Back to All Events

PROD-01 Process Engineer in the Automotive Industry


Complex training module that will prepare the trainees on work of Process Engineer.

MODULE I:

Automotive Project Management for Process Engineers - 2 days

  • WBS of the Organization and standard tasks of Process Engineer on an automotive project

  • Customer Specific Requirements (CSR) – what does it mean and what’s the impact on production process?

  • Project team and communication over the project, cooperation between Process Engineer and Project Team Members and Production

  • Risk analysis for Process Engineer

  • Project Master plan (scheduling of Process Engineer main tasks)

  • Standard project phases and milestones in the automotive industry

  • Calculation of production cost in project RFQ phase based on customer requirements

  • Investment planning based on the calculation of production cost

  • Trial and pre-serial production planning

  • Process Engineer check-list while overtaking the project to serial production phase

MODULE II:

Quality for Process Engineers - 2 days

  • Quality? Customer satisfaction while having the minimal cost for the organization.

  • Produced vs. controlled quality

  • Tolerance studies for Process Engineers

  • Product feasibility study from process point of view

  • Process Engineer role in DFMEA/PFMEA preparation process

  • SPC for Process Engineers

  • MSA for Process Engineers

  • Control plan for Process Engineers

  • Rework – rules for rework operation, creation of instructions

  • Internal production release – main rules

  • Customer production release (PPAP), examples of OEMs (Daimler, VW, PSA, Renault-Nissan,…)

  • Main KPIs for Process Engineer

  • Process audit acc. to VDA 6.3 requirements

  • Management of non-conform/suspicious parts from production

MODULE III:

Production Preparation - 1,75 day

  • Definition of prototype production process

  • Definition of production operation duration based on automotive standards (MTM, REFA,…)

  • Balancing of workstations

  • Concept and verification of serial production process

  • Process Flow Chart

  • Creation of lean lay-outs

  • Ergonomics for Process Engineers

  • Working Instructions

  • Process of operators training

  • Preparation of RFQs for purchased of project specific production means (tools, line, …)

  • Availability of Spare parts for (critical) machines and tools

  • Back-up plans

Logistics for Process Engineers  -  0,25 day

  • Definition and calculation of packaging quantity for internal, customer and sub-supplier flow

  • Customer forecasts and orders – impact on process

  • Pull system in production planning

  • Production planning impact on process

MODULE IV:

Lean Manufacturing  - 0,75 day

  • Types of waste and their elimination

  • 5S in production

  • Value Stream Mapping (VSM)

  • Total Productive Maintenance (TPM)

  • Continuous improvement (CI)

Capacity planning and verification - 0,75 day

  • OEM specific requirements on capacity (examples of VW, PSA, Renault, Daimler, …)

  • Process calculations and capacity assurance definition

  • Capacity verification before project specific production means purchase

  • Project ramp-up curve

  • Internal and customer capacity audit (VW, PSA, Renault, ...)

Problem solving tools and methods - 0,25 day

  • Daily production meetings for Process Engineers

  • Overview of problem solving tools and methods

  • Process Lessons Learned management

Final test - 0,25 day

Duration: 8 days (4 modules, each of them 2 days)

Dates: 

Dates soon.

Price:
In-house module: 890 EUR/day (member), 975 EUR/day (non-member) + travel cost for a group up to 10 participants.

Module in Bratislava: 220 EUR/day (member), 250 EUR/day (non-member). In case of 2 or more participants from the same   plant offer 10% discount on the second and all other participants. Refreshment and lunch are included in the training price.

Training Registration Form (PDF)
Training Registration Form (online)  

Later Event: November 18
PROD-04 SMED in an Efficient Way