R results, or auditing MSA studies for adequacy. Covers AIAG MSA 4th edition.

Statistical Process Control (SPC) — select the correct control chart, interpret out-of-control signals using Western Electric rules, calculate and interpret Cp, Cpk, Pp, Ppk. Use when setting up SPC for a new characteristic, interpreting control chart signals, responding to special cause variation, or auditing SPC implementation. Covers AIAG SPC 2nd edition and IATF 16949 §8.3.3.

Advanced Product Quality Planning (APQP) — plan and track a new product launch through all 5 phases, identify deliverables per phase, run gate reviews, and ensure quality outputs are complete before Start of Production (SOP). Use when launching a new part, managing an APQP project, or auditing APQP completeness. Covers AIAG APQP 2nd edition and IATF 16949 §8.3.

Control Plan — build, review, or audit a Prototype, Pre-launch, or Production Control Plan linked to PFMEA failure modes and controls. Use when creating a new control plan, updating after a process change or corrective action, or auditing an existing CP for completeness and PFMEA alignment. Covers AIAG Control Plan reference manual and IATF 16949 §8.5.1.

Design Verification Plan and Report (DVP&R) — build or review a test plan that links each DFMEA failure mode to a specific test, pass/fail criterion, sample size, and timing. Use when creating a DVP for a new design, reviewing a supplier's DVP for completeness, or auditing whether all design risks are covered by validation testing. Covers IATF 16949 §8.3.4.3 and AIAG APQP Phase 2.

Production Part Approval Process (PPAP) — verify PPAP submission level, audit all 18 elements, check completeness for customer approval, prepare PSW. Use when a supplier needs to submit parts for approval, when reviewing a PPAP package, or when determining which PPAP level is required. Covers AIAG PPAP 4th edition with Ford, BMW, VW, and Stellantis OEM-specific requirements.

DMAIC (Define-Measure-Analyze-Improve-Control) — Six Sigma structured problem-solving for chronic, data-driven quality improvement projects. Use when a problem recurs despite corrective actions, when a process needs systematic capability improvement, or when a customer requests a Six Sigma approach. Use 8D for reactive single-incident problems; use DMAIC for recurring systemic issues requiring statistical analysis. Covers IATF 16949 §10.1 and ISO 9001 §10.3.

Run a PDCA cycle, Plan Do Check Act improvement cycle, or structured improvement project. Guides through problem analysis, piloting, verification, and standardisation. Distinguished from 8D: PDCA is for proactive improvement initiatives, 8D is for reactive defect response. Use for process optimisation, lessons learned implementation, and quality objectives.

Build a design risk analysis, DFMEA worksheet, or interface analysis using the AIAG-VDA FMEA Handbook 2019. Covers design intent, interface failures, boundary diagram, and design robustness before manufacturing. Use during new product development, design changes, or when a field failure reveals a design weakness. Required for IATF 16949 §8.3 scope.

Supplier Corrective Action Request (SCAR) — escalate a supplier non-conformance to a formal corrective action request, define response requirements, evaluate the supplier's 8D response, and verify effectiveness. Use when an NCR escalates to a SCAR, when a supplier delivers repeated non-conformances, or when a field failure is traced to a supplier. Covers ISO 9001 §8.4 and IATF 16949 §8.4.1.

Open an 8D, run a G8D or TOPS-8D investigation, respond to a warranty complaint, or handle a customer quality escape with the 8 Disciplines methodology. Covers D0 emergency response through D8 team recognition with gate validation. Required for automotive OEM complaints — Ford, BMW, VW, Stellantis — and any quality escape needing documented root cause and PCA.

Write a corrective action report, CAPA, respond to an NCR or audit finding, or document an 8D D5 root cause action. Covers the full CAR structure: root cause analysis, corrective actions, implementation evidence, and verification of effectiveness (VOE) per ISO 9001 §10.2. Use for any quality escape requiring documented systemic corrective action.

Build an Ishikawa diagram, cause and effect analysis, or 6M fishbone to brainstorm and categorise all possible causes before narrowing to root cause with 5-Why. Covers Man, Machine, Method, Material, Measurement, and Environment (Mother Nature). Essential for 8D D4 brainstorming sessions and CAPA root cause investigations.

