Learn FMEA, Control Plan & SPC step-by-step to identify risks, control processes and prevent defects in real production
STOP DEFECTS BEFORE THEY HAPPEN
What you’ll learn
- Understand how FMEA, Control Plan and SPC are connected within APQP.
- Perform FMEA using Severity, Occurrence, Detection and risk prioritization.
- Build a Control Plan based on real process risks.
- Understand and use control charts (Xbar-R, I-MR, p-chart).
- Calculate and interpret Cp and Cpk in practice.
- Distinguish between control limits and specification limits.
- Identify process instability and take corrective actions.
- Improve process capability by centering the process.
Course Content
- Introduction & APQP –> 6 lectures • 7min.
- FMEA –> 10 lectures • 10min.
- Control Plan –> 4 lectures • 6min.
- SPC Fundamentals –> 4 lectures • 2min.
- Control Charts –> 3 lectures • 2min.
- Limits and Capability –> 7 lectures • 11min.
- Advanced SPC Charts –> 3 lectures • 2min.
- SPC Interpretation & Actions –> 5 lectures • 5min.
- Practical Use –> 2 lectures • 1min.
- Summary –> 1 lecture • 1min.
Requirements
STOP DEFECTS BEFORE THEY HAPPEN
Do you want to understand how real production processes are controlled, stabilized, and improved?
Have you ever experienced recurring defects, unstable processes, or unclear responsibilities in quality management?
This course will give you a complete, practical understanding of three essential tools used in modern manufacturing and APQP:
– FMEA – to identify and evaluate risks
– Control Plan – to define how those risks are controlled
– SPC – to monitor process performance and detect issues early
These tools are not standalone methods.
They form a structured system used across automotive, electronics, and high-reliability industries to prevent defects before they happen.
What you will learn:
- How to perform FMEA step by step
- How to evaluate risks using Severity, Occurrence and Detection
- How to calculate and interpret RPN
- How to understand AIAG-VDA logic and risk prioritization
- How to build and interpret a Control Plan
- How to define measurement methods, frequencies and reaction plans
- How SPC works in real production environments
- How to read and interpret control charts (Xbar-R, I-MR, p-chart)
- The difference between control limits and specification limits
- When to intervene, and when to stop production
This is not just theory.
This is how quality management works in real life.
Bonus tip:
If you want to master structured problem solving as well, check out my other courses on 5 Why and 8D.