Quality Manager Course – Short Syllabus

 Fundamentals of Quality Management

• Quality concepts & definitions
• Cost of Quality (COQ)
• PDCA Cycle
• Process approach
• Risk-based thinking

2️⃣ ISO 9001:2015 – Quality Management System (QMS)

• Clause-wise understanding
• Context of organization
• Leadership & Quality Policy
• Planning & Risk Management
• Support (HR, Infrastructure, Calibration)
• Operation control
• Performance evaluation
• Improvement & CAPA

3️⃣ IATF 16949 (Automotive QMS) (Very important for manufacturing)

• IATF structure & additional requirements
• Customer Specific Requirements (CSR)
• Product safety & traceability
• Contingency planning
• Warranty management
• Supplier development

4️⃣ Core Quality Tools

• APQP – Advanced Product Quality Planning
• PPAP – Production Part Approval Process
• FMEA – Risk analysis (DFMEA / PFMEA)
• SPC – Statistical Process Control
• MSA – Measurement System Analysis
• CP –  Control Plan

5️⃣ Problem Solving & Improvement

• 7 QC Tools (Pareto, Fishbone, Histogram, etc.)
• 8D Methodology
• Root Cause Analysis (5 Why, Fishbone)
• Kaizen & Continuous Improvement
• Poka-Yoke (Mistake Proofing)

6️⃣ Internal Auditing & Compliance

• ISO 9001 & IATF audit requirements
• Audit planning & checklist preparation
• Process auditing
• Nonconformity writing
• Corrective action follow-up

7️⃣ Supplier Quality Management

• Supplier selection & evaluation
• Supplier audits
• Incoming inspection
• Supplier performance monitoring
• Supplier corrective actions

8️⃣ Production & Process Quality

• Process validation
• First piece approval
• In-process inspection
• Final inspection
• Rework & rejection control

9️⃣ Customer Quality Management

• Complaint handling
• Customer returns & warranty
• Customer satisfaction measurement
• Corrective & preventive actions

🔟 Data Analysis & Reporting

• KPI & Quality objectives
• PPM, Rejection %, OEE basics
• Trend analysis
• Management review reporting

1️⃣1️⃣ Documentation & System Control

• Quality Manual & Procedures
• SOPs & Work Instructions
• Record control
• Document change management

1️⃣2️⃣ Leadership Skills for Quality Managers

• Team handling
• Cross-functional coordination
• Training & competency development
• Communication with customers & auditors

🎯 Quality Manager Interview Questions

🔹 Basic Quality Concepts

1. What is Quality? How do you define it in manufacturing?
2. What is Cost of Quality? Explain its components.
3. What is the PDCA cycle? Give a practical example.
4. Difference between Quality Control and Quality Assurance?
5. What is Risk-Based Thinking in ISO 9001?

🔹 ISO 9001:2015 Questions

1. Explain the structure of ISO 9001:2015.
2. What is “Context of the Organization”?
3. How do you identify risks and opportunities?
4. What are quality objectives? Give examples.
5. What is documented information?
6. How do you control external providers (suppliers)?
7. What is Management Review? What inputs & outputs are required?
8. What actions do you take when a nonconformity occurs?
9. Difference between Correction and Corrective Action?
10. How do you ensure customer satisfaction is monitored?

🔹 IATF 16949 (Automotive)

1. What are Customer Specific Requirements (CSR)?
2. What is Product Safety in IATF?
3. Explain Traceability requirements.
4. What is Contingency Planning?
5. What is Warranty Management?
6. What is the difference between ISO 9001 and IATF 16949?
7. What is layered process audit (LPA)?

🔹 Core Quality Tools

1. Explain APQP phases.
2. What is PPAP? What are its submission levels?
3. What is FMEA? Difference between DFMEA & PFMEA?
4. What is RPN? How do you reduce it?
5. What is Control Plan?
6. What is SPC? What are control charts?
7. Difference between Cp and Cpk?
8. What is MSA? Explain Gage R&R.
9. What is a Special Characteristic?

🔹 Problem Solving

1. Explain 8D methodology.
2. What is Root Cause Analysis?
3. Difference between 5 Why and Fishbone?
4. What is Poka-Yoke? Give example.
5. How do you handle repeated customer complaints?

🔹 Audits

1. What are the types of audits?
2. How do you prepare an internal audit plan?
3. What is a process audit?
4. How do you write a nonconformity?
5. What is the difference between Major & Minor NC?
6. How do you close audit findings?

🔹 Supplier Quality

1. How do you select and evaluate suppliers?
2. What is Supplier PPM?
3. How do you handle supplier rejection?
4. What is Supplier Audit?
5. How do you develop a poor-performing supplier?

🔹 Production & Process Quality

1. What is First Piece Approval?
2. What is Process Validation?
3. How do you control in-process quality?
4. What actions do you take when rejection increases suddenly?

🔹 Customer Quality

1. How do you handle customer complaints?
2. What is 8D response to customer?
3. What is customer PPM?
4. How do you improve customer satisfaction?

🔹 Data & KPI

1. What KPIs do you monitor as a Quality Manager?
2. How do you analyze rejection trends?
3. What is OEE? How does quality impact it?
4. How do you present quality data to management?

🔹 Documentation & System

1. What documents are mandatory in ISO 9001?
2. How do you control document revisions?
3. Difference between SOP and Work Instruction?

🔹 Leadership & Practical

1. How do you handle conflict between production and quality?
2. How do you train operators on quality?
3. Describe a major quality issue you handled.
4. How do you prepare for a certification audit?
5. How do you ensure continuous improvement?