IATF 16949 / ISO 9001 Quality Core Tools
CMAKNOWLEDGE.IN — QUALITY SYSTEMS
IATF 16949 & ISO 9001 Quality Core Tools Suite
Six calculators that work from your own raw data, interpret every result against the standard's predefined acceptance bands, and export to a real, audit-ready Excel workbook.
Statistical Process Control
Cp/Cpk/Pp/Ppk computed directly from your raw measurements — not from a guessed sigma.
Formulas & predefined bands
σ(overall) = sample standard deviation of all readings
Cp = (USL − LSL) / (6 × σ_within) Cpk = min[(USL−x̄)/(3σ_within), (x̄−LSL)/(3σ_within)]
Pp = (USL − LSL) / (6 × σ_overall) Ppk = min[(USL−x̄)/(3σ_overall), (x̄−LSL)/(3σ_overall)]
IATF/AIAG bands: Cpk ≥ 1.33 capable · 1.00–1.32 marginal · < 1.00 not capable
Measurement Systems Analysis — Gage R&R
AIAG Average & Range method, computed from an actual appraiser × part × trial data grid.
AIAG Average & Range method
X̄diff = max(appraiser mean) − min(appraiser mean) AV = √[(X̄diff×K2)² − EV²/(parts×trials)] (K2: 3.65 for 2 appraisers, 2.70 for 3)
Rp = range of part averages PV = Rp × K3 (AIAG d2* table by part count)
GRR = √(EV²+AV²) TV = √(GRR²+PV²) %R&R = 100×GRR/TV
AIAG rule: <10% acceptable · 10–30% conditional/marginal · >30% unacceptable
FMEA — RPN & Action Priority
Classic RPN plus a severity-led Action Priority read, each interpreted against its own predefined band.
Formula & scope note
Action Priority follows a severity-first, then occurrence, then detection decision order consistent with published AIAG-VDA guidance. It is an independently-built approximation, not a reproduction of the handbook's proprietary lookup table — confirm against your organization's controlled FMEA procedure before using it on a live PPAP submission.
| Severity band | Rule applied |
|---|---|
| 9–10 | High if O≥2 or D≥5, otherwise Medium |
| 7–8 | High if O≥4 and D≥5; Medium if O≥2; else Low |
| 5–6 | High if O≥6 and D≥7; Medium if O≥4; else Low |
| 1–4 | Medium if O≥8; otherwise Low |
PPAP — Level & Document Checklist
All 18 AIAG PPAP elements, mapped against the submitted-vs-retained rule for the level you pick.
Cost of Poor Quality & PPM Tracker
Defect rate in parts-per-million, first pass yield, and what this period's defects actually cost.
Formulas & predefined bands
FPY% = (Total−Scrap−Rework−Returns) / Total × 100
COPQ = (Scrap×cost)+(Rework×cost)+(Returns×cost)
Bands: PPM ≤ 500 strong · 500–5,000 needs improvement · > 5,000 corrective action required
OEE — Overall Equipment Effectiveness
Availability × Performance × Quality, with the biggest loss driver called out automatically.
Formulas
OEE = Availability × Performance × Quality
Master session workbook
One Excel file with every module's data, results and interpretation on its own sheet, plus a summary sheet — timestamped for audit or study logs.
