Trainings Automotive

Our most requested competence training for Industry guidelines, methods and international management system standards.

Our Exemplar Global certified training courses on ISO 9001, IATF 16949, etc. are modular and may be booked according to personal needs.

Module 1 (2 days): Understanding the standard

Module 2 (advanced, 2 days): Qualification as internal auditor

Module 3 (advanced, 1 day): Qualification as Lead or Supplier auditor

ALL AUDITOR CERTIFICATION TRAININGS ALIGN WITH THE REQUIREMENTS OF ISO 19011.

Although the ISO 9001 requirements have been removed from IATF 16949:2016 Automotive Quality Management System requirements and are published as a separate ISO standard, IATF 16949 is not a stand-alone standard and must be used in conjunction with ISO 9001.

This course was developed to cover all requirements of both the ISO 9001:2015 and IATF 16949:2016 standards, including the new IATF 16949 requirements for Internal and Second Party Auditors regarding Core Tools and Customer Specific Requirements. Audits conducted to ISO 19011.

Target audience:

All modules can be valuable for Quality Assurance Managers, IATF 16949:2016 implementation and transition team members, management representatives, and all others who would like to develop competency in IATF 16949:2016 and the auditing process for first, second and, third party auditing.

Training structure:

Module 1

• Application of quality management principles in the context of ISO 9001:2015 and IATF 16949:2016.
• Relation of the quality management system to the organizational products, services, and operational processes.
• Organization’s context and interested party needs and expectations related to the planning and implementation of a quality management system.
• Application of the principles, procedures and techniques of auditing.

Module 2

• Conducting of an effective audit in the context of the auditee’s organizational situation
• Application of regulations, and other considerations relevant to the management system, and the conduct of the audit.
• Personal attributes necessary for the effective and efficient conduct of an audit.
• How to establish, plan and task the activities for the audit team; in line with ISO 19011.
• Effective communication with the auditee and audit client.
• Organization and direction of audit team members.
• How to prevent and resolve conflicts with the auditee or within the audit team.
• Preparation and completion of the audit report.
• Purpose and application of the core tools
• Linkage between the core tools and the IATF 16949 requirements
• Importance of customer specific requirements

Module 3

• Leading audit teams to ISO 19011
• Review of audit process and audit management strategies
• Practical application of principles of leading audit teams and conducting interviews

Full training avialable in German.

APQP: Advanced Product Quality Planning | 1 day

The seminar explains the process of Advanced Product Quality Planning (APQP) within an organization. An overview of the five phases of APQP is given, comparing the APQP approach with VDA 6.3, internal management systems and IATF 16949.

Target audience:

Those who have direct responsibility for introducing new products and/or a new manufacturing processes and systems would benefit from this seminar. This includes program/product managers, quality managers, design engineers, manufacturing engineers, APQP team members and others who have direct responsibility for process standardization and improvement.

Training structure:

• The five phases of APQP and the benefits of the APQP strategy
• Inputs and outputs of the five phases of APQP
• Process elements and key requirements of VDA 6.3 in relation to APQP
• APQP and the specifications for „product realization“ according to IATF 16946
• Connections between APQP, VDA 6.3 and IATF 16949

Special features:

• The training may include requirements of the company quality management system.

Full training avialable in German.

Production Part Approval Process | Production Process Approval | 1 day

The training builds on APQP and provides the participants with comprehensive knowledge of PPAP/PPA which is the final part of the APQP process: basic requirements, documentation, customer specific requirements, evaluation.

Target audience:

Development engineers, quality assurance officers, supplier developers, production engineers, internal Auditors.

Training structure:

• Introduction and overview to PPA process
• PPAP within the framework of the operational QMS
• Management of sampling documents
• Submission stages
• Archiving of records and master samples
• Representative production run
• PPAP documents for submission
• Part submission confirmation and status
• Assessment of PPAP documents

Special features:

• Customer-specific documents and processes can be included in the training.
• The training can be aligned to PPAP (AIAG), depending on your needs. In each case, differences and parallels to the other standard are taken into account.

Note: The VDA has announced a revised version of PPF for summer 2020. All changes can be considered at short notice after the document comes into force.

