Quality tools, from the well-known "Five Tools" to today's evolving "Six Core Tools" represent not just a numerical increase, but a profound revolution in quality control philosophy across the entire industry.
I. Foundation of the Classic System: The Golden Age of Five Tools
In the 1980s, the U.S. automotive industry AIAG integrated a system known as the "Quality Five Tools": APQP, FMEA, SPC, MSA and PPAP. This toolkit quickly became the universal quality language for global automotive supply chains. These five tools mutually support each other, forming a complete quality control cycle.
II. Cracks in the System: The Execution Gap in Practice
However, the classic system gradually revealed problems in practice. The most obvious shortfall appeared in the Control Plan segment. As an output of APQP, the Control Plan should theoretically be the critical link connecting design and manufacturing, but in actual operations, it is often reduced to a form document meant to satisfy customer audits rather than a dynamic tool that truly guides production.
III. Digital Leap: The Core Upgrade from Five to Six
In 2019, AIAG and the German Automotive Industry Association (VDA) jointly released the new FMEA handbook; in 2024, AIAG launched the independent "Control Plan" handbook. This marks the formal establishment of the "Six Core Tools".
The key to this change lies in the independence and strengthening of the "Control Plan". The new CP handbook is no longer just a part of APQP, but an independent, complete control system that specifies detailed process control requirements from prototyping through mass production.
The new FMEA introduces a more structured "Seven-Step Approach" and an Action Priority assessment based on Severity, Occurrence, and Detection, replacing traditional subjective scoring methods. This change makes risk analysis more systematic and standardized.
Ⅳ. Deep Innovation: From Documents to Processes
The most essential difference between the old and new systems lies in the shift in mindset.
The old system was document-centric, emphasizing "all required documents must be present"; the new system is process control-centric, focusing on "every stage is truly under control." This transformation is most evident in the Control Plan.
Under the new system, the Control Plan becomes a dynamic, living production guidance document. It must be updated as processes change, must be understood and used by operators, and must be directly linked to actual error-proofing devices and inspection equipment.
V. Conclusion
In an era where quality is a core competitive advantage, companies that can truly integrate quality tools into business processes and continuously improve will gain a favorable position in fierce market competition. Every evolution brings us one step closer to the dream of "Zero Defect." The transformation from Five Tools to Six Tools is not just a methodological update, but an upgrade in thinking mode.
Ningbo Qianhao is a professional precision casting and machining manufacturer. We specialize in investment casting, integrating lost foam casting, lost wax casting, silica sol casting, automated composite casting and shell mould casting in our own foundries. Steadfastly conducting annual systematic professional training on core quality tools including APQP, FMEA and SPC, we stay abreast of cutting-edge industry standards and deeply integrate the latest methodologies into every aspect from design to production. Partnering with Qianhao means more than a compliant supplier; it means a reliable foundry partner committed to quality as a strategic core and continuous improvement.
Author: Ji Yanxiu, Quality Department.