Quality Assurance & Quality Control Essentials: Building Consistency, Compliance & Excellence in Industrial Operations

📌 Course Title:
Quality Assurance & Quality Control Essentials: Building Consistency, Compliance & Excellence in Industrial Operations

🎯 Purpose of the Training:
Practical course for industrial professionals that combines QA/QC fundamentals with supplier quality, quality planning tools, document and traceability control, critical-characteristic/change management, and AI-enabled monitoring all linked to ISO 9001 and aligned with ISO 45001 safety requirements. Delivered with AI-enhanced learning and practical templates so learners can apply skills immediately.

🧩 Target Audience:
• Production & Operations personnel
• QA/QC specialists and technicians
• Maintenance & Engineering staff
• Team leaders, supervisors, and line managers
• New hires in manufacturing, pharma, automotive, or food sectors

🎓 Learning Objectives (expanded):
By the end of this course, participants will be able to:
• Distinguish QA vs QC and apply RACI role definitions.
• Use core QC tools (Pareto, Fishbone, Control Charts, Check Sheets) and SPC.
• Apply SOPs, document control and traceability (batch/lot/serial, labeling).
• Use Quality Planning tools: APQP, PPAP, FAI, Control Plans, FMEA.
• Perform supplier quality activities: supplier selection, audits, SCAR, supplier KPIs.
• Operate basic AI-enabled monitoring concepts: predictive quality, real-time monitoring, machine vision, and AI safety monitoring (PPE, fatigue, gas sensors).
• Implement CAPA, lean and Six Sigma basics and measure performance with QA and HSE KPIs (defect rate, DPMO, FPY, MTBF, MTTR, LTIFR, TRIR).
• Complete and use practical templates (SCAR, Supplier Eval, FAI report, CAPA, labeling checklist) in daily work.

📅 Course Duration:
~1.5 Hours (Self-paced AI-based microlearning) modules are short, with practical exercises and downloadable templates.

📚 Modules Overview

Module

Title

Key Content (additions in italics)

Module 1: Introduction to Quality Management
Definition of quality, industry importance, evolution to TQM, link to OH&S policy, examples of quality-related safety incidents.

Module 2: QA vs QC – Understanding the Differences
Roles, goals, prevention vs detection, real industrial examples, RACI responsibilities (QA, QC, Production, Supplier, Management).

Module 3: Quality Assurance Systems
Documentation & SOPs, audits, process validation, risk-based thinking, ISO 9001; document control, traceability, labeling; supplier management basics (audits, SCAR, KPIs).

Module 4: Quality Control Techniques & Tools
Inspection methods, SPC, 7 QC tools, digital sensors; critical characteristics (CTQ, safety-critical), change management, Temporary Deviation Notification (TDN).

Module 5: AI in QA/QC
Predictive analytics, real-time AI monitoring, machine vision; AI for safety (PPE detection, fatigue, gas sensors); KPI examples and RACI for alerts.

Module 6: Quality Metrics & Continuous Improvement
KPIs (defect rate, DPMO, FPY), CAPA, Lean & Six Sigma; quality planning tools (APQP, PPAP, FAI, Control Plans, FMEA); timing metrics (MTBF, MTTR, CAPA/SCAR closure).

Module 7: Case Studies & Industry Best Practices
Industry examples (automotive, pharma, manufacturing), lessons learned; practical templates (SCAR, supplier evaluation, FAI, audit checklist, labeling); interactive exercises.

Module 8: Final Assessment & Certification
AI-based quiz, scenario simulation, personalized feedback; HSE knowledge check, emergency response, template evaluation.

📊 Methodology (expanded):
• AI-narrated microlearning videos and short trainer scripts for each section.
• Step-by-step guides for QC tools and planning tools (APQP / PPAP / FAI / Control Plans / FMEA).
• Practical templates (downloadable/printable): SCAR, Supplier Evaluation, FAI Report, CAPA action plan, Traceability & Labeling checklist, Daily QC checklist, Machine Maintenance checklist, NCR template.
• Case-based exercises and role-based RACI workshops.
• Short KPI dashboards & example SPC/control charts for hands-on interpretation.
• Module-end knowledge checks and a final scenario-based assessment.

📈 Expected Outcomes (expanded):
Participants will be able to:
• Apply SOPs and document-control practices (revision and retention).
• Run supplier qualification and SCAR processes and track supplier KPIs.
• Use APQP/PPAP/FAI and Control Plans to ensure first-time quality.
• Use AI-enabled monitoring concepts to reduce defects and support OH&S.
• Measure performance with combined quality and safety KPIs and close CAPA/SCAR within target times.

💡 Notes on Integration with ISO 45001:
• ISO 45001 elements are integrated across modules notably in Module 1, Module 3, Module 4, Module 5 and Module 6 to ensure quality activities also support hazard identification, incident reporting, operational control, worker participation and performance evaluation.
• Training will explicitly show how QA/QC tasks tie to OH&S clauses (e.g., risk registers, incident investigation linked to RCA and CAPA).

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