Course Catalog TaC International 2015 - EN

Training and Consulting
Course catalogue 2015
www.festo-tac.com
We are training.
We are consulting.
We are industry.
Dear reader,
Are you satisfied with your current productivity?

This question is central to our thoughts and actions.
Festo is a global engineering and manufacturing company that maintains its

own global training and consulting teams for customers all around the world.
Operating in the same economic sector and environment as our customers, we
have a level of understanding and insight into your challenges that allows us to
meet your needs by providing targeted training and consulting solutions. And are
able to deliver our training services around the world in local languages to the
high standard that both you and we require.
Our portfolio combines training courses with tailor-made Knowledge Checks,

e-learning, courseware and hands-on learning systems. This unique integration
increases the effectiveness of learning, optimises learning outcomes, and maxim-
ises learning transfer. We can conduct a comprehensive analysis of your staff’s
training needs to effectively align the contents and aims of in-house courses with
your business objectives. On completion of the analysis, you are presented with
a detailed report on your employees’ current knowledge levels and a competence
development plan that addresses your key business objectives.
You can take advantage of our latest offering to fill potential competence gaps:
We now provide tailor-made competence programs in the fields of maintenance,
mechatronics and supply chain management. They consist of a range of training
courses and project work specifically geared to the employee‘s role and industry
needs – an optimal basis for their everyday work. Employers see immediate
improvements in staff performance, confirming the programs as a sound invest-
ment with an excellent ROI.
This catalogue provides details of our competence programs, courses and serious
business games. Please do not hesitate to contact us directly to discuss your
needs and ideas.
Dr. Daniel Boese Dr. Theodor Niehaus

Managing Director Managing Director
Festo Didactic GmbH & Co. KG Festo Didactic GmbH & Co. KG
3
Content
8 Intro
17 Training courses
17 Technology
18 PN111 Modern industrial pneumatics

PN291 Modern industrial pneumatics for operators
19 PN351 Systematic safety improvement in pneumatic systems
HY511 Modern industrial hydraulics
20 HY181 Mastering mobile hydraulics
HY132 Proportional hydraulics
21 AUT111 GRAFCET – The new process description
PLC211 Simatic S7 – Fundamentals
22 PLC271 CODESYS version 2 – A hardware-independent introduction to CODESYS
PLC281 CODESYS version 2 – A hardware-independent introduction to PLC programming
23 PLC371 CODESYS version 3 – A hardware-independent introduction to CODESYS
PLC381 CODESYS version 3 – A hardware-independent introduction to PLC programming
New 24 PLC441 Maintenance and troubleshooting of PLC systems
New PLC451 Technical communications
New 25 PLC471 Simatic S7 analogue and PID control
New PLC481 S7 workshop
26 EL131 Electricity for non-electrical industrial staff 1
EL141 Electricity for non-electrical industrial staff 2
27 PA121 Valves in process automation
PA221 Principles of industrial measurement and instrumentation
28 PA201 Practical mastery of closed-loop control
PA291 Fundamentals of closed-loop control technology
29 PA231 Water purification processes in modern water works
PA241 Safe and efficient water transport and distribution
30 PA251 Key processes of wastewater transport
PA261 Modern wastewater treatment processes
31 PA271 Monitoring, controlling and optimising operations in water and wastewater treatment plants
PA281 Energy optimisation in water and wastewater treatment plants
New 32 PA321 Fundamentals of water technology
New PA331 Operating membrane filtration processes
New 33 PA341 Mastering rapid sand filtration
PN331 Pneumatics for water management
34 ROB111 Robotics - Fundamentals
ROB121 Motion control solution CMCA
35 ROB131 Maintenance of Tripod EXPT
ED811 Mastering the basics of electrical drives
36 PN381 Vacuum in handling technology
PN121 Maintenance and troubleshooting of electropneumatic systems using PLC controls
4
37 PN142 Effective industrial problem-solving techniques
PN163 Valve terminal CPX - Commissioning, modification and fault elimination
38 HY521 Maintenance and troubleshooting in hydraulic systems
SN171 Mastering machinery safety 1
39 SN182 Mastering machinery safety 2
PA141 Explosion safety
40 PN361 Energy saving in pneumatic systems
New PT131 Maintenance strategies for maintenance operators
New 41 PT141 Conventional metal processing
New PT151 Metal processing with CNC machines
New 42 PT161 Material transport with crane and forklift
New PT171 Assembly and installation
New 43 PT181 Commissioning of mechatronic systems
45 Organisation
46 LP111 SYNCHRO – Introduction to Lean Production and VSM

LP131 SMED – Reducing setup time with SMED
47 LP511 Lean Administration Game
LP211 Production control methods
48 LP161 Analysing and designing value streams
LP261 Systematically designing value-added processes
New 49 LP271 Work organisation
New LP281 Fundamentals of Total Productive Maintenance
New 50 LP291 TOC – Theory of constraint in practical use
New LP301 Heijunka – levelling and smoothing
New 51 LP311 Pull – Kanban and CONWIP
New TCM151 Energy manager: Role, competences and responsibilities
52 IM181 Basics of effective maintenance
New BM111 Maintenance excellence
New 53 BM121 Asset management
New BM131 Maintenance strategies for maintenance managers
New 54 BM141 Safety, energy and environmental management
New BM151 Energy market legislative contest
New 55 BM161 Energy consumption: Diagnosis and analysis
New BM171 Energy Management System: Design and implementation
New 56 BM181 Business administration compact
New SCM201 Introduction to supply chain management
New 57 SCM212 Supply chain processes
New SCM221 Warehouse role inside the supply chain
New 58 SCM231 Managing warehouse levels and purchasing policies
New SCM241 Warehouse planning
New 59 SCM251 Improving warehouse processes and activities
New SCM261 Transportation management
New 60 SCM271 Warehouse personnel management
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63 People
64 LS111 Leadership training module 1

LS242 Leadership training module 2
65 LS253 Leadership training module 3
New LS261 Leading the maintenance department
66 *) Competenceweb® concept – uncontested competences and execution
*) High performance coaching for executives
67 *) Managing change
*) Managing by travelling around – remote management
68 *) Optimal performance at work program
*) Managing Germans in a German organisation as a non-German
69 *) General cultural training
*) Doing business in all parts of the world
70 *) Multicultural team development
*) Doing successful business as a woman in Asian and Oriental cultures
71 *) Successful purchasing strategy for China
*) Dealing with indirect communication in China
72 *) Intellectual property – knowledge transfer
*) Fit for India
73 *) Working with North Americans
*) Successful communication with Latin America
74 *) Intercultural training for the Arabic market
*) Working with managers in Eastern Europe
75 *) Best practices in international human resources development: Investors in people
*) Developing an international human resources strategy
76 *) The human resources department as a brand
*) Positioning human resources as a business partner
77 *) Employment law
*) Intercultural assessment center
78 *) The balanced scorecard for international HR
*) The role of human resources in mergers, acquisitions and integrations
79 *) Human resources development forum in China
*) Keeping your Chinese co-worker - employee retention
80 *) Downsizing – the benefit of outplacement for organisations
CO231 Technical service: customer-oriented
81 *) Blue Ocean – ideas of uncontested market space
*) Global key account management
82 *) International marketing
TTT111 Train-the-Trainer – Mastering key trainer skills
*) We offer this course in co-operation with our partner Change International Ltd.
6
85 Competence programs
86 Competence programs maintenance

New 88 Maintenance specialist
New 92 Maintenance and asset manager
New 96 Energy efficiency for operators
New 98 Energy efficiency for managers
102 Competence programs mechatronics

New 104 Assembly specialist
New 108 Fluidics specialist
New 113 Maintenance specialist
New 117 PLC and robotics specialist
New 121 Process improvement specialist
126 Competence programs supply chain management

New 128 Supply chain management fundamentals
New 130 Production supervisor
New 135 Production control specialist
New 139 Process improvement specialist
New 144 Tool setter
New 147 Warehouse manager
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We know you have high goals.
We want you to achieve more.
We show you new ways forward.
8
Training and Consulting
The industrial evolution is in full swing: As a driver of industrial automation, we are
processes are becoming more complex, time proud to present our contribution on the
is becoming more precious and costs and following pages. It demonstrates that, for
cost structures are becoming more important. decades, we have, together with you, our
With our training services, we show you in customer, taken the right direction:
black and white how Festo Didactic is effec- that of the greatest productivity.
tively keeping up with this evolution.
9
We drive automation for your success.
We are your partner to inspire you.
We shape the future together.
What makes us engineers of productivity?
We have a very big goal: your productivity. Our motivation is to achieve this goal together with you.
We take advantage of everything possible to make you more successful: our knowledge, our capabilities,
our performance, our products and our services. We achieve this goal with four outstanding qualities for
which we stand: security, efficiency, simplicity and competency. And this makes us what we are. Experts
who don’t give up. Professionals who make the working day easier for you. Trainers and consultants who
always manage to get a bit more out of your technologies, your organization and your people.
In a word, this makes us engineers of productivity.
Security Simplicity Facts & figures:

You are on the safe side with Festo. Those who focus on central tasks are pro-
More than
Whether it is about new machinery direc- ductive. We make it as easy as possible for
tives and their implementation or quick,
professional problem-solving support,
you in your process chain, from selection,
configuration and operation to documen-
300,000 industrial
customers
at any time and in any situation, you can

always rely on our experienced, global
tation, commissioning, service and repair.
Because we know your requirements, you 3,000 public training
courses/year
company network. This increases not only can calmly concentrate on your core busi-
your satisfaction, but your productivity as
well.
ness. This saves you time and money.
39 training languages
Efficiency
Competency
We have experts working at Festo. Experts 16,000 experts
We give our all for you – in customer sup-

port as well as for your technical solution.
who know your challenges. Experts who
smooth the way to greater productivity for 176
On-site-in countries
You have faith in the experienced trainers you with dedication, technical and eco-
250
and the reasoned concepts which ensure nomical know-how and experience – and branch offices
that your systems consume less material who are always nearby! These experts and
and energy. Not only are unplanned down- their knowledge are our potential for suc-
times reduced, the operating costs of the
machines and systems also fall. Above all,
cess – for you! You will notice this from
support and development to the last day
60 national companies
this increases one thing: your productivity. of our collaboration.
10
Worldwide availability? No problem.
Always available and absolutely reliable: we offer innovative products, solutions and services around the
world. With over 250 branch offices in 176 countries, we ensure that we are always in close proximity to our
customers. That is why experts from Festo can work in close cooperation.
11
We practice what we teach
Training in technology and

productivity – from a global
engineering and manufacturing
company
Manufacturing know-how Globally qualified trainers Methods and formats
Festo is both a global engineer- Our networks of qualified train- Our trainers draw on the entire
ing and manufacturing com- ers in the areas of technology, range of methods and formats –
pany and training and consulting organisation and people share from an interactive presentation
organisation with experienced resources and best practices for a large group to the coaching
instructors and consultants. and contribute to continuous of individuals in production
This gives us deeper insights improvement and development teams.
into key industry issues than of new products to address cus-
other training providers. tomer needs.
We practice what we teach.
And we can use this experience

to help you optimise the two
sides of the productivity equa-
tion – people and technology.
12
Improving the people part of productivity
Our approach is competency-

based – getting people fit for
productivity
What we train Technology How we train

– Introduction of a new
Festo offers a wide range of technology Our training is competency-
training services covering the – Development of all skills based, which means:
three skills areas technology, needed to serve a production – Benefits for all stakeholders
organisation and people and cell are clear
the three factors in productivity: Organisation – “Before” and “after”
quality, time and cost. – Establishment or enhance- snapshots of skills make the
ment of continuous improve- ROI transparent
Training is based on customer ment processes – It complements the
needs, for example: – Introduction of Kanban competency matrix approach
People to improving individual
– Improvement in performance
communication – It fosters a will to achieve
– Implementation of in both trainer and trainees
problem-solving techniques – It provides orientation and
Quality a sense of achievement in
– Increase of individuals’ technology training
sensitivity to quality – Hands-on exercises with
– Reduction of rework and industrial components
reject rate reinforce the transfer of
Time new skills
– Optimisation of set-up time
– Minimisation of unplanned
downtime
Costs
– Avoiding waste
– Reduction of capital tied up
in work-in-progress
13
Getting exactly the right training
Our training formats and

services allow us to respond
flexibly to your needs
No matter which training format Standard training If you are not sure which skills
you choose – whether public or profile a team needs, our Train-
in-house, a course, a workshop, In public courses, a predefined ing Needs Analysis (TNA) will
a best-practice event or cor- set of competencies are trans- identify requirements and audit
porate strategy games – the ferred. Approximately 42,000 current skills in a report.
focus is always on first-hand course participants attend over
experience. 3,000 of our public courses To optimise transfer, a post
worldwide every year. course review can be run a few
In both public and customised Our trainers deliver modular weeks after training – this audits
training, the outcomes are trans- quality-assured training in the upgraded skills set against
parent to all stakeholders, 39 languages. the agreed outcomes.
allowing them to track progress
towards achieving the required Customised training Competence development
competencies. Rapid transfer to projects
daily practice is a key quality There are three levels to
criterion – we help you to meas- customised training: If your customised training
ure and optimise this. exceeds the scope of a single
Customised courses designed course, qualification programs
And we match the delivery of our to achieve agreed outcomes are can be established. These com-
training services exactly to your generally in-house to achieve prise several courses with inter-
needs, instructor-led full day or greater focus on your business vals between to transfer to the
evening courses, virtual instruc- needs, increased flexibility and workplace and integration of in-
tor led or web-based – it is your reduced cost, often with the house projects with goals such
decision. added advantage that partici- as optimising setup time.
pants do not have to travel.
14
Customer-specific projects and consulting
Improving specific Key Per-

formance Indicators (KPIs) such
as downtime or setup time
Optimising production Principles Benefits and results
Through value stream mapping Application of tried and tested – Higher qualification of all
we jointly track the progress of processes employees
a product through production – Elimination of errors and – Increase in machine efficiency
with the aim of enhancing malfunctions of up to 40 %
efficiency and avoiding waste. – Identification and resolution – Reduction in errors and rejects
Experienced consultants employ of the root causes of problems of up to 90 %
state-of-the-art methods and – Optimisation of all process – Reduction of unplanned
tools that have been tried and factors downtime of up to 90 %
tested at customer sites and in – Close communication with – Reduced accident rate
the Festo Group’s award-win- machine operators
ning production facilities. Format: workshop and in-house
Cleanliness, order, discipline project.
and standardisation as the
basis for quality.
15
16
Technology
Profound technical expertise
For over 40 years, we have been providing support

for all development 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.
We set the highest standards for our training.

You will notice the difference between our courses
and competitors’: We provide fresh answers to long-
standing challenges, helping you to advance your
company’s plans.
Our trainers know the areas of work of your partici-

pants. This knowledge extends beyond purely tech-
nical requirements.
17
Pneumatics Pneumatics
Modern industrial pneumatics Modern industrial pneumatics for operators
PN111 PN291
Contents Contents
This 3-day course covers the following topics: This 3-day course covers the following topics:
• Drives: Cylinders for different drive purposes • Safety in pneumatics
• Valves: Various valve types • Actuators and valves
(pneumatically/electrically controlled, designs, • Controls:
different mid positions etc) – pneumatic and electrical control of the valves
• Controls: Pneumatic and electric control of valves – position and speed control
– Position control: Limit switches and sensors • Basic principles of compressed air supply:
– Speed control: Uses of throttle valves Production, preparation, distribution
– Logic control: AND/OR valves • Daily preventive maintenance
– Pressure control: Uses of adjustable pressure sensors • Identifying abnormalities in production
– Time-dependent control • Basic troubleshooting of pneumatic systems
• Fundamentals of industrial electric controls: • Various breakdown analysis tools
Buttons, contacts, relays • Regulations
• Fundamentals of compressed air supply:
Production, preparation, distribution Outcomes
• Symbolic representation of devices, standards The participant:
• Identifying and eliminating faults, including safety aspects • can identify and tag malfunctions in production
• Cutting installation costs – from single valve to valve terminal • can perform regular preventive maintenance procedures
• can fill out and analyse various breakdown charts and tools
Outcomes • can identify and troubleshoot basic pneumatic breakdowns
The participant: • can communicate failures and breakdowns to the
• can design, assemble and test basic pneumatic circuits maintenance crew
• can maintain and troubleshoot pneumatic components and basic
control systems Article number
• can identify and describe the design, features and operation of 567522
pneumatic components
• can identify and explain symbols for pneumatic components
• can interpret technical specifications and data relating to
pneumatic components
• understands the fundamentals of compressed air generation
Article number
559395
18 More information: www.festo-tac.com