Full training avialable in German.

Design FMEA | 1-2-3 days

The seminar enables the participants to work in an FMEA team. The participants learn about the structure and development of a design FMEA, as well as how to use the corresponding tools.

Target audience:

Leaders responsible for design activities, design engineers, NPI development teams, process engineers, quality engineers.

Training structure:

• System and design FMEA: block diagrams, the use of an interaction matrix to identify the connection between components and higher-level systems
• Product development and quality
• Implementation of a design FMEA: Identification of functions, malfunctions, causes as well as avoidance and discovery measures, documentation
• Implementation of the results of the Design FMEA into a Design Verification Plan (DVP&R)
• Determination of functional failure modes and errors, and their significance
• Incorporating Special Characteristics and features in product design
• Using FMEA risk assessments as the basis for the continuous improvement process

Full training avialable in German.

Process FMEA | 2-3 days

The training provides practical knowledge on the development and linking of process flow diagrams, P-FMEA and production control plans in order to improve and standardize processes.

Target audience:

Leader responsible for process design and development and process engineers, APQP team members, manufacturing engineers, quality representatives as well as PPAP coordinators and project managers.

Training structure

• Performance of a P-FMEA
• Flowcharts
• Requirements and special features
• Risk assessment
• Types of defects, prevention and detection
• Production control plan
• Work instructions

 

Special features: D-FMEA and P-FMEA

• If desired, the use of the corresponding software can be integrated into the training; the training duration is thus increased by one day.
• The FMEA training can be conducted according to the specifications of AIAG, VDA or the new harmonized FMEA. Training on the new FMEA necessarily includes software training, as the use of corresponding programs is specified by the standard.

Note: After Daimler has announced that from now on only FMEAs according to the new standard will be accepted, it is expected that the other OEMs will follow suit. It is certainly recommended to train according to the new standard.

For FMEA-experienced employees Omnex also offers trainings that focus on the differences and changes (training material currently in English; German as training language is still possible).

Full training avialable in German.

Statistical Process Control | 2 days

The seminar provides basic knowledge of statistics, such as mean value, range, standard deviation and their application in relation to production processes, deals with process capability and the creation and evaluation of different control charts.

Target audience:

Development engineers, development teams, process engineers, quality engineers, shift supervisors, team leaders in production who are entrusted with tasks related to the execution and planning of sampling inspections to determine process capability.

Training structure

• Variation and its causes
• Basics of statistics: population and sample, distribution, mean value, range, standard deviation, normal distribution
• Stable processes and predictability, sporadic and systematic errors
• Overregulation and funnel experiment
• Central limit theorem
• Process capability and confidence intervals and proportion of defective products for bilateral tolerances as a function of process capability. Process capability criteria for PPAP acceptance
• Commonly used SPC Control charts
• Statistical steering with control charts
• Out-of-control signals for xbar cards, rules for pattern recognition
• Process improvements with SPC
• Stumbling blocks in the implementation of SPC
• Process capability and test process suitability

Special features:

• As there is a variety of different control charts, specific operational needs can be addressed by prior arrangement in order to optimize the effectiveness of the seminar.
• The seminar contains practical exercises to illustrate the function and benefits of statistical tools.
• If desired, the use of software can also be considered.

Full training avialable in German.

Measurement System Analysis – 2 days

The seminar imparts practical knowledge on test process suitability, MSA objectives, procedure, MS evaluation methods. Course includes the use of the common software for some practical exercises.

Target audience:

Quality managers, measurement and laboratory technicians, internal auditors, persons responsible for the planning, application and maintenance of measurement systems.

Training structure

• Introduction to test process suitability
• Measurements in the testing process
• Resolution and discrimination of gages
• Normal distributions
• Bias, Linearity and Stability
• GRR according to AIAG and ANOVA methods
• Procedures 1, 2 and 3
• Incapable measuring systems and conditional release
• Attributive measuring systems
• MSA 4

Full training avialable in German.

