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, STELLANTIS, 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, STELLANTIS, 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, STELLANTIS, 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)

In-house module in customer location only

In-House modules only