The automotive core tools are five linked methodologies that underpin a disciplined, low-risk product launch and ongoing process control: APQP (Advanced Product Quality Planning) and the Control Plan, PPAP (Production Part Approval Process), FMEA (Failure Mode and Effects Analysis), MSA (Measurement Systems Analysis) and SPC (Statistical Process Control). Together they're a mandatory part of IATF 16949 — see our IATF 16949 consultancy page for the full certification.
Many of the businesses we work with already hold IATF 16949 but have core tools that exist only on paper — FMEAs that were written once and never updated, control plans that don't match the shop floor, or PPAP packs assembled in a rush. We implement and coach the tools as working documents your engineers actually use, not audit props.
You need a disciplined, low-risk launch from concept to production, with the right deliverables at each gate.
You hold IATF 16949 but an audit or customer has flagged FMEAs, control plans or measurement data that don't stand up to scrutiny.
Phased launch planning and control plans that link process characteristics, controls and reaction plans.
Complete, right-first-time PPAP packages built to the correct customer submission level.
Structured risk analysis to the AIAG-VDA method, with action priority (AP) ratings and FMEAs that stay live.
Measurement systems analysis so you can trust the data your SPC and PPAP submissions are built on.
Control charts and process capability (Cp/Cpk, Pp/Ppk) that control processes, not just record them.
Hands-on coaching for your engineers, backed by our core tools training courses where deeper upskilling is needed.
We assess your current APQP, PPAP, FMEA, MSA and SPC against IATF 16949 and customer requirements.
We agree which tools need building from scratch, rebuilding, or just tightening up.
We build the documents on your actual parts and processes, not generic examples.
We coach your engineers until they can maintain and apply the tools unsupported.
If you're certified to IATF 16949, yes — APQP, PPAP, FMEA, MSA and SPC are all required elements. That said, we can focus on whichever tools are weakest first rather than rebuilding everything at once.
AIAG-VDA is the newer, harmonised FMEA method (replacing the older separate AIAG and VDA methods) and is now the expected approach for most automotive OEMs. It uses action priority (AP: high/medium/low) rather than a single risk priority number (RPN).
PPAP has five submission levels defining how much documentation goes to the customer, from a part submission warrant alone (Level 1) to a full package with all supporting data (Level 5) — your customer specifies which level applies.
Yes — many clients want a mix of hands-on implementation and training so their own engineers build the capability. See our training page for standalone core tools courses.
We quote every project on a fixed-scope basis after a free scoping call, based on which tools and how many parts are in scope.
Most of our clients need more than one of these — here's what tends to go together.
Automotive quality management certification, CSRs and core tools coaching.
Internal audit programmes, VDA 6.3 process audits and second-party supplier audits.
Structured root cause analysis that closes issues out for good — 8D, 5-Why, CAPA.
Six Sigma and Lean deployment led by a Master Black Belt to cut cost, waste and variation.
Tell us which tools need attention and which parts are in scope, and we'll quote a fixed price.
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