Effective Team-oriented problem solving | 2 or 3 days

This course focuses on team-oriented solving for complex or chronic problems. Using the 8D methodology steps, students will learn and practice how to solve complete and 8D and ensure permanent elimination of the problematic (root) causes. This course aligns with AIAG CQI-21.

Target audience:

All those who participate in or lead a problem-solving team and are using 8D to report results.

Training structure

• Introduction: Problem solving
• Assembling the right (size) team for problem solving
• Developing the correct problem description
• Containment: temporary measures to prevent further escapes
• Root cause (3L – error/root causes)
• Finding permanent shutdown measures
• Decision-making, and common pitfalls
• Evaluate permanent shutdown measures
• Preventing repeat defects, failures and complaints
• Ensuring team success
• Managerial Root Cause
• Use of checklists

Special features:

• Internal company cases can be worked through, evaluated and discussed in the training.
• Documents of the 8D process can be integrated into the training.
• Both measures significantly increase the practical applicability of what has been learned.

Seminar Content

This five-day course is designed to give the attendee a detailed understanding of Automotive SPICE and methods for assessing software development processes.

The Automotive SPICE Process Assessment Model is used to perform conformant assessments of the software process capability in the development of automotive systems in accordance with the requirements of ISO/IEC 33002.

Upon completion of this course you will be able to apply the evaluation methods used in Automotive SPICE to assess and improve your company’s processes. Methods to integrate Automotive SPICE with both ISO 26262 (Functional Safety) and IATF 16949 (Automotive Quality Management Systems) will be covered in class.

The auditing guidelines of ISO 19011—including the audit process and methodologies, e. g., planning and conducting an audit, writing nonconformity statements, preparing an audit summary and report, and verifying corrective actions—and their application in an Automotive SPICE developmental environment will be covered. Case studies from the automotive industry to develop skills for identifying nonconformities will be used.

Who Should Attend

The seminar has been developed for professionals in system and software engineering (architects, developers, test engineers, etc.), process managers, project managers, consultants, quality managers and other participants involved with development projects of software and electronics companies in the automotive industry.

The second part of the seminar (assessment) is primarily designed for those performing assessments, but can also be valuable for Software Managers, ASPICE Implementers, Quality Assurance Managers, ASPICE Implementation and/or Transition Team Members, and all others who would like to develop competency in Automotive SPICE.

Recommended Training and/or Experience

We recommend the participants have some experience in the development of complex technical systems or in process optimization. Background in developing embedded systems projects, software systems projects, quality management systems, or functional safety will be helpful.

A basic understanding of project management, quality management and system and software engineering processes is helpful, but not required.

Seminar Materials

Each participant will receive a seminar manual and a breakout workbook that includes a running case study of an Automotive Software Project to illustrate an Automotive SPICE audit.

Seminar Goals

• Detailed understanding of what Automotive SPICE PAM 3.0 is and the motivation behind the model
• Detailed understanding of process capability levels 1 (HIS-Scope), 2 and 3
• Detailed understanding of traceability requirements according to Automotive SPICE
• Understanding of how to evaluate process risks and drive process improvements
• Understanding of how Automotive SPICE integrates with other standards (ISO 26262 and IATF 16949)
• Sufficient knowledge and understanding of the assessment process according to Automotive SPICE
• Detailed understanding of how to perform internal and/or second party assessments
• Understanding of how to rate and determine the capability level

Seminar Outline

Day One

• Introduction to Automotive SPICE: Definition, History, Structure, Key Concepts
  • Breakout Exercise – Project Management (MAN.3)
• Understanding Automotive SPICE Requirements (SYS.2, SW.1)
  • Breakout Exercise – Requirements (SYS.2, SW.1)

Day Two

• Understanding Architectural, Design, Implementation, and Testing (SYS.3, SW.2, SW.3)
  • Breakout Exercise – Testing (SW.4, SW.5, SW.6, SYS.4, SYS.5)
• Supporting Processes and Supplier Monitoring (SUP.8, SUP.9, SUP.10, ACQ.4)
  • Breakout Exercise – Quality Assurance (SUP.1)

