Training and Consulting - festo-didactic.com

Training and ConsultingCourse catalogue 2013

www.festo-tac.com

Technology, Organisation,People.

The perfect interplay of thesemain factors is essential in orderto successfully put knowledgeinto practice at a company.These factors lay the founda-tions for top performance andfinancial success.

The Festo Competence Modelcombines social, logisticaland technical skills to form a success-oriented approach for initial and further training.

Festo

Global player inAutomation and Didactic

15,500 people worldwide areworking at Festo towards inno-vative advances in the produc-tion of capital and consumer goods.This reflects Festo’s philosophyof full partnership and close proximity to more than 300,000 customers in over 200 indus-tries, realised via 250 Festo locations and 59 national Festo companies.

The focus of all activities is onpeople and technology. From itsfoundation, Festo has seen itselfas a strong partner and an inte-gral component of societies andbusiness worldwide.

Sustainable commitment to people and technology

Training in technology and productivity – from a global engineering and manufacturing company

Manufacturing know-how

Festo is both a global engineer-ing and manufacturing com-pany and training and consulting organisation with experienced instructors and consultants.This gives us insight into the challenges and opportunities not normally available to train-ing providers. We practice what we teach.

And we can use this experience to help you optimise the two parts of the productivity equa-tion – people and technology.

Globally qualified trainers

Our networks of qualified train-ers in the areas of Technology, Organisation and People share resources and best practices and contribute to continuous improvement and development of new products to address cus-tomer needs.

Methods and formats

Our trainers draw on the entire range of methods and formats –from an interactive presentation for a large group to the coach-ing of individuals in production teams.

We practice what we teach

Improving the people part of productivity

Our approach is competency-based – getting people fit for productivity

What we train

Festo offers a wide scope of training services covering the three skills areas, Technology, Organisation and People and the three factors in productivity, quality, time and cost.

Training is based on customer needs, for example:

Technology– Introduction of a new

technology– Development of all skills

needed to serve a produc-tion cell

Organisation– Establishment or improvement

of continuous improvement processes

– Introduction of KanbanPeople– Improvement in

communication – Implementation of problem-

solving techniquesQuality– Increase of individuals’

sensitivity to quality– Reduction of rework and

reject rate Time – Optimisation of set-up time – Minimisation of unplanned

downtimeCosts– Avoiding waste– Reduction of capital in work

in progress

How we train

Our training is competency-based, which means that – benefits for all stakeholders

are clear – “before” and “after” snap-

shots of skills make the ROI transparent

– it complements the com-petency matrix approach to improving individual performance

– it fosters a will to achieve in both trainer and trainees

– it provides orientation and a sense of achievement in technology training

– Hands-on exercises with industrial components rein-force the transfer of new skills

Getting exactly the right training

With our training formatsand services we can respond flexibly to meet your needs

No matter wich training format is chosen – whether public or in-house, a course, workshop, best-practice eventor corporate strategy games – the focus is always on first-hand experience. In both public andcustomised training, the out-comes are transparent to all stakeholders, and allow them to track progress towards achiev-ing the required competencies. Rapid transfer to daily practice is a key quality criterion – we help you to measure and opti-mise this.

Standard training

In public courses, a predefined set of competencies are trans-ferred. Approximately 42,000 course participants attend over 3,000 of our public courses worldwide every year.Our trainers deliver modularand quality-assured trainingin 39 languages.

Customised training

There are three levels tocustomised training:

Customised courses designed to achieve agreed outcomes are generally in-house to provide customers with a greater focus on the requirements of their business, increased flexibility and reduced expenses, often with the advantage of no travel for participants.

If you are not sure which skills profile a team needs, our Train-ing Needs Analysis (TNA) will identify the requirements and audit current skills in a report.

To optimise transfer, a post course review can be run a few weeks after training – this audits the upgraded skills set against the original profile.

Competence development projects

If your customised training exceeds the scope of a single course, qualification programs can be established. These com-prise several courses with time between that allow transfer to the workplace and integration of in-house projects with targets such as optimising set-up time on a machine.

The best of both worlds – blended learning

E-Learning

E-learning is designed for those who want to brush up their knowledge or master the basics of a new topic but are unable to visit a course. Festo web-based training programmes provide flexibility in training – anywhere, any time. Tutors can promote creativity and increase motivation.