Pneumatics Hydraulics
Systematic safety improvement in Modern industrial hydraulics

pneumatic systems
PN351 HY511
Contents Contents
• Correct dimensioning • Equipment and circuit diagram symbols, reading and interpreting
• Operation modes basic hydraulic circuit diagrams
• Safe designing example • Physical principles
– Hazardous areas • Structure and mode of operation of basic components
– Risk analyses • Measuring volumetric flow and pressure
– Safety measures • Technology and characteristic data of valves and drive elements
• 10 technical safety functions • Intensive training for industrial practice: setting up systems in
• Emergency stop accordance with circuit diagrams, commissioning
• Pneumatic safety tips
Outcomes
Outcomes The participant:
The participant: • can design, assemble and test basic hydraulic circuits
• can recognise the hazards in pneumatic processes • is able to maintain and troubleshoot basic hydraulic control
• is able to analyse the risk factors of simple pneumatic designs systems
• can apply safety measures and safety circuits • can identify and describe the construction, designs features and
• understands the principles of emergency and safety solutions operation of hydraulic components
• can raise the safety of simple pneumatic designs • can interpret technical specifications and data relating to hydraulic
components and systems
Article number • can interpret safety measures
574393 • is familiar with graphical symbols for hydraulic components
• can perform simple calculations of pressure, flow and force
Article number
559448
More information: www.festo-tac.com 19

Hydraulics Hydraulics
Mastering mobile hydraulics Proportional hydraulics
HY181 HY132
Contents Contents
• Hydrostatic transmission and related components • Structure, function and characteristic data of proportional, way,
• Steering unit pressure and flow control valves
• Working hydraulics • Generation of set points
• Load holding • Adapting amplifier electronics to required conditions
• Load sensing in constant and variable displacement pumps • Development and interpretation of proportional hydraulics circuit
• Pressure and flow control diagrams
• Fundamentals of proportional control • Intensive practical training through setup of circuits according to
• Commissioning and maintaining mobile systems circuit diagrams and setting parameters for optimal commissioning
• Procedures for maintenance, troubleshooting and commissioning
Outcomes • Open- and closed-loop control
The participant: • Servo valve technology and control
• can identify the components and explain their functions in a
given mobile hydraulic circuit Outcomes
• can build and test hydrostatic transmissions, working hydraulics The participant:
and steering circuits • can explain the structure and mode of operation of proportional,
• can explain load sensing functions and other efficiency components way, pressure and flow control valves
• can make adjustments to the control parameters of mobile • is able to interpret the characteristic data of proportional valves
hydraulics • can choose the right proportional or servo solution for the
• can measure the required parameters in a mobile hydraulic circuit application
• can systematically troubleshoot and explain maintenance • is able to develop, read and interpret proportional hydraulics circuit
procedures diagrams
• can explain the safety measures in mobile equipments • can explain the principles of servo valve technology and control
• can explain the difference between open- and closed-loop controls
Article number • is able to identify and solve the most common faults in proportional
573359 and servo hydraulics systems
Article number
559451

PLC PLC
GRAFCET – Simatic S7 –
The new process description Fundamentals
AUT111 PLC211
Contents Contents
• Explanation of the key elements of the standard • Basic structure of the Simatic S7 controller
• What can GRAFCET do that Function Chart cannot? • Roles of the input and output modules
• Modes of operation • The 3 programming languages: FUC, LD and IL
• Hierarchies • The basic instruction set of Simatic S7
• Macro- and microstructures • GRAFCET – Designing an application
• Decentralised intelligence and sequences • Introduction to networking
• Creating example GRAFCETs • Archiving and restoring PLC programs
Outcomes Outcomes
The participant: The participant:
• knows the advantages, benefits and application fields of GRAFCET • can configure and commission a Simatic S7 controller
• knows the characteristics and structure of GRAFCET plans • can create, read out and change hardware configurations
• can read and understand a GRAFCET plan • can create and commission PLC programs with logic operations
• can visualise automation technology problems step by step with and sequences
GRAFCET • can combine various program modules into structured programs
• can draw their own GRAFCET plans of varying degrees of difficulty • can isolate and eliminate faults and errors using the diagnostic
buffer and status display
Article number • can design, program and implement basic automation tasks
559452
Article number
559381

PLC PLC
CODESYS version 2 – CODESYS version 2 –

A hardware independent introduction to A hardware independent introduction to
CODESYS PLC programming
PLC271 PLC281
Contents Contents
• Overview of the IEC 61131-3 standard • Design and functions of a PLC
• Introduction to the Codesys programming environment • Overview of the IEC 61131-3 standard
• Use of the 6 programming languages IL, ST, LD, FBD, SFC, CFC • Overview of automation structures and bus systems
• Use of visualisation • Functionality of the Codesys programming environment
• Working with simulation • Use of the 6 programming languages IL, ST, LD, FBD, SFC, CFC
• Functions, function blocks and libraries • Offline simulation
• Conversion of PLC programs • Visualisation
• Use of variable and symbolic operands • Configuration and commissioning Festo automation systems
• Using the help function
• Aids for troubleshooting Outcomes
The participant:
Outcomes • can use and combine IEC 61131-3 languages (Codesys version 2.3)
The participant: to program a professional solution for an industrial application
• can explain the scope and potential of Codesys quickly and efficiently
• can explain the positioning of Codesys to other programming • can program IEC 61131-2 compatible industrial controllers
environments • can describe the sequence of the MPS Distribution Station using
• can select the best programming language for a given task GRAFCET
• can identify which products can be programmed with Codesys • can program the sequence of the MPS Distribution Station using a
• can select appropriate languages for specific tasks and combines language or combination of languages
them to a complete project • can use debugging tools to simulate, test and trace
• can create a basic simulation based on the internal SoftPLC from • can use Codesys features to troubleshoot
Codesys and test programs • masters the fundamentals of visualisation
• can create a basic visualisation (for example, of a belt or • can create and use different kinds of variables (local, global)
distribution station) • knows how to find help within the software
Article number Article number

570614 570612

PLC PLC
CODESYS version 3 – CODESYS version 3 –

A hardware independent introduction to A hardware independent introduction to
CODESYS PLC programming
PLC371 PLC381
Contents Contents
• Overview of the IEC 61131-3 standard • Design and functions of a PLC
• Introduction to the Codesys programming environment • Overview of the standard IEC 61131-3
• Use of the 6 programming languages IL, ST, LD, FBD, SFC, CFC • Overview of automation structures and bus systems
• Use of visualisation • Functionality of the Codesys programming environment
• Working with simulation • Use of the 6 programming languages IL, ST, LD, FBD, SFC, CFC
• Functions, function blocks and libraries • Offline simulation
• Conversion of PLC programs • Visualisation
• Use of variable and symbolic operands • Configuration and commissioning Festo automation systems
• Using the Help function
• Aids to troubleshooting Outcomes
The participant:
Outcomes • can use and combine IEC 61131-3 languages (Codesys version 3.2)
The participant: to program an professional solution for an industrial application
• can explain the scope and potential of Codesys quickly and efficiently
• can explain the positioning of Codesys compared to other • can program IEC 61131-2-compatible industrial controllers
programming environments • can describe the sequence of the MPS® Distribution Station using
• can select the best programming language for a given task GRAFCET
• can identify which products can be programmed with Codesys • can program the sequence of the MPS® Distribution Station
• selects the appropriate languages for specific tasks and combine using a language or combination of languages
them to a complete project • can use debugging tools to simulate, test and trace
• can create a basic simulation based on the internal SoftPLC from • can use Codesys features to troubleshoot
Codesys and test programs • masters the fundamentals of visualisation
• can create a basic visualisation • can create and use different kinds of variables (local, global)
(for example, of a belt or distribution station) • knows how to find help within the software

577954 577956

PLC PLC
Maintenance and troubleshooting of Technical communications

PLC systems
PLC441 PLC451
Contents Contents
• Functional correlations between mechanics – pneumatics – • Parallel and serial data communication
electrics – PLC • Fieldbus system overview
• Commissioning of machines and machine systems • Kinds of networking structures
• Structure and function of PLC • AS interface
• Using PC for troubleshooting • Differences between conventional PLC systems and
• Troubleshooting as a team fieldbus systems
• Using technical documentation • Master, passive and active slaves
• Process FMEA (Failure Mode and Effect Analysis) as tool for • Characteristics of different fieldbus systems
preventive maintenance • Online network diagnostics using host PLC programming software
• Parallel and serial communication between machines • Interfacing between compatible fieldbus systems
• Improving machines using maintenance strategies • Network reaction to errors
• Practical commissioning, installation and configuration of the
Outcomes following networks: parallel data communication, Profibus DP,
The participant: AS-Interface
• is able to think in processes and functional correlations • Commissioning, installation and configuration
• can read technical documentation
• is familiar with the function of PLC and PLC programs Outcomes
• can use software tools for troubleshooting The participant:
• can identify and remove failure causes • is able to plan networking systems
• can apply FMEA to eliminate faults in a system • can choose the right networking approach
• can find faults in a network
Article number • is able to differentiate between commonly used fieldbus systems
579223
Article number
579225