Day Three

• Understanding Capability Levels 2 and 3
  • Breakout Exercise – Evaluation of PA 2.1 and 2.2
  • Breakout Exercise – Evaluation of PA 3.1 and 3.2
• Integration of Automotive SPICE with ISO 26262 and IATF 16949
  • Breakout Exercise – Mapping HIS ASPICE Processes to IATF 16949 Clauses
  • Breakout Exercise – Mapping ASPICE to ISO 26262
  • Breakout Exercise – Scenario Evaluation (SUP.9)
• ASPICE Final Exam

Day Four

• Introduction to Assessment Programs
• Assessment Planning and Preparation
  • Breakout Exercise – Creating Assessment Plan and Schedule
• Performing the Assessment
• Audit Findings and Nonconformity Statements
• Reporting the Assessment Results

Day Five

• Assessment Follow-up
  • Breakout Exercise – Performing Automotive SPICE Assessment

Our most requested competence training for Industry guidelines, methods and international management system standards.

Our Exemplar Global certified training courses on ISO 9001, IATF 16949, etc. are modular and may be booked according to personal needs.

Module 1 (2 days): Understanding the standard

Module 2 (advanced, 2 days): Qualification as internal auditor

Module 3 (advanced, 1 day): Qualification as Lead or Supplier auditor

ALL AUDITOR CERTIFICATION TRAININGS ALIGN WITH THE REQUIREMENTS OF ISO 19011.

Seminar Content

This five-day seminar covers all 12 parts of the ISO 26262 standard to give those attending the information necessary to understand the standard, and move your organization toward conformance. ISO 26262 is the Functional Safety standard that is applied to Safety Related Systems that include electric/electronic systems installed in production passenger vehicles. The course combines presentations with hands-on work and is conducted in English. There is an optional ISO 26262 Certification exam at the end of the class for those wanting to demonstrate and document their knowledge.

This course combines presentations, along with in-class group exercises to put what you are learning into practice. Concepts are reinforced by a running case study of an air bag system. Forms are used to complete the exercises as a part of the integrated workshops that include Item Definition, Hazard Analysis and Risk Assessment (HARA), Safety Goals, ASIL levels, Functional Safety Concept, Technical Safety Concept, and Hardware/Software Interface.

Who Should Attend

Those involved in the design, development, and production of electrical and electronic based vehicle products, including the systems, software and hardware engineers, and managers. Basically, all those responsible for the development and implementation of hardware and software systems in motor vehicles.

Participants should be, or plan to be, actively managing, or involved in, or aware of electrical and/or electronic items, systems, or elements that are incorporated in motor vehicles. And have the abilities, education, and experience required for the above roles.

Recommended Training and/or Experience

Participants should be involved in or aware of software and hardware development as it relates to the motor vehicle industry.

Seminar Materials

Each participant will receive a seminar manual including case studies.

Seminar Goals

• Tailor the necessary activities to support vehicle safety lifecycle management, development, production, operation, service, and decommissioning
• Information provided in the class can be used for ISO 26262 implementation
• Understand functional safety aspects of the entire development process including requirements specification, design, implementation, integration, verification, validation, and configuration.
• Understand the risk-based approach for determining risk classes Automotive Safety Integrity Levels (ASILs)
• Use ASILs for achieving an acceptable residual risk
• Provide requirements for validation and confirmation measures to ensure a sufficient and acceptable level of safety is being achieved

Daily Agenda (approximate, based on class discussions)

Seminar Outline

Day One

• Chapter 1: Introduction and Overview to ISO 26262
  • ISO 26262 Purpose, Scope and Framework
• Chapter 2: Management of Functional Safety (Part 2)
  • Safety Culture
  • Project Dependent Safety Management
  • Safety Case
  • Breakout Exercise 1: Safety Case Outline
  • Confirmation Measures
• Chapter 3: Production and Operation (Part 7)
• Chapter 4: Safety Element out of Context (Part 10)
• Chapter 5: Concept Phase (Part 3)
  • Item Definition
  • Breakout Exercise 2: Item Definition