Already, more than 30 digital training programmes are availa-ble in many languages and cover topics like:

Technology Pneumatics, Hydraulics,Electrical engineering, Electronics, Electrical safety measures, Electrical drives, Sensors, Actuators, PLC, Open-and closed-loop control, GRAFCET, Safety engineering, Machine vision, Process auto-mation, Water and wastewater treatment Organisation Poka Yoke, Value Stream Analysis and mapping, 5S, Project management, Time management PeopleCustomer orientation, Team performance, Personnel management

Blended learning

Blended learning combines the flexibility and freedom of web-based training with the lasting benefits of face-to-face training.All our training programmesoffer the following benefits:– Excellent didactic and

multimedia course topics– Scope for self-study during

classroom-based training– Learning scenarios can be

individually customised– Can be used in conjunction

with the Classroom Manager– Can be integrated into training

concepts which use other media

– Participant guidance– Monitoring of learning

progress and certification

Flexible blended learning programs

Training Course Overview-Technology-Organization-People

Technology

Triple benefits

ExperienceFor over 40 years, we have beenproviding support for all devel-opment stages of automation technology. Our training courses use the latest technology.Close collaboration with our industrial division ensures access to the latest machines and systems, while our trainers have first-hand expertise.

InnovationWe place tough demands onour training. At our training courses, you will notice the dif-ference compared to other train-ing pro-viders. We provide new answers to long-standing ques-tions that help you to make decisive steps in your company plans.

VisionOur trainers know the areas ofwork of your participants.This knowledge extends beyondpurely technical requirementsto questions concerning topicssuch as Just in time, TPM andKanban.

Technology

Online booking: www.festo-tac.com

Modern industrial pneumatics – Fundamentals

PN111

Target groups

Contents

Outcomes

Prerequisites

Duration

Article number

In this course you will cover in detail the most up-to-date products, current tools and methods related to pneumatics used in industry. Our principle is learning from the real world for the real world!

Operators, maintenance, design/engineering, trainers

• Drives: Cylinders for different drive purposes• Valves: Various valve types (pneumatic/electric controlled, structures, different mid positions etc)• Controls: Pneumatic and electric controls of valves

– Position control: Limit switches and sensors– Speed control: Uses of throttle valves– Logic control: And/or valves– Pressure control: Uses of adjustable pressure sensors– Time-dependent control

• Fundamentals of industrial electric controls: Buttons, contacts, relays• Fundamentals of compressed air supply: Production, preparation, distribution• Symbolic representation of devices, standards• Identifying and eliminating faults, including safety aspects• Cutting installation costs – from single valve to valve terminal

The participant:• can design, assemble and test basic pneumatic circuits• can maintain and troubleshoot pneumatic components and basic control systems• can identify and describe the design, feature and operation of pneumatic components• can identify and explain symbols for pneumatic components• can interpret technical specifications and data relating to pneumatic components• knows the fundamentals of compressed air generation

Basic technical understanding

3 days

559395

Pneumatics

Technology


PN132

Target groups

Contents

Outcomes

Prerequisites

Duration

Article number

This course allows you to extend your technical and methodological knowledge and to identify andeliminate faults without delay using a systematic procedure and the ability to understand the functionalrelationships of complex machinery.

Maintenance, trainers

• Functional relationships between mechanical elements, pneumatics, electronics and PLC• Design and function of pneumatic and electropneumatic components• Basic principles of sensor technology• Reviewing, completing and using machine documentation• Developing and applying troubleshooting strategies in a team• Optimising systems using fault documentation• Learning and applying safety regulations and valid standards• Process FMEA (Failure Mode and Effect Analysis) as a method of preventive maintenance• Optimisation of a production-related system with TPM (Total Productive Maintenance) components• Practical exercises on systematic troubleshooting

• The participants:• can describe the functional relationship between mechanical, pneumatic,

electronic and PLC components• masters troubleshooting techniques and strategies• is familiar with safety aspects of pneumatic systems• can effectively use PLCs to identify and locate failures in an electro pneumatic system

PN 111 Modern industrial pneumatics – Fundamentals trainingBasic PLC training

3 days

559396

Pneumatics

Troubleshooting and Maintenance of electropneumatic systemsusing PLC controls

Technology


Effective industrial problem solving techniques

PN142

Target groups

Contents

Outcomes

Prerequisites

Duration

Article number

Modern industrial plants have a high level of complexity, making it increasingly difficult for maintenance staff to detect the cause of faults with technical competence and experience alone. A methodical approach is required. This includes analysis of the environment, communication with specialist departments and systematic use of appropriate problem-solving techniques.


• Definitions, understanding and communicating problems• Troubleshooting using problem solving techniques• Causes of downtime and how to prepare a fault list• Methods/tools for analysing weak spots

(Pareto, cause-effect diagram, brainwriting, FMEA, measure list, measure plan)

The participant:• becomes familiar with the technical structure of a complex machine• understands the causes of downtime and failures• can prepare and evaluate failure lists• can solve technical problems using a structured approach

PN111 “Modern industrial pneumatics – Fundamentals” or equivalent knowledge

2 days

559417

Technology

16 Online booking: www.festo-tac.com

PN291

Target groups

Contents

Outcomes

Prerequisites

Duration

Article number

In the factories which implement TPM, autonomous maintenance is one of the back bones of the implementation. To achieve autonomous maintenance, the operator should know the basics of the related technology so that he/she can do the defined maintenance and troubleshooting of the machines or pro-duction lines. This training course has been designed for the operators so that they become technical operators in the field of pneumatics.

