Filtering by: Production

Dec
2
to Dec 3

PROD-03 Improvement Management in Production

Competitive advantages or even survival of companies might be achieved only through innovations and improvement of what exists today. Improvement management is not a firm concept but offers different tools to be applied based on specific production plant conditions. Thanks to them higher and higher standards may be set without having negative impact on operators’ workload or huge investments. 

Your needs are:

  • Understand improvement technics in production

  • Set a robust process for Improvement Management in the Mass production phase

  • Apply the right continuous improvement tools

  • Measure the improvement through relevant indicators

  • Involve people on all organizational level to continuous improvement process

Target group:

  • Continuous improvement specialists

  • Technology

  • Quality

  • Logistics

  • Purchasing

  • Production

Training content:

  • Continuous improvement management and IATF 16 949

  • Process Improvement and Standardization

  • Overview of continuous improvement methods - Quality Circles, Six Sigma, Idea Management, …

  • Process continuous improvement versus Process Reengineering

  • People involvement and motivation

  • Process visualization

  • Lean meetings

  • Improvement Management Indicators definition and follow-up

  • Case Study

Duration: 2 days.

Dates

in-house session only

Price:
In-house module: 890 EUR/day (member), 975 EUR/day (non-member) + travel cost for a group up to 10 participants.
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Nov
18
9:00 AM09:00

PROD-04 SMED in an Efficient Way

Production teams prefer bigger batches, the logistics department requires low inventories, customers expect high flexibility, … How to fulfill all requirements? Even if there’s no “best practice” applicable for all companies, SMED method is one of key tools to eliminate down time and speed up the production changes while minimizing impacts on the organization. The training module “SMED in an efficient way”  offers theoretical background and many practical examples of SMED implementation to get the maximum result. 

Your needs are:

  • Decrease the machine stop time and increase OEE

  • Decrease the lead time for the customer

  • Increase flexibility and reduce stock levels

  • Satisfy “on time” delivery

  • Respect “takt-time”

  • Decrease the overall production/warehousing cost

Target group:

  • Continuous improvement specialist

  • Technology

  • Quality

  • Maintenance

  • Production

  • Process Specialists

Training content:

  • SMED as a part of Lean approach

  • Traditional machine set-up

  • 5 steps of SMED implementation

  • SMED and production planning

  • Organizational requirements

  • Connection between SMED and TPM

  • Measurement of SMED method efficiency

  • SMED continuous improvement process

  • SMED implementation examples

  • Case Study

Duration: 2 days

Dates

In-house modules only

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

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Nov
12
to Nov 13

PROD-02 Lean Production – understand and experience

The best project phase for product/process improvement and lean production implementation is the pre-production phase. This does not mean that production optimization does not have its place in the mass production phase. The opposite is true. The supplier is pushed to reduce the cost to remain competitive on the market and interesting for the customer.

There are many training modules on the market presenting the lean production “best practice”, seven types of waste, etc. But their automatic implementation is not sufficient. At ABP Management we are convinced that the most important is to change the people’s mindset.

Your needs are:

  • Understand the meaning of Lean production

  • Know and be able to use the basic Lean tools

  • implement the process of continuous improvement in the company

  • Identify and focus on critical processes

  • Involve all employees to the optimization

  • Get some improvement ideas from practice

  • Evaluate and measure the improvement actions

Target group:

  • Continuous improvement specialists

  • Technology

  • Quality

  • Logistics

  • Purchasing

  • Production

Training content:

  • Production systems implementation

  • “Lean Thinking”

  • Synchronizácia procesov (Pull systém, mapovanie toku hodnôt)

  • Failures elimination (poka-yoke, self-control)

  • Production means maintenance(TPM, maintenance strategz)

  • Productivitz improvement (e.g. through SMED, 5S, ...)

  • People qualification, job rotation

  • Process standardization

  • Requirements and Key Success Factors for Lean production implementation

  • Case Study

Duration: 2 days.

Dates: 

in-house modules only

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

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Nov
12
to Nov 13

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: 

in 2019 in-house modules only, first open session in 2020

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.

