Quality Manager / MR (Management Representative) Course Syllabus

📚 Who Should Attend?

• Quality Engineers & Quality Executives
• Management Representatives (MR)
• QA/QC Professionals
• Production & Process Engineers
• Internal Auditors
• Anyone preparing for Quality Manager roles

Module 1 – Fundamentals of Management Systems

• What is IMS (Integrated Management System)
• Overview of ISO 9001, IATF 16949
• Process Approach & Risk-Based Thinking
• PDCA Cycle
• High Level Structure (HLS)

Module 2 – ISO 9001:2015 Requirements

• Context of the Organization (Clause 4)
• Leadership & Commitment (Clause 5)
• Planning & Risk Management (Clause 6)
• Support Processes (HR, Training, Communication, Documentation) – Clause 7
• Operation Control – Clause 8
• Performance Evaluation – Clause 9
• Improvement – Clause 10

Module 3 – IATF 16949:2016 (Automotive QMS)

• IATF Structure & Automotive Approach
• Customer-Specific Requirements (CSR)
• Product Safety & Traceability
• Contingency Planning
• Warranty Management
• Supplier Development & Monitoring

Module 4 – Documentation & MR Responsibilities

• Quality Manual & Policy
• SOPs, Work Instructions, Formats
• Document Control & Record Control
• Role of MR (Management Representative)
• Handling Certification Body Audits

Module 5 – Internal Audit System

• ISO 19011 Guidelines
• Audit Planning & Audit Program
• Process Audit & System Audit
• Audit Checklist Preparation
• Audit Reporting & NCR Writing
• Corrective Action & Effectiveness Check

Module 6 – Risk Management & Opportunities

• Risk Identification Methods
• SWOT & Turtle diagram  in QMS
• Risk Register Preparation
• Preventive Action System

Module 7 – KPI & Performance Monitoring

• Setting Quality Objectives
• Department-wise KPIs
• Data Analysis Tools
• Management Review Meeting (MRM) Inputs & Outputs

Module 8 – Nonconformity & Corrective Action

• NCR Handling
• Root Cause Analysis (5 Why, Fishbone)
• CAPA System
• Continual Improvement Methods

Module 9 – Customer Focus & Complaint Handling

• Customer Satisfaction Monitoring
• Complaint Handling System
• 8D Problem Solving
• Cost of Poor Quality (COPQ)

Module 10 – Certification & External Audits

• Stage 1 & Stage 2 Audit Process
• Surveillance & Re-certification Audits
• How to face Auditor Questions
• Common Audit Nonconformities

Module 11 Bonus Practical Sessions

✔ Live documentation examples
✔ Audit role-play
✔ KPI dashboard preparation
✔ NCR & CAPA case studies
✔ Core Tools sample formats

🏆 Key Benefits

⭐ Become job-ready for Quality Manager / MR roles
⭐ Understand complete ISO & IATF system implementation
⭐ Gain confidence to face external audits
⭐ Improve problem-solving & risk management skills
⭐ Get practical knowledge, not just theory

📜 Certification

Participants will receive a Course Completion Certificate after successful training.

🎯 Quality Manager / MR – Important Interview Questions

🔹 IMS & ISO Basics

1. What is an Integrated Management System (IMS)?
2. Explain the PDCA cycle with an example from your company.
3. What is Risk-Based Thinking in ISO 9001?
4. What is the High-Level Structure (HLS)?
5. Difference between Quality Assurance and Quality Control?

🔹 ISO 9001:2015 Questions

1. What are the main clauses of ISO 9001:2015?
2. What is meant by “Context of the Organization”?
3. How do you identify interested parties?
4. What is the role of leadership in ISO 9001?
5. What are quality objectives? Give examples.
6. What is documented information?
7. Difference between document and record?
8. How do you control external providers?
9. What is operational control?
10. What are the inputs and outputs of Management Review Meeting (MRM)?
11. What is continual improvement?
12. What is the difference between correction and corrective action?

🔹 IATF 16949 Questions

1. What is the difference between ISO 9001 and IATF 16949?
2. What are Customer Specific Requirements (CSR)?
3. Explain product safety requirements in IATF.
4. What is contingency planning?
5. What is traceability and why is it important?
6. What is layered process audit (LPA)?
7. What is warranty management?

🔹 Core Tools (Automotive)

1. What is APQP and its phases?
2. What is PPAP? When is it required?
3. What is FMEA? Difference between DFMEA & PFMEA?
4. What is Control Plan?
5. What is MSA? Types of MSA studies?
6. What is SPC? What are control charts?

🔹 MR (Management Representative) Role

1. What are the responsibilities of an MR?
2. How do you ensure the QMS is maintained?
3. How do you report QMS performance to top management?
4. How do you prepare for a certification audit?
5. How do you handle an auditor’s nonconformity?

🔹 Internal Audit

1. What is the purpose of an internal audit?
2. Difference between system audit and process audit?
3. How do you prepare an audit checklist?
4. What is an audit finding?
5. Difference between Major and Minor NCR?
6. What is audit evidence?

🔹 Risk & Improvement

1. How do you identify risks in a process?
2. What tools are used for root cause analysis?
3. Explain 5 Why analysis with an example.
4. What is CAPA?
5. What is preventive action in ISO 9001?

🔹 Customer & Problem Solving

1. How do you handle a customer complaint?
2. What is 8D methodology?
3. What is Cost of Poor Quality (COPQ)?
4. How do you measure customer satisfaction?

🔹 KPI & Performance Monitoring

1. What KPIs are used in the Quality department?
2. How do you analyze quality data?
3. What is trend analysis?
4. How do you present data in MRM?

🔹 Audit Situational Questions

1. If an operator is not following SOP, what will you do?
2. Auditor found records missing — how will you respond?
3. Customer complaint increased suddenly — your action plan?
4. Rejection rate increased in production — how will you investigate?
5. Supplier quality is poor — how will you control it?