Operators

• Safety in pneumatics• Actuators and valves• Controls:

– Pneumatic and electrical control of the valves– Position and speed control

• Basic principles of compressed air supply: Production, preparation, distribution• Daily preventive maintenance• Identifying abnormalities in the production• Basic troubleshooting of pneumatic systems• Various breakdown analysis tools• Regulations

The participant:• can identify and tag malfunctions in the production• can perform regular preventive maintenance procedures• can fill out and analyse various breakdown charts and tools• can identify and troubleshoot basic pneumatic breakdowns• can communicate failures and breakdowns with maintenance crew

None

3 days (2 days in classroom, 1 day shop floor workshop)

567522

Autonomous Maintenance - pneumatic fundamentals for Operators

Pneumatics

Technology


Pneumatics

Safety improvements in pneumatic systems

PN351

Target groups

Contents

Outcomes

Prerequisites

Duration

Article number

Just like good functionality and economic efficiency, safety is essential to the success of any product.What is more, the European directives and standards require intelligent solutions and raise the level of professional skills required. As a result, there is a wide range of different products, information and quali-fications for safety engineering. However, most of them focus on the control level. This course familiarises participants with integrated control and pneumatic solutions for the right commissioning, troubleshooting, set-up, maintenance and simple optimisation of a system.

Operators, maintenance, engineering, designers, trainers

• The right dimensioning• Operation modes• Safe designing example

– Hazardous areas– Risk analyses– Safety measures

• 10 technical safety functions• Emergency stop• Pneumatic safety tips

The participant:• Recognises the hazards in pneumatic processes• Analyses the risk factors of simple pneumatic designs• Applies safety measures and safety circuits• Understands the principles of emergency and safety solutions• Raises the safety reliability of simple pneumatic designs


2 days

574393

Technology


Energy saving in pneumatic systems

PN361

Target groups

Contents

Outcomes

Prerequisites

Duration

Article number

The issues related to energy saving are becoming more vital each day. In the factories or even in the small workshops, the intelligent use of every energy source and the right sizing and selection of components save significant amounts of cost, time, waste etc. Compressed air is a very important energy source for industrial production. The possibilities to save costs from production to consumption of compressed air are enormous. But everything begins with the attention of the people who work with it. The training course focuses on peoples’ attention of costs and improving the areas of compressed air production, distribution, preparation and the pneumatic circuits. This training especially matches the customers’ training needs who had already received a Festo Energy Saving Service.

Operators, maintenance, engineering, designers, trainers

• The cost of compressed air with measurements• The cost of leaks• The compressed air consumption of various circuits• The cost of over and under sizing of components• The right sizing for efficiency• Energy efficient circuits• Correcting the failures that caused efficiency wastes

The participant:• Understands the relation between the consumption and the cost of energy sources • Applies efficiency measures in the preparation, distribution and consumption of compressed air• Corrects the failures that cause efficiency waste• Applies efficiency measures in pneumatic circuits• Selects efficient components for various applications• Measures the air consumption of various pneumatic applications• Improves the lifetime of various pneumatic components


2 days

574395

Pneumatics

Technology


There is a trend among operators of water treatment plants towards the increased use of pneumatic drives instead of electric drives. The advantages in terms of cost, system reliability, reduced complexity, ease of use and maintenance clearly speak for this technology.

This three-day course gives the participants an insight into process automation in water-related plants, making an important contribution to the process reliability of these plants.

Anyone employed in the area of industrial process or water treatment facilities

• Production and distribution of compressed air• Spotting and eliminating waste• Reading of circuit diagrams and interpretation of control sequences• Design and function of directional control, pressure, shutoff and flow control vales• Function of linear and rotary drives• Correct adjustment of process drives and their sensors• Safe and precise manual intervention• Safe decommissioning in case of total loss of auxiliary energy• Practical exercises, designing and testing of circuits and troubleshooting

The participant:• can confidently identify relationships within the process• can avoid damage and failure in the case of user-specific errors through safe and precise intervention

Basic technical understanding

2 days

573629

PN331

Target groups

Contents

Outcomes

Prerequisites

Duration

Article number

Pneumatic Fundamentals for Water Management

Pneumatics

Organization & People

An excellent company

We know what makes anexcellent company:a focus on customer satisfaction,corporate and quality strategy, employee satisfaction, efficient processes, responsible and tar-get-oriented employee mana-gement, job-oriented qualifica-tion, positive business results and a positive impact on society.

We will prepare your entireorganisation for the new tasksyou will face.