Problem scoping with Is/Is-Not for 8D D2 problem description, CAPA investigation, or hypothesis elimination. Defines the precise boundary by contrasting what IS observed vs what IS NOT — eliminating hypotheses that don't fit the pattern. A Ford-originated automotive technique used in every structured quality investigation.

Interactive 8D coach for running a live G8D or TOPS-8D investigation step by step, validating root cause depth, rejecting weak containment, and checking D7 systemic prevention. Use when running an 8D investigation live, reviewing a draft 8D before customer submission, or training a team on the 8 Disciplines methodology.

Interactive internal audit guide for ISO 9001:2015 and IATF 16949:2016 — walks through key clauses interactively, scores findings as Major NC / Minor NC / OFI, and generates a structured audit report. Use when conducting an internal audit and needing real-time finding documentation and a structured clause-by-clause audit approach.

PFMEA and DFMEA gap audit against AIAG-VDA FMEA Handbook 2019 — reviews an existing FMEA for missing failure modes, incorrect AP ratings, unaddressed H-AP items, missing special characteristics, and PFMEA-to-Control Plan linkage gaps. Returns a structured gap report with specific findings and required actions before PPAP or audit submission.

Write a non-conformance report or NCR fast — converts bullet-point inputs into professional objective-evidence language, suggests Critical/Major/Minor severity, recommends disposition, and flags missing required information. Use when writing an NCR quickly or when informal defect observations need to become formal quality records.

Interactive root cause analysis facilitator — runs a structured 5-Why why chain session, challenges each answer with evidence requirements, detects symptomatic and circular reasoning, and produces a validated Why chain with reversal check. Use for 8D D4, CAPA investigations, FMEA cause analysis, or any quality investigation requiring confirmed root cause identification.

Audit a SKILL.md or REFERENCE file, score it 0–10, identify major and minor findings, and generate copy-paste improvements. Use when reviewing a new skill before merging, auditing an existing skill for gaps, checking cross-skill consistency, or validating that a skill meets the Quality-Engineering-Skills framework standards. Triggers: audit this skill, score this SKILL.md, review reference file, check skill quality, find gaps in skill, validate skill before PR.

Conduct an IATF audit, check supplemental requirements, or prepare for a manufacturing process audit or IATF 16949:2016 third-party assessment. Covers customer-specific requirements (CSR), all 16 automotive supplemental clauses, and the three required audit types: QMS audit, manufacturing process audit, and product audit. Use for internal IATF audits or supplier quality audits at automotive organisations.

Conduct an internal audit by clause, answer ISO 9001 internal audit questions, or prepare evidence for §4 §5 §6 §7 §8 §9 §10. Provides key audit questions by clause, finding classification (Major NC / Minor NC / OFI), and audit report writing. Use when planning or conducting an ISO 9001:2015 internal audit or preparing for third-party certification.

Submit an 8D to a customer, format a Ford 8D report, BMW G8D, VW QMSS, or OEM complaint response for formal submission. Covers OEM-specific format requirements, evidence standards, and discipline-by-discipline writing rules for D0–D8. Use when preparing an 8D report for Ford, BMW, VW/Audi, Stellantis, or any customer requiring formal 8D closure.

Write a non-conformance report, NCR, reject a supplier, or document a defect with objective-evidence language and correct severity grading (Critical/Major/Minor). Covers disposition recommendations and segregation requirements for incoming inspection failures, in-process defects, customer returns, and audit findings.

Drill into root cause with a 5-Why why chain, why analysis, or structured root cause investigation. Builds a Why chain from symptom to systemic root cause, validates each step with evidence, and detects circular reasoning. Use for 8D D4, CAPA, FMEA cause analysis, or any quality investigation requiring confirmed root cause identification.

Build a PFMEA worksheet, process risk analysis, or AP table using the AIAG-VDA FMEA Handbook 2019 7-step approach. Covers Structure Analysis, Function Analysis, Failure Analysis, Risk Analysis (Action Priority H/M/L), Optimization, and Documentation. Required by IATF 16949 and OEM customer-specific requirements for new processes, process changes, and post-escape PFMEA updates.