Day Two

• Chapter 5: Concept Phase (Part 3)
  • Hazard Analysis and Risk Assessment (HARA)
  • Severity, Exposure and Controllability
  • Safety Goals
  • Breakout Exercise 3: HARA
  • Functional Safety Requirements
  • Breakout Exercise 4: Functional Safety Requirements
• Chapter 6: ASIL-Oriented and Safety-Oriented Analyses (Part 9)
  • Example Scenario
  • Safety Analyses in ISO 26262
• Chapter 7: System Level Development I (Part 4)
  • Technical Safety Concept
  • Hardware-Software Interface (HSI)

Day Three

• Chapter 8: Hardware Level Development I (Part 5)
  • Specification of Hardware Safety Requirements
  • Hardware Design
  • Evaluation of the Hardware Architectural Metrics
  • Breakout Exercise 5: Fault Metrics
  • Evaluation of Safety Goal Violations Due to Random Hardware Failures
• Chapter 9: Evaluation of Hardware Elements (Part 8)
  • Classification of Evaluated Hardware Element
  • Hardware Evaluation
  • Proven-in-Use Argument
• Chapter 10: Hardware Level Development II (Part 5 revisited)
  • Initiation of Product Development at the Hardware Level
  • Hardware Integration and Verification
• Chapter 11: Software Level Development (Part 6)
  • General Topics for Product Development at the Software Level
  • Specification of Software Safety Requirements

Daily Agenda (approximate, based on class discussions)

Day Four

• Chapter 11: Software Level Development (Part 6)
  • Software Architectural Design
  • Breakout Exercise 6: Walkthrough vs. Inspection
  • Verification by Review
  • Control Flow Analysis and Data Flow Analysis
  • Software Unit Design and Implementation
  • Software Unit Verification and Testing
  • Coverage Metrics
  • Software Integration Testing
• Chapter 12: System Level Development II (Part 4 revisited)
  • Item Integration and Testing
  • System Integration and Testing
  • Vehicle Level Integration
  • Safety Validation
  • Functional Safety Assessment
  • Release to Production
• Chapter 13: Supporting Processes (Part 8)
  • Integration of ISO 26262 with ISO 9001 or IATF 16949
  • Breakout Exercise 7: Integration with Other Standards

Daily Agenda (approximate, based on class discussions)

Day Five

• Chapter 13: Supporting Processes (Part 8)
  • Distributed Development
  • Specification and Management of Safety Requirements
  • Configuration Management
  • Change Management
  • Verification
  • Documentation Management System
  • Qualification of Software Tools
  • Breakout Exercise 8: Confidence in Tools
  • Qualification of Software Components
  • Evaluation of Hardware Elements
  • Proven in Use Argumentation
  • Interfacing an Application that is Out of Scope of ISO 26262
  • Integration of Safety-Related Systems not Developed According to ISO 26262
• Chapter 14: Guideline on Application of ISO 26262 to Semiconductors (Part 11)
• Chapter 15: Adaption of ISO 26262 to Motorcycles (Part 12)
• Chapter 16: ISO 26262 Implementation Strategy

Optional ISO 26262 Certification Exam – Final 3 hours of Day Five

Three Levels of Certification

Level 1

Functional Safety Engineer Provisional (FSEP)

Knowledge Requirements:

• One week of Functional Safety Training and pass the ISO 26262 Certification exam.

Prerequisites:

• At least three years of relevant professional experience, an engineering degree or work experience equivalency with degree.

Level 2

Functional Safety Engineer (FSE)

Knowledge Requirements:

• One week of Functional Safety Training and pass the ISO 26262 Certification exam.

Prerequisites:

• Submit a case study demonstrating experience in Functional Safety that can be verified. The case study should demonstrate a broad understanding from Safety Plan to Safety Case (work products).
• Interview with an Omnex Functional Safety Expert.
• At least five years of relevant industry experience.

Level 3

Functional Safety Expert (FSX)

Knowledge Requirements:

• One week of Functional Safety Training and pass the ISO 26262 Certification exam

Prerequisites:

• Submit two case studies demonstrating the ability to conduct confirmation reviews, evidence of communication and a broad understanding from Safety Plan to Safety Case.
• Interview with an Omnex Functional Safety Expert.
• At least five years of relevant industry experience.