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Oct
19
9:00 AM09:00

PROD-06 Ergonomics in Production

Ergonomics is a cross-disciplinary science of fitting work to the human body and it’s importance in the automotive industry is dramatically increasing in recent years. For some managers ergonomics is not a priority as it is considered to be an additional cost. In fact, it’s the opposite. Ergonomic solutions may increase the operator’s efficiency, decrease the waste time and above all improve the working conditions, health and motivation of employees.

Training session animated by qn ergonomics expert having 16 years experience with ergonomics in the automotive industry (full time job).

The training session may be organized in plant only (need to go to production).

Your needs are:

  • Understand and use ergonomic methods and techniques for risk
    assessment and identification of workplace risk factors

  • Design work places with good ergonomics

  • Improve the ergonomics on existing workstations

  • Avoid operators’ pain or injuries in the production/office

  • Get the certification ISO 45 001

  • Take the ergonomics into consideration in line balancing

Target group:

  • Ergonomics specialists

  • Process designers

  • Engineering

  • Logistics

  • Production

  • Functional Managers

Training content:

  • Principles of ergonomics and its application

  • Physical aspects in the design of work, workplaces and equipment

  • Ergonomics and workplaces design

  • Workstations ergonomics analysis

  • Workstations ergonomics classification

  • ISO and ergonomics

  • Time systems (MTM/MOST/REFA) and ergonomics

  • Ergonomics continuous improvement

  • Ergonomics analysis of selected work station in production by trainer and by participants (video)

Duration:  2 days (0,5 days theoretical presentation, 1,5 day workshops).

Dates:

In-house modules only (dates to be agreed individually)

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

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Sep
21
9:00 AM09:00

PROD-05 5S in Production & Administration

Standardization, visual management and continuous improvement are the main contributions of a simple but powerful tool 5S. Using this method the operator will have only necessary objects close to his or her workplace, production and administration will be clean, visual management at high level and set standards may continuously improve. In addition to the understanding of 5S methodology the participants will be able to implement 5S audit system in the production and in offices.

Your needs are:

  • Understand the 5S principles

  • Increase the operators, maintenance or administration efficiency

  • Avoid issues you experience due to inefficient organization of workplaces

  • Improve the visual management in the company

  • Establish the system of 5S audits

  • Reach the expected objectives in a short period of time

  • Implement acquired knowledge in practice

Target group:

  • Continuous improvement specialist

  • Technology

  • Quality

  • Administration

  • Production

  • Functional Managers

Training content:

  • 5S history and its place in company processes

  • 5S versus Lean production and Standardization

  • Management responsibility

  • 5 steps of the method

    • Sort

    • Straighten

    • Shine

    • Standardize

    • Sustain

  • Process of 5S implementation in plant

  • Examples from practice (before and after)

Duration: 1 day.

Dates:

In-house modules only. 

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:250 EUR/day (member), 280 EUR/day (non-member).
In case of 2 or more participants from the same plant we offer 10% discount on the second and all other participants. Refreshment and lunch are included in the training price.

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Sep
17
to Sep 18

PROD-07 Value Stream Mapping (VSM) & its Efficient Use

Even if the material stays in the plant for weeks, the processes adding value on the product may last several minutes only. Value Stream Mapping method helps you identify waste and define potentials for improvements through teamwork during planned workshops. If not used only once, this tool may become one of the strategic tool for continuous process improvement with significant financial and organizational benefits.

Your needs are:

  • Decrease the “throughput time” in the organization

  • Decrease the inventories and WIP

  • Unveil opportunities for optimization

  • Create well-educated VSM team

  • Use VSM in a proper way at the right processes at the right time

  • Use VSM as a strategic improvement tool

Target group:

  • Continuous improvement specialist

  • Process Specialists

  • Quality

  • Logistics

  • Production

Training content:

  • VSM as a strategic continuous improvement tool

  • VSM team definition

  • Understanding: Added Value Creation

  • Material and Information flows identification

  • Process of current value stream mapping

  • Pictograms and document lay-out

  • Waste identification

  • Process of current state improvement (PDCA)

  • Elaboration of future state map

  • Measurement of VSM contribution

  • Definition of key processes to analyze

  • VSM workshops planning & organizing

  • Case Study

Duration: 2 days.

Dates

In-house module only. 

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 we 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)  

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