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Free Download PPAP Process Flow, PFMEA & Control Plan Masterclass
Published 8/2026
Created by Learning Ville
MP4 | Video: h264, 1920x1080 | Audio: AAC, 44.1 KHz, 2 Ch
Level: All Levels | Genre: eLearning | Language: English | Duration: 5 Lectures ( 51m ) | Size: 864.7 MB
Build Process Flow Diagrams, PFMEAs and Control Plans using risk-based thinking, practical examples and Excel template
What you'll learn
Understand the purpose and significance of all 18 PPAP elements Build a complete Level 3 PPAP package from product drawing through PSW Understand how PPAP fits within APQP and the product launch process Create and review Process Flow Diagrams, PFMEAs and Control Plans Maintain the PPAP "golden thread" between drawing requirements, risks, controls and validation evidence Identify and manage Special Characteristics (SC) and Critical Characteristics (CC) Conduct and interpret Variable Gauge R&R studies Understand Attribute GR&R and categorical inspection systems such as GO/NO-GO inspection Interpret repeatability, reproducibility, %GR&R, ndc, agreement, Kappa, false accepts and false rejects Perform and interpret process capability studies using Cp and Cpk Prepare balloon drawings and dimensional inspection reports Review material certificates, laboratory evidence and performance-test results Understand Customer Engineering Approval and Authorized Engineering Changes Apply Customer-Specific Requirements to a PPAP submission Understand checking aids, master samples, sample production parts and AAR requirements Determine when Bulk Material Requirements are applicable Complete and review a Part Submission Warrant (PSW) Audit a PPAP package for cross-document inconsistencies before customer submission Use a populated Excel PPAP workbook as a practical reference for real manufacturing applicationsRequirements
No previous PPAP experience is required Basic knowledge of manufacturing or quality is helpful but not essential Microsoft Excel or compatible spreadsheet software is recommended for working through the supplied PPAP template An interest in general quality, supplier quality, manufacturing engineering or quality managementDescription
Master the three connected documents at the heart of manufacturing process control
A Process Flow Diagram, PFMEA and Control Plan should never be treated as three independent documents created simply to satisfy a PPAP checklist.
They should tellone consistent manufacturing story.
This practical course teaches you how to create, review and connect these three essential quality tools
Process Flow Diagram → PFMEA → Control Plan
Using a realisticADC12 aluminium water-pump housing, we follow the manufacturing process from incoming material through casting, machining, inspection, leak testing and final release.
Rather than simply explaining what goes into each form, the course focuses on the engineering logic connecting them.
Build a Process Flow Diagram
You will learn how to map the complete manufacturing sequence, including
Incoming material Receiving inspection Storage Die casting Trimming and deburring Machining Drilling and tapping Cleaning Dimensional inspection Leak testing Final inspection Packaging and releaseYou will also learn why inspection, transportation, storage, rework and outsourced operations should not simply disappear from the process map.
The Process Flow Diagram establishes the manufacturing architecture for the risk analysis that follows.
Develop a practical PFMEA
Once the process is understood, we ask
What could go wrong?
You will learn how to develop a Process Failure Mode and Effects Analysis covering
Process functions Requirements Potential failure modes Effects of failure Severity Potential causes Occurrence Prevention controls Detection controls Detection ratings Risk Priority Number (RPN) Recommended actions Responsibility Target dates Revised riskYou will also learn an important principle
PFMEA is not simply an exercise in calculating RPN.
A low RPN does not automatically mean a risk should be ignored, particularly where severity or customer impact is significant.
Understand Severity, Occurrence and Detection
Using practical manufacturing examples, you will learn how to interpret
Severity - How serious would the effect be?
Occurrence - How likely is the cause to occur?
Detection - How likely are existing controls to detect the problem before escape?
For traditional RPN-based PFMEA
RPN = Severity x Occurrence x Detection
But the course goes beyond the mathematics and teaches students how to use engineering judgement when prioritising risk.
Convert PFMEA risk into effective controls
The next question is
What are we actually going to control in production?
This is where the Control Plan becomes critical.
You will learn how to define
Process characteristics Product characteristics Special Characteristics Specifications and tolerances Measurement equipment Control methods Sample sizes Inspection frequencies SPC requirements Reaction plans ResponsibilityBuild the golden thread
A major focus of this course is document alignment.
If the PFMEA identifiesmain bore tool wear as a significant manufacturing risk, the Control Plan should contain an appropriate control for that characteristic.
If a characteristic is designatedSC on the engineering drawing, students should be able to trace it through
Drawing → Process Flow → PFMEA → Control Plan
If the documents tell different stories, the PPAP is weak regardless of how attractive the individual forms look.
Develop meaningful reaction plans
Students will also learn why
"Inform supervisor"
is usually not an adequate reaction plan.
A useful reaction plan may need to address
STOP → CONTAIN → SEGREGATE → INVESTIGATE → CORRECT → VERIFY → RELEASE
By the end of the course, students should be able to create and challenge Process Flow Diagrams, PFMEAs and Control Plans as anintegrated manufacturing risk-management system.
4. What Students Will Learn
Students will be able to
Understand the relationship between Process Flow, PFMEA and Control Plan Create a manufacturing Process Flow Diagram Identify missing manufacturing and inspection operations Develop a practical Process FMEA Define process functions and requirements Identify credible failure modes, effects and causes Assign Severity, Occurrence and Detection ratings Calculate and interpret traditional RPN Understand why RPN alone should not determine risk priority Identify appropriate prevention and detection controls Develop meaningful risk-reduction actions Understand Special and Critical Characteristics Build a practical production Control Plan Select appropriate measurement and control methods Define sample sizes and inspection frequencies Create effective reaction plans Maintain traceability between PFMEA and Control Plan Audit Process Flow/PFMEA/Control Plan alignment Identify common PFMEA and Control Plan mistakes Apply the PPAP golden-thread principle5. Course Requirements
No previous PFMEA experience required Basic manufacturing knowledge is useful but not essential Microsoft Excel or compatible software recommended No requirement to complete Courses 1 or 2 first6.
Who this course is for
Supplier Quality Engineers and Supplier Quality Managers Quality Engineers and Quality Managers Manufacturing and Process Engineers APQP and PPAP Engineers New Product Introduction (NPI) Engineers Supplier Development Engineers Automotive and manufacturing professionals Quality inspectors and metrology professionals moving into quality engineering Engineering graduates seeking practical PPAP knowledge Suppliers preparing PPAP submissions for customers Professionals preparing for interviews or roles involving PPAP, APQP and supplier qualityHomepage
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