Our consultants will advise youremployees on the developmentof an independent and auto-nomous working style. The aimof their work is to enable compa-nies to efficiently structure work, organisation and qualification processes.

Organisation


Taking the form of a strategy game, this training gives you a holistic view of material and information flows within a company and sensitises you to different types of waste in processes. You learn to analyse the causes of delivery problems and low productivity and to develop and implement ideas for meeting cus-tomer needs and improving processes. The main goal is to instil lean thinking in your company. The strategy game provides practical experience for all employees involved in lean production projects.

Operators, maintenance, design/engineering, trainers, managers

• Inventory minimisation as an important basis for increased productivity• The principle of pull production control• Advantages compared to conventional production control methods• Types and function of different pull production control methods• Application of methods• Kanban – the classic pull principle• SMED – Optimisation of setup processes with Single Minute Exchange of Die• CIP as part of the business game• Introduction to Value Stream Mapping (VSM)

The participant:• can analyse the causes of delivery problems and low productivity• can develop and implement ideas for meeting customer requirements and process improvements

2 days

561209

LP111

Target groups

Contents

Outcomes

Duration

Article number

Continuous Improvement- Introduction to Lean Production and VSM

Lean Production

Organisation


Lean Production

Optimum batch size is often determined based on minimum inventory and job changeover costs. But this approach has one critical flaw: It views changeover costs as unchangeable. This often results in overpro-duction, excessive inventories, adjusted transport routes and scrapping, high cycle times and delivery problems. This course enables you to radically reduce machine and plant downtime caused by setup.

Operators, maintenance, design/engineering, trainers, management

• Relationship between batch size and setup time• Reducing setup times as the only way to reduce batch sizes and inventories in production• The SMED (Single Minute Exchange of Die) method and its phases• The OTED (One Touch Exchange of Die) method• Constructive solutions for fast setup processes• Work organisation options for fast setup processes• Influence on production control• Practical implementation of methods in a model plant

The participant:• is able to recognise waste• knows the importance of short setup times for fast and economical order processing,

flexible production and low inventories• can apply and teach the SMED method

1 day

559425

SMED – Reducing set-up time with SMED

LP131

Target groups

Contents

Outcomes

Duration

Article number

Organisation


Lean Production

Although efficient administrative processes are essential for the productive operation of any company, complex administrative tasks often exhibit a high level of waste, such as unnecessarily long meetings, duplication of work, fuzzy responsibilities and an unfiltered flood of information. This waste is counter-productive to the aim of administration − contributing to value creation in the company.

The overall performance of a company can only be improved if processes in the administrative units are analysed, employees sensitised to change and processes continuously optimised. The flow of information must strictly be focussed on essentials and all unnecessary actions must be eliminated.

The Lean Administration Game gives participants the opportunity to experience the astonishing improve-ments that can be made in administrative processes – by playing a 45 minute game several times and improving it each time. As a result the participants also learn to identify and eliminate the different types of waste.

Design/engineering, trainers, management

• Value creation and waste in administration• Principles for designing lean administrative processes• Identifying deficiencies in existing processes with the help of a detailed process analysis• Professionally designing administrative processes • A clean and tidy working place as basis for efficient working• Optimisation approaches for administrative processes and their practical implementation in a

concrete example• Organisational requirements for successful process optimisation• Immediate implementation and revision of the acquired knowledge

The participant:• can describe the principles of Lean Administration • has experienced the dramatic improvements that Lean Administration can bring• can describe the eight types of waste• has gained experience in identifying and eliminating forms of waste

2 days

55942Cc

Lean Administration Game

LP511

Target groups

Contents

Outcomes

Duration

Article number

People


CO111

Target groups

Contents

Outcomes

Prerequisites

Duration

Article number

This course presents a compelling new approach to customer communication. Proven tools guide the ser-vice professional and develop the core skills needed for effective communication. The training course is part of the four-part Service Ambassador program providing you, as a service engineer, with the skills to build relationships, enhance loyalty, discover opportunities and differentiate their business from the competition.


• Identifying the ‘environmental factors’• The core competencies of a professional and successful service engineer• Comparing ‘modern consultative’ and ‘adversarial’ communication• The communication cycle• Key skills for ‘setting the stage’• Strategic questioning skills• Listening skills and the barriers to effective listening• Identifying customer needs and expectations• ‘Delivering the result’ – customer focus• Achieving customer satisfaction and future commitment

The participant:• has developed an increased awareness of customer perceptions• is able to apply the customer ‘communication cycle’• has enhanced customer-focused communication skills• has developed skills to help identify customer needs and expectations• can identify ways to enhance the customer’s opinion of themselves and their company• can develop a personal action plan to help implement benefits gained in daily working

Practical understanding of the machines for which customer support is required as well as experience in visiting customers in an after-sales technical support role

2 days

560278

Communication skills for service technicians

Communication

Training and Consulting - festo-didactic.com

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