PLC PLC
Simatic S7 analogue and PID control S7 workshop
PLC471 PLC481
Contents Contents
• Analogue value processing • Complex hardware tests
• A/D converter and D/A converter • Further exploration of STEP 7
• Standardisation of analogue input values • Sequence programming in FUC
• Frequency measurement • Application of organisational modules
• Maximum and minimum limits of an analogue value • Declaration of variables in function modules and functions
• Difference between local and global variables • Application of standard and system function modules
• 16/32-bit converter • Application of IEC modules from the library
• Current input, voltage output • Operation modes: setup, automatic, single step, emergency stop
• Analogue sensors • Analysis of necessary communication between modules
• I/O-components in machines
• Data and tool transfer
Outcomes
The participant: Outcomes
• can plan and program a task that requires analogue value The participant:
processing • understands and can create complex program structures
• can integrate an analogue unit into a PLC program • is able to plan, realize and evaluate complex PLC programs
• can read and handle output analogue values • is able to commission modules and machines
• can connect analogue components correctly • can undertake structured programming
• can address and parameterize analogue components • can work with and generate data modules
• can commission and test the system • can find errors in complex programs quickly and efficiently
• can integrate analogue value processing into a program • can spot the reasons for machine breakdowns with the aid of the
PLC program
Article number • makes changes and additions to programs developed by others
579227
Article number
579229

Electricity Electricity
Electricity for non-electrical industrial staff 1 Electricity for non-electrical industrial staff 2
EL131 EL141
Contents Contents
• What is electric current? What effects does it have? • Safety in electric circuits
• Units and symbols • Electric field and magnetism
• Ohm’s Law • Coils
• Measuring in the circuit • Capacitors
• Voltage supplies – direct current, alternating current • Calculating and interpreting values
• Loads in electrical circuits • Three-phase current
• Series connection • Work and power
• Parallel connection • Motors
• Voltage divider • Fundamentals of sensor technology
• Circuit principles
• Electrical components (relay, contactor etc.) Outcomes
• Avoidable and unavoidable measuring errors The participant:
• Conductors – semiconductors – non-conductors (insulators) • is able to explain and apply the safety procedures for working in
electrical circuits
Outcomes • can name the electrical sensors and actuators, and relate them to
The participant: real-life applications
• can explain the working principle of an electrical circuit and • is able to build and commission circuits of intermediate complexity
all the basic physical phenomena with sensors and common electrical actuators
• can effectively measure an electrical circuit (valves, motors, safety circuits)
• can name the key electrical components used in industry • is able to diagnose the most common faults in electrical circuits
• can build and commission basic electrical circuits • is able to calculate the cost of using electricity
• can read basic electrical circuit diagrams
Article number
Article number 577953
577951

Process automation Process automation
Valves in process automation Principles of industrial measurement

and instrumentation
PA121 PA221
Contents Contents
• Overview of design and function of process valves, • Basic electric principles and electrical safety
taking international standardisation into account • Transducers and sensors
• Physical principles and material selection related to media • Principles of measurement (flow, level, temperature and pressure)
and process valves • Control valves, their components and functions
• Testing and certification requirements for process valves • Control theory
(such as works test certificate) • Fundamentals of control loops
• Cavitation – what is cavitation, how to avoid cavitation damage • Instrumentation symbols and drawings
with specially designed valve types • Practical training on software and hardware with loop tuning and
• Principles and selection of process valve actuation adjustment
(manual, hydraulic, electric and pneumatic) • Safety concerns and procedures when operating control systems
• Reading and interpreting process valve symbols
• Influence of international regulations on the process valve selection Outcomes
(AWWA, API etc.) The participant:
• SIL regulation (Safety Integrity Level), explosion safety and the • can measure and describe the difference between basic electrical
influence on the process valves principles
• can identify, describe and measure the difference between
Outcomes analogue and digital signals
The participant: • can identify and measure sensors used to measure
• can select, assemble and test complex process valve installations process variables and understands their principles
• can maintain and troubleshoot complex process valve installations • can identify and describe the components of a control valve
• can identify and describe the construction, design features and • can explain the main parts of open- and closed-loop systems,
operation of process valves their functions and signal flows
• can interpret technical specifications and data relating to process • can identify the symbols and components used in instrumentation
valves and systems drawings
• can identify and explain graphical symbols for process valves
• can perform simple calculations of pressure, flow and force Article number
• knows the role of process valve actuation – manual, hydraulic, 565684
electric and pneumatic
• knows how to prevent cavitation damage
• is aware of current innovative developments and trends in process
valve automation products and their application
Article number
565673

Process automation Process automation
Practical mastery of closed-loop control Fundamentals of closed-loop control

technology
PA201 PA291
Contents Contents
• Operation of the components in a closed-loop control system inclu- • Specifics of open-loop control
ding static and dynamic functions • Introduction into closed-loop control
• Requirements for open- and closed-loop stability and • Basic terminology of closed-loop control
control system tuning methods • Characteristics of the two-step controller method
• Functionality of cascade control loops and the advantages of • Hands on exercises with P controller, I controller and PI controller
cascade control over single-element • Operation of a controlled system with Two-step-, P, I and
• Feedback control, and tuning a cascade control loop for optimum PI controllers
control • Fundamentals of fine tuning a PI controller
• Principles and design features of feed-forward control and tuning a
feed-forward control system for optimum control Outcomes
• Operation and function of ratio control systems and tuning of ratio The participant:
control systems • can name and explain the closed-loop control variables
• Safety concerns and procedures when operating control systems • can commission a basic closed-loop control system
• can initiate and modify basic closed-loop control system
Outcomes • can operate, describe, indentify and analyse a control system
The participant:
• can commission a basic closed-loop control system Article number
• can initiate and modify basic closed-loop control systems 578563
• can identify components
• can read a circuit diagram or wiring schematic This course is an abbreviated version of the course PA 201 “Practical
• can connect components according to a circuit diagram or wiring mastery of closed-loop control”
schematic
• can operate, describe, identify and analyse a control
• knows the fundamentals of closed-loop controls
Article number
565682

Water management Water management
Water purification processes Safe and efficient water transport

in modern water works and distribution
PA231 PA241
Contents Contents
• Phases of precipitation and flocculation • Operation of pumps
– Types of substances in water – Types of pumps and the principles of their operation
– Phases in coagulation and flocculation processes – Components of pumps
– Optimizing dosage of coagulants • Water transport to high tower
• Chlorine dosage and disinfection – Constant supply of drinking water
– Disinfection control – Manual control of the filling level
– Measurement of chlorine concentration • Water supply to different pressure zones
– Simulation of two settlement zones located at different altitudes
Outcomes – Manual valve control
The participant: • Water loss
• learns how to control coagulation and flocculation processes – Analysis of water consumption
• can evaluate the processes of precipitation and flocculation and – Identification of water loss
identify overdosing – Leak detection
• can create a sedimentation graph
• knows how to dose chlorine Outcomes
• can measure and interpret chlorine dosage The participant:
• can explain the effects of chlorine overdosing • can identify and explain types of pumps and their components
• can supervise and control a pump and the relationship between
Article number pressure and flow
577543 • is able to control the fill level of a tank
• can implement measures to ensure water supply to different
pressure zones
• is able to keep the fill level of a high tower constant under varying
basic conditions
• can detect leakages with zero-consumption measurement
Article number
577545

Key processes of wastewater transport Fundamentals of modern

wastewater treatment processes
PA251 PA261
Contents Contents
• Principles of water flow in pipes • Sedimentation
• Transport of solids – Principles of sedimentation
• Operation of sewer systems – Factors and process parameters affecting sedimentation
– Stormwater management – Sedimentation tank types
– Types of rain overflow devices and basins – Sedimentation tank zones and processes
– Sludge withdrawal and recycling
Outcomes • Biological treatment (activated sludge)
The participant: – Aerobic wastewater treatment
• can describe sedimentation and re-mobilisation in a combined – Activated sludge process
sewer system – Calculations for activated sludge
• can explain the impact of blockage in a sewer system – Maintaining solids concentration by sludge recirculation
• is able to differentiate between dry weather and rain flow and
explain the influence on solid transport Outcomes
• can forecast effects of exceeding the hydraulic capacity The participant:
• can name the basic mechanism that lead to first flush • knows the factors that influence sedimentation processes
• can describe the function and different types of rain overflow • understands and can control sedimentation processes
basins • understands the activated sludge processes
• is able to explain the role of the throttle device and the overflow • knows the consequences of overload in a wastewater treatment
plant
Article number • can measure and control the amount of oxygen needed
577547
Article number
577549

Monitoring, controlling and optimising Energy optimisation in water and

operations in water and wastewater wastewater treatment plants
treatment plants
PA271 PA281
Contents Contents
• Data collection • Forms of energy and its sources
• The following parameters are collected: • Energy consumption in water and wastewater treatment
– Fill levels • Optimisation of energy consumption for aeration
– Volumetric rates • Energy efficiency
– Line pressure • Cost impact of ineffective systems
– Electric voltage, power • Causes of energy waste
– Oxygen (O2) • Energy management systems
– Chlorine (Cl2)
• Interpretation of characteristic data parameters Outcomes
• Automated closed-loop control of pumps, valves and aeration The participant:
• is able to evaluate detailed energy consumption and the costs of
Outcomes energy sources
The participant: • can determine main consumers in a plant
• can define and supervise goals related to water and wastewater • can detect faults that cause waste of energy
treatment • can define and supervise quality goals related to energy
• can identify relationships within the processes consumption
• can use different control strategies • can compare the efficiency of systems (for example, pumps)
• can control fill level • is able to optimise energy demand of control strategies
• can manage volumetric flow control (automated close-loop control), such as fill level, flow control or
• is able to handle drain control aeration
• can control aeration • can evaluate measures for energy saving
• can develop an energy management system
Article number • can estimate the potential for energy production in a wastewater
577551 treatment plant
Article number
577553

Fundamentals of water technology Operating membrane filtration processes
PA321 PA331
Contents Contents
• Setup and commissioning of a processing plant • Membrane process streams
– Reading and creating flow charts • Function principles of particle separation
– Installing piping for processing components • Functional principle of ion separation
– System analysis • Factors influencing separation
• Manual measurement • Osmosis/reverse osmosis
– Hydrostatic and hydrodynamic pressure measurement • Crossflow/dead end filtration
– Manual fill-level and flow control • Flushing process
– Determination of quantity and volume
• Documentation of process sequences Outcomes
– Graphical analysis The participant:
– Systematic troubleshooting • can describe the factors influencing separation
– Creating test protocols • can name the effects of exceeding hydraulic capacity
– Determination of energy demand • can outline the membrane filtration parameters that determine
the process
Outcomes • can describe the basic function of backwashing
The participant: • can describe a step program for membrane filter operation and
• can read and understand simple technical drawings indicate the function of the individual steps and their benefits
• knows the structure and function of elementary • can optimise a flushing program
process engineering components
• is able to manually control simple processes Article number
• can make statements about the state of a process on the basis 579105
of measured values
• can identify influences or disturbance variables acting on the
process parameters of flowrate and pressure
• can draw and analyse simple pump characteristic curves
• is able to determine the interaction between pressure and
volumetric flow in a piping system
Article number
579103

Mastering rapid sand filtration Pneumatics for water management
PA341 PN331
Contents Contents
• Functional principles of particle separation • Production and distribution of compressed air
• Factors influencing separation • Identifying and eliminating waste
• Cake/deep-bed filtration • Reading circuit diagrams and interpretation of control sequences
• Dry/wet filtration • Design and function of directional control, pressure, shutoff and
• Slow/rapid sand filter flow control vales
• Flushing process • Function of linear and rotary drives
• Continuously flushed filters • Correct adjustment of process drives and their sensors
• Safe and precise manual intervention
Outcomes • Safe decommissioning in the event of total loss of auxiliary energy
The participant: • Practical exercises, designing and testing circuits, troubleshooting
• can describe the factors influencing separation
• can name the effects of exceeding hydraulic capacity Outcomes
• can outline the sand filtration parameters that determine the The participant:
process • can confidently identify relationships within the process
• can describe the basic function of backwashing and the role of • can avoid damage and failure in the event of operator errors
air and water flushing through safe and precise intervention
• can describe a step program for rapid sand filter operation and
indicate the function of the individual steps and their benefits Article number
• can optimise a flushing program 573629
Article number
579107

Handling systems Handling systems
Robotics – Motion control solution CMCA

Fundamentals
ROB111 ROB121
Contents Contents
• Handling devices • Motion functions
– Fundamentals, types and applications, advantages and – Positioning
disadvantages – Synchronisation
– End effectors – Homing
• Mechanics • Dynamics
– Degrees of freedom, joints – Distance, speed, acceleration and jerk
– Linear motion, circular motion • Handling systems architecture
• Coordinate systems – Festo kinematics
– World, reference • CMXR
• Movement vs. speed – Overview and performance
– Drives, servo and induction motors • Teach pendant and Festo Teach Language (FTL)
– Feedback – Overview, programming
• Motion control – Integrated Codesys PLC
– Basic blocks • Applications
– Typical data of a motion control system – Examples
• Applications – “Hands-on”
– Examples – Pick and Place
– “Hands-on” – Optimising
Outcomes Outcomes
• is able to identify the different types of handling systems • can identify the different pieces of equipment that are part of the
• can describe the mechanics behind robotics systems motion control systems
• can describe the working principles behind the control of • can commission a motion control system
movement and speed • masters standard programs of handling (Pick and Place) with
• is able to explain what a coordinate system is FTL language for the Festo Electrical Handling Systems and the
• can enunciate the principles of a motion control system Teach pendant
• can optimise the program to achieve the maximum performance
Article number
578435 Article number
578437

Handling systems Handling systems
Maintenance of Tripod EXPT Mastering the basics of electrical drives
ROB131 ED811
Contents Contents
• Maintenance • Linear and rotary mechanical drives
– Greasing of the axis and rods (Tooth belt, spindle, ball screw, torque motor)
– Adjustment of rod lost detection • Motors (DC motors, AC motors – synchronous and asynchronous,
• Repair servo, stepper)
– Replacing a belt and acquiring the feed constant • Direct drives (linear and torque motors)
– Replacing of rod • Brakes for electrical drives
• Control system • Mechanical gear units for electrical drives
– General overview of the components • Displacement encoders (incremental, absolute, resolver)
– Working with the Teach pendant • Selection criteria for electrical drives
– Creation of a status report • Controllers
– Replacing control components including parameterisation • Festo Configuration Tool (FCT) software package
• Troubleshooting
– Typical errors Outcomes
The participant:
Outcomes • is able to select the most appropriate components for a given
The participant: application, safely commission drives and locate and eliminate
• can maintain the Tripod according to the manufacturer’s simple faults
specifications • can explain the functional principles of synchronous machines
• works with the Teach pendant to diagnose and troubleshoot and steppers
the system • can describe the functional principles of servo and stepper
• can exchange minor components controllers
• can differentiate between the various types of encoders and
Article number identify their function and specific application
578439 • can explain the differences between the various types of brakes
• is able to analyse a system consisting of different electric drives,
controllers, brakes, gear boxes and explain their configuration and
relationship
• can differentiate between the range of gear boxes for electrical
drives and identify their function and specific application
• can differentiate between the various types of mechanical drives
(axes), and explain their construction
• can explain the relevant parameters of the configuration software
and their effect on the drive system positioning and torque control
Article number
562553

Handling systems Troubleshooting
Vacuum in handling technology Maintenance and troubleshooting of

electropneumatic systems using PLC controls
PN381 PN121
Contents Contents
• Introduction to vacuum technology • Functional relations between mechanic, pneumatic, electronic
• Vacuum generation in handling technology and PLC components of a system
• Vacuum components in handling technology • Reading and using machine documentation
• Component selection criteria • Set up and commissioning of a system with pneumatics and
PLC control
Outcomes • Optimising systems using fault documentation
The participant: • Methodical approach to find analyse failures in systems
• understands the generation and provision of vacuum • Applying FMEA technique to prevent failures
• is able to describe the fundamentals of vacuum • Practical exercises in troubleshooting
• can select and dimensions suction cups
• can interpret the material properties of handling with vacuum Outcomes
• can interpret the vacuum generator properties The participant:
• can design simple vacuum circuits • can set up and commission a pneumatic system with a PLC control
• can interpret the documentation of the system
Article number • can interpret the construction, design features and operation of
575774 components and their relations
• can design and analyse a machine fault list
• knows how to apply various methods to analyse the root causes of
the failures and take actions
• can apply FMEA to prevent failures on a system
Article number
559396

Troubleshooting Troubleshooting
Effective industrial problem-solving Valve terminal CPX –

techniques Commissioning, modification and
fault elimination
PN142 PN163
Contents Contents
• Defining, understanding and communicating problems • Design and function of three different CPX valve terminal series
• Troubleshooting using problem-solving techniques – MPA
• Causes of downtime and how to prepare a fault list – Midi
• Methods/tools for analysing and eliminating root causes – VTSA
(Pareto, cause-effect diagram, brainwriting, FMEA, measure list, • Valve functions
measure plan) • Creating pressure zones
• Drawing and reading pneumatic circuit diagrams
Outcomes • Functional relationships between pneumatics and electrical
The participant: engineering
• can effectively understand and communicate problems • Terminal configuration and spare parts ordering
• is able to build a team to start the analysis of a major problem that • Modification and replacement of parts
could not be solved individually • Versatile electrical connection technology
• can apply various techniques to identify and eliminate the root • Adjustable failsafe behaviour
cause of the problem • Detection and elimination of pneumatic and electric controls
• can design and analyse a machine fault list for various production • Diagnosis via fault LEDs at the Profibus node
systems • Creating a Profibus configuration using STEP7
• can take effective actions and control action plans for a permanent • Testing and diagnosis via Profibus using a programming unit
fix of the problem • Programmed diagnosis
• applies basic FMEA analysis on industrial systems
Outcomes
Article number The participant:
559417 • is familiar with the CPX valve terminals and operation principles
• can interact with the CPX interface
• can diagnose failures of CPX valve terminals
• can make a diagnosis via Profibus
Article number
559389

Troubleshooting Safety
Maintenance and troubleshooting of Mastering machinery safety 1

hydraulic systems
HY521 SN171
Contents Contents
• Important hydraulic components • Standard EN ISO 13849-1 for the Performance Level (PL) and
• Circuit design and reading circuit diagrams Mean Time To Failure (MTTF) calculations
• Hydraulic troubleshooting techniques • Standard EN ISO 13849-2 for the validation of the safety systems
• Analysing circuits for troubleshooting designed for the machinery
• Hydraulic maintenance approach • Standard EN IEC 62061 for electrical, electronic and programmable
• Troubleshooting guides equipment
• Safety Integrity Level (SIL)
Outcomes • Combination of several machines and Integrated Manufacturing
The participant: System (IMS)
• knows the features of important hydraulic components
• can interpret the technical data of the component Outcomes
• understands how availability of production equipment The participant:
can be improved • can apply the machinery directive
• knows the efficient maintenance methods • can determine which other directives have to be applied
• can read and analyse hydraulic circuit diagrams • can determine and describe the limits of the machinery
• can effectively troubleshoot hydraulic circuits • can explain the changes contained in the “new” machinery directive
• can safely commission the system • is able to describe the relationship between the directives and the
harmonised standards
Article number • can carry out a risk assessment and address the residual risks
559449 • can explain the difference between a machinery and a partially
completed machinery
• can list the documents that have to be prepared for the machinery
and the partially completed machinery
• is able to define the life phase of the machinery and to identify the
responsible person for each life phase of the machinery
• can use the information from the EN ISO 13849-1 and 13849-2 (PL)
• is able to develop the safety circuits for different categories
• performs the necessary calculations for PL, MTTD based on the
B10 value
• can prepare a declaration of conformation or a declaration of
incorporation based on the harmonised standards
Article number
577959

Safety Safety
Mastering machinery safety 2 Explosion safety
SN182 PA141
Contents Contents
• Standard of electrical safety of machinery is EN IEC 60204-1:2006 • Explosion safety fundamentals EN 60079, EN-1127, EN-13463,
Safety of machinery –Electrical equipment of machines – Part 1: IEC61241– plus appropriate guidelines, function and duties,
General requirements. selection and qualification
• ATEX Directive 94/9/EC, IECEex, UL-Aex ...
Outcomes • Process safety management, risk management
The participant: • Process hazards analysis
• can define the definition of a basic Integrated Manufacturing • Implementation of explosion safety management
System (IMS) • Documentation and approvals
• can define the limits of the IMS
• is able to identify a task zone in an IMS Outcomes
• can define the span of control in an IMS The participant:
• can describe the measures that have to be taken to suspend • understands and can use EU guideline 94/9EG plus related
safety functions guidelines
• can identify the person responsible for the design of the IMS • knows explosion safety – function and duties, selection and
• can locate the connection of the incoming supply qualification
• can design a control cabinet and the electric installation in a • knows fundamentals of technical explosion safety –
machine electrical and mechanical
• can identify the required electrical protection class (IP) • knows appropriate legal regulations and responsibilities of the ope-
• can carry out the required calculations for the electric installation in rator/owner
the machine, cross wire section, current carrying capacity, cable • understands the reaction and properties of materials, chemicals
length, overcurrent protection, etc. and mixtures in gas and dust areas
• is able to explain the difference between protective and functional • knows/understands relevant standards
bonding (ISO/DIN/AWWA/ANSI ...)
• can design a “safe” IMS • can perform accreditation and relevant guidelines
• can define the limits of the machine and the covered area for the (German Lloyd, FDA ...)
task zone • can organise and develop operational explosion safety measures
• can design a safety system for the IMS and implement them in operational concepts
• can use the 60204 calculation tool • can develop EX documentation and initiate approvals
• is able to create the appropriate documentation for the IMS and the • can communicate with internal and external bodies
control system of machinery • is familiar with the framework, definitions, systems, hardware and
• can provide the necessary information about the required power software requirements
supply (electric, pneumatic, hydraulic, etc.)
Article number
Article number 565675
577961

Energy efficiency Production engineering
Energy saving in pneumatic systems Maintenance strategies for

maintenance operators
PN361 PT131
Contents Contents
• Costs of compressed air with measurements • Production systems and their influence on maintenance
• Costs of leaks • Six typical machine losses
• Compressed air consumption of various circuits • Roles and self-perception of maintenance department
• The cost of oversizing and undersizing components • Maintenance strategies in comparison:
• Rightsizing for efficiency – Fire-fighting strategy
• Energy efficient circuits – Preventive maintenance
• Correcting the faults that cause efficiency waste – Total Productive Maintenance (TPM)
– Reliability Centered Maintenance (RCM)
Outcomes – Risk Based Maintenance (RBM)
The participant: • Methods to find the right strategy
• understands the relationship between consumption and costs • Key Performance Indicators for maintenance departments
of energy sources • Process for implementing maintenance strategies
• can apply efficiency measures in the preparation, distribution • Examples and practical exercises
and consumption of compressed air
• is able to correct faults that cause efficiency waste Outcomes
• can apply efficiency measures in pneumatic circuits The participant:
• can select efficient components for various applications • is familiar with different maintenance strategies and their
• is able to measure the air consumption of various relationship to production systems
pneumatic applications • is able to choose the right strategy for each machine in relation to
• can improve the lifetime of various pneumatic components the value stream
• can plan the implementation process
Article number • knows Key Performance Indicators for maintenance departments
574395 and can use them to measure the success of maintenance
strategies
Article number
579231

Production engineering Production engineering
Conventional metal processing Metal processing with CNC machines
PT141 PT151
Contents Contents
• Metalworking materials • Design of a CNC lathe and CNC milling machine
• Selection of material according to the task • CNC control system
• Metalworking: Drilling, turning, milling, sawing, filing, deburring • CNC processing
• Technical drawings: reading and drawing • x-y-z axes
• Geometric dimensioning and tolerances • Clamping device
• Processing methods • Zero point
• Production plan • CNC commands
• Measuring instruments: caliper, micrometer, metal ruler • Programming methods
• Measuring methods
• Types of join Outcomes
The participant:
Outcomes • can understand, write and implement a small program for a
The participant: CNC lathe or CNC milling machine
• masters the fundamental skills of metalworking • can take tool corrections into account in a program when milling
• can read technical drawings and can produce simple workpieces or turning
according to drawings • can read drawings for simple workpieces and use CNC processing
• can select the right processing methods and prepare production in production
plans • can check, measure and evaluate workpieces
• can specify, evaluate and check the results of their own work and • can plan workflows
can, if necessary, make corrections
• can choose the right-fit system Article number
579235
Article number
579233

Production engineering Production engineering
Material transport with crane and forklift Assembly and installation
PT161 PT171
Contents Contents
• Use of cranes and forklifts • Mechanical assembly of elements and components
• Accident prevention and work safety • Fastening technologies
• Operating with cranes and forklifts • Configuration, installation and marking of pneumatic components
• Drive types • Connecting of pneumatic and electrical components
• Stability • Installing networks and fieldbus systems
• Regular inspections • Testing components
• Handling of products and loads • Correction
• Traffic rules and traffic routes
• Driving manoeuvres Outcomes
• Theoretical and practical test The participant:
• can read technical documentation and is able to correct these
Outcomes • can choose, configure and assemble mechatronic components and
The participant: systems on the basis of technical documentation
• is able to operate cranes • can install pneumatic tubes and electrical cables and wires
• can drive forklifts • can test mechatronic components
• is able to transport product in a safe manner • is able to find and eliminate faults and document the correct status
• knows and observes the relevant safety regulations in the technical documentation

579237 579239

Production engineering
Commissioning of mechatronic systems
PT181
Contents
This 3-day course covers the following topics:
• Planning commissioning
• Connecting mechatronic system to the power supply
• Testing protection measures
• Testing modules
• Load and testing software
• Safety check of whole machine
• Machine documentation and necessary corrections
• Documentation of commissioning
• Introducing customers to the function and operation of the
mechatronic system
Outcomes
The participant:
• is able to commission and test mechatronic systems
• can do all necessary safety checks
• can check the complete function of mechatronic system
• can document the process of commissioning
• is able to introduce customer employees to the function and
operation of the system
• can explain and present the documentation of machine
Article number
579241

Organisation
A well-organised company
We know what makes an excellent company:

a focus on customer satisfaction, corporate and
quality strategy, employee satisfaction, efficient
processes, responsible and goal-oriented employee
management, job-oriented qualification, positive
business results and a positive impact on society.
We will prepare your entire organisation for the new

tasks you face.
Our consultants will advise your employees on the

development of an independent work style. The aim
of their work is to enable companies to efficiently
structure work, organisation and qualification pro-
cesses.
45
Lean production Lean production
SYNCHRO – SMED –
Introduction to Lean Production and VSM Reducing setup time with SMED
LP111 LP131
Contents Contents
• Inventory minimisation as an important basis for increased • Relationship between batch size and setup time
productivity • Reducing setup times as the only way to reduce batch sizes and
• The principle of pull production control inventories in production
• Advantages compared to conventional production control methods • The SMED (Single Minute Exchange of Die) method and its phases
• Types and function of different pull production control methods • The OTED (One Touch Exchange of Die) method
• Application of methods • Constructive solutions for fast setup processes
• Kanban – the classic pull principle • Work organisation options for fast setup processes
• SMED – Optimisation of setup processes with Single Minute • Influence on production control
Exchange of Die • Practical implementation of methods in a model plant
• CIP as part of the business game
• Introduction to Value Stream Mapping (VSM) Outcomes
The participant:
Outcomes • is able to recognise waste
The participant: • knows the importance of short setup times for fast and economical
• is able to understand the principles of lean thinking order processing, flexible production and low inventories
• knows fundamental methods for improvement • can apply and teach the SMED method
• can analyse the causes of delivery problems and low productivity
• can develop and implement ideas for meeting customer Article number
requirements and process improvements 559425
Article number
561209

Lean Administration Game Production control methods
LP511 LP211
Contents Contents
• Value creation and waste in administration • Main features, design and structure of efficient value-added
• Principles for designing lean administrative processes systems
• Identifying deficiencies in existing processes with the help of a • The role, significance and responsibilities of production control
detailed process analysis in efficient value-added systems
• Professionally designing administrative processes • Production control and the balance between ability to deliver,
• A clean and tidy working place as basis for efficient working inventory reduction and capacity utilisation
• Approaches to optimising administrative processes and their • Criteria and conditions for the control and planning of production
practical implementation in a concrete example • Basic principles and important variables of control and planning:
• Organisational requirements for successful process optimisation replenishment time, min/max-control, safety stock, re-order points,
• Immediate implementation and revision of the acquired knowledge lot sizes for ordering
• Selected production control concepts summarised and compared:
Outcomes load-dependent order release, cumulative quantity concept,
The participant: Kanban, Theory of constraints (constraint-focused production),
• can describe the principles of Lean Administration levelling and smoothing (Heijunka), CONWIP (Constant WIP)
• has experienced the dramatic improvements that • Practical exercises
Lean Administration can bring
• can describe the eight types of waste Outcomes
• has gained experience in identifying and eliminating forms of waste The participant:
• is familiar with typical parameters and manipulated variables in the
Article number production control process
559422 • is able to apply them to strike a balance between ability to deliver,
inventory reduction and capacity utilisation
• is familiar with common methods of production control and their
scenarios and conditions of application
• can select suitable methods for their company
Article number
570620

Analysing and designing value streams Systematically designing value added

processes
LP161 LP261
Contents Contents
• Lean thinking as the basis for recording value streams • Structuring value-added systems and principles of their design
• Preparatory steps for value stream analysis • Basic principles of value-added systems:
• The SIPOC method (Source – Input – People – Output – Customer) flow, pull, reduction of waste
for delineating processes • Methods and tools for designing flows within the company:
• The stages of current state value stream analysis production lines, U-cells
• Practical implementation of current-state value stream mapping • Methods and tools for eliminating bottlenecks: reducing setup
using a concrete example times with the SMED method, maximum machine availability with
• Stages and restrictions when mapping a new, efficient value stream TPM, ensuring quality failure production
• Customer takt as key performance indicator for designing new • Methods and tools for controlling production according to
processes customer demand: Kanban, Heijunka, Just In Time, Just In Sequence
• Practical implementation of future value stream mapping using a • Methods and tools for measuring success:
concrete example Key Performance Indicators (processing time, quality rate,
• Deriving a project plan productivity, capital tied up in inventories, and on-time delivery)
• Fundamental aspects of introducing value stream mapping • Practical examples and case studies
Outcomes Outcomes
• is familiar with the method of value stream mapping and will be • understands the basic structure of value-added systems, how they
able to apply it are adapted to specific companies, and the important methods and
• can record and present the value-added process and is able to use tools
the current-state value stream map to identify waste, weak points • can apply the basic principles of lean production and is capable of
and deficits determining which methods are important for their company
• understands the design of processes that are lean yet still robust • has acquired a comprehensive understanding of the application of
and stable processes, and is able to apply value stream mapping the tools and instruments through various practical examples
when developing a future process
• knows which factors must be taken into account in order to use Article number
value stream mapping in their company 8029215
Article number
559431

Work organisation Fundamentals of Total Productive

Maintenance
LP271 LP281
Contents Contents
• Occupational safety • Lean Manufacturing and TPM
• Energy efficiency • Six typical machine losses
• Order and cleanliness at the workplace (5C) • The OEE (Overall Equipment Effectiveness)
• Planning and designing of work plans • Total Productive Maintenance: Targets and elements
• Communication in working processes • TPM as part of production systems
• Documentation of problems and failures • Measuring and analysing of machine losses
• Continues improvement processes • The important implementation steps
• TPM as a holistic concept with influences and interactions to the
Outcomes whole company
The participant: • Case studies and practical exercises
• is able to work in a safe and efficient way
• knows the relevant tools and methods for improvement Outcomes
• is able to create and improve work plans The participant:
• is able to communicate failures and problems • knows the maintenance strategy TPM, its elements and targets
• recognises the need of TPM
Article number • is able to implement parts of TPM
579247 • can help colleagues to apply TPM
Article number
579249

TOC – Heijunka –
Theory of constraint in practical use Levelling and smoothing
LP291 LP301
Contents Contents
• TOC: fundamentals and function • Heijunka – a system for production control and process
• The interaction between gating, replenishment and improvement
buffer management • The principle of levelling and smoothing: from batch production to
• Influences of inventories: statistical fluctuation of dependent One-Piece-Flow
occurrences – effects of fortune; inventory as function of • EPEI – Every Part Every Interval
replenishment time • Typical process interruptions and errors: long setup times,
• First dimensioning of stock and dynamical modification low machine efficiency, different shift models, distances,
• The economical stock and the system of priorities by order release quality problems
• Structure and function of gating: protection of bottlenecks, • Levelling and smoothing in practice
avoiding overflow in production, correct time for order release • Combination of Heijunka and Kanban
• Sequence control of production orders: How can a very complex • Application possibilities and limits
production environment be controlled? How can bottlenecks • Case studies
be identified? • Practical Exercises
• EOO in practical using
• Practical exercises Outcomes
The participant:
Outcomes • is familiar with the approach of levelling and smoothing
The participant: • knows in which production types Heijunka can be applied
• is familiar with the principles, the advantages and disadvantages • can design and calculate Heijunka
of Theory of constraint • can plan implementation processes for Heijunka
• knows in which production types TOC can be applied
• knows the elements and the function of TOC Article number
• can calculate TOC orders 579253
Article number
579251

Lean production Competence management
Pull – Energy manager:

Kanban and CONWIP Role, competences and responsibilities
LP311 TCM151
Contents Contents
• Low inventories and high reliability of delivery as basis for • Role and responsibilities of the energy manager
excellent productivity • Tasks and activities as energy manager
• Function of Pull principle • Necessary competences
• Kinds of Pull: Kanban and CONWIP • Competence profile of energy manager
• Design of control cycles • Structures and processes for efficient energy management
• Calculation of control cycles • The maintenance manager as energy manager
• Communication in control cycles • Integration of energy management into daily maintenance work
• The process of implementation • The impact of maintenance on energy saving
• Case studies • Continuous improvement of systems efficiency
• Practical exercises • Choosing software to monitor the essential parameters
Outcomes Outcomes
• is familiar with the pull principle, its functions and advantages • knows the role, tasks and responsibilities of an energy manager
• knows in which production types Kanban and CONWIP can be • knows the competence profile of an energy manager and is able
applied themself to meet requirements
• can design Kanban and CONWIP control cycles • can analyse, improve and design internal processes for energy
• is able to calculate replenishment times and inventories in buffers optimisation
• can plan processes for implementation of Kanban or CONWIP • is able to plan, realize and evaluate projects for energy efficiency
• can involve energy efficiency issues in the Continuous Improvement
Article number Process
579270
Article number
579245

Improvement management Business management
Basics of effective maintenance Maintenance excellence
IM181 BM111
Contents Contents
• Role of maintenance and technical service • From corporate policy to maintenance strategy
• The six typical sources of loss in machines and systems • Creating maintenance targets
• Maintenance, inspection and repair • Corporate and maintenance figures
• Key indicators for maintenance: • Lean Thinking, Lean Production and Lean Maintenance
OEE (Overall Equipment Effectiveness), TEEP (Total Equipment • Synchro Game
Effectiveness Productivity), MTBF (Mean Time Between Failures), • Value streams in the company
MTTR (Mean Time To Repair) • Value stream analysis and design
• Structure and design of systematic fault detection • Planning maintenance tasks
• Creating maintenance and inspection plans • Maintenance budget
• Analysis of weak spots and targeted improvement of machines • Process fine analysis and design
and systems • Maintenance as an in-house service for business excellence
• Spare parts management • Maintenance ROI
• Maintenance organisation • Case studies and practical exercises
• Evaluation of maintenance work
• Practical examples and exercises Outcomes
The participant:
Outcomes • knows the strategy of their company and understands which
The participant: aspects influence it
• is familiar with the different areas and roles of maintenance • is able to define a strategy for maintenance and asset management
• is able to identify the six typical kinds of losses on machine and • can plan activities in the maintenance department and develop the
systems and improve these in a systematic way necessary budget
• is familiar with typical maintenance documents and be able to use • can analyse current processes and improve them or design
them in their daily work new ones
• is capable of integrating and optimising their own work in the • knows typical economic data for maintenance department
processes of the maintenance area performance and is able to measure it

8029213 579254

Business management Business management
Asset management Maintenance strategies for

maintenance managers
BM121 BM131
Contents Contents
• Asset management in the company • Production systems and their influence on maintenance tasks
• Life cycle of machines and assets • Six typical machine losses
• Planning of machines and assets • The key figures OEE (Overall Equipment Effectiveness) and
• Failure Mode and Effect Analysis (FMEA) TEEP (Total Effective Equipment Productivity)
• Investment costing and costing methods • Comparison of maintenance strategies:
• Asset-specific maintenance and budget planning • Firefighting, rotational maintenance, TPM, RCM, RBM,
• RAMS analysis condition monitoring (predictive maintenance)
• Project management • Methods for choosing the right maintenance strategy
• Definition of life cycle costs • Key performance indicators
• Identification of weaknesses and issues for machines and assets • Process for the introduction of maintenance strategies
• Problem-solving techniques: • Case studies and exercises
Problem-solving cycle, 5x Why, Ishikawa Pareto, Kepner-Tregoe
• Continuous improvement of machines and assets Outcomes
• Spare parts and warehouse management The participant:
• Case studies and exercises • knows typical maintenance strategies and their influence on
productions systems
Outcomes • can choose them dependent on the machines and processes
The participant: in the factory
• understands the term asset management and is able to support • is able to introduce maintenance strategies, realize them,
their machines and assets and maximise performance for the and measure the results using typical performance data
company
• knows the life cycle and phases of machines and assets Article number
• can plan maintenance tasks for each machine and define 579258
asset-specific budgets
• is able to analyse assets using RAMS analysis, identify weaknesses
and eliminate them with using problem-solving techniques.
Article number
579256

Safety, energy and environmental Energy market legislative contest

management
BM141 BM151
Contents Contents
• European laws, regulations and standards for work safety, • Importance of the energy efficiency
fire prevention, environmental safety and safe machine operation • Energy performance indicators
• Technical standards: ATEX, PED • Purpose of an Energy Management System (EMS)
• European Machine Directive • Benefits of a systemic energy management
• Danger and risk analysis • Requirements of ISO 50001
• Typical energy sources in the company: electrical energy, oil, • Integrated approach to ISO managing systems
water, gases, compressed air ... • Environmental management:
• Energy consumption and losses comparison with different standards (EN ISO 14001, EMAS)
• Evaluation of efficiency of various types of energy • Tools for implementation and improvement of EMS
• Energy value stream analysis and design • Challenges and risks related to the implementation of EMS
• Planning alternative sources of energy • Success factors for EMS
• Typical emissions: waste, water, CO2, contaminated air • Compulsory appointment of the energy manager, their competence
• Carbon audits • Person in charge of energy in the residential and industrial fields
• Handling hazardous substances • Electricity and gas markets, rates and current prices, various supply
• Case studies and exercises possibilities
• „White certificates“ (TEE)
Outcomes • Identifying and eliminating waste
The participant:
• is able to cut energy costs, minimize machine operation risk and Outcomes
comply with EU and national legislative requirements The participant:
• knows the European laws, regulations and standards for work • knows the importance of energy efficiency and of
safety, fire prevention and safe machine operation Energy Management System (EMS)
• can analyse plant energy consumption and identify and eliminate • understands the requirements of ISO 50001 and there integration
energy losses at ISO managing systems
• can plan and implement alternative sources of energy • can deduce the consequences for the company
• knows how to identify plant emissions and is able to develop • knows the important steps for implementation of ISO 50001
carbon audits • is able to plan tasks for an energy manager

579260 579262

Energy consumption: Energy Management System:

Diagnosis and analysis Design and implementation
BM161 BM171
Contents Contents
• Regulatory requirements for the energy efficiency of final • Fundamentals of company organisation
electricity consumers • Project management, risk assessment and planning techniques
• Legal requirements and standards for energy consumption • Problem solving to handle critical situations
diagnosis • Contractual conditions in energy sector
• Energy auditing process (project financing, Energy Performance Contracting )
• Techniques for energy data capture • Renewable energy sources and their incentives
• Energy performance indicators and consumption analysis • Heating and cooling systems
• Industrial plant & building • Thermal regulation and supply
• Measuring of the energy efficiency of an industrial process • Compressed air distribution and lighting
• Identification of opportunities: • Cogeneration, trigeneration and district heating
analysis charts, energy signature and control papers • Technical and economic comparison of alternative solutions and
• Analysis of costs/benefits, evaluation of interventions definition of the funding strategy
• Writing of an energy diagnosis report • Draft, review and governance of the action plan
• Defining and monitoring an energy improvement plan • Forecasting and reporting on targets
• Critical factors for investments and company profitability • Effect of behaviours on energy performances
• Internal communication and awareness
Outcomes • External communication and Green Marketing
The participant:
• knows the regulatory requirements for the diagnosis and analysis Outcomes
of energy systems The participant:
• can control the energy audit process • can design and implement an Energy Management System
• can realize diagnosis and analysis processes • knows the different kinds of energy and opportunities for
• can document the results optimisation
• knows critical factors for investments and company profitability • knows types of renewable energy and their advantages
• can compare types of energy and make the right choices for the
Article number company
579264 • is able to plan the implementation process
• can realize and evaluate the process
Article number
579266

Business management Supply chain management
Business administration compact Introduction to supply chain management
BM181 SCM201
Contents Contents
• First level business indicators: turnover, cost and profit • Introduction
• Relationship between business indicators and Key Performance • Definition, importance and current trends of
Indicators supply chain management
• Different kinds of cost: variable, fixed and stepped fixed • The fundamentals of supply chain management
• How lean manufacturing can help • Supply chain – Views
• Kinds of cost calculation and their consequences for process • Operations – Manufacturing, MRP, ERP, Inventory, Lean/JIT, TQM
improvement • Distribution – Logistics
• Process-oriented performance figures • Integration – “Theory of Constraints”
• Case studies • Game experience – three rounds of a simulation to produce and
• Practical exercises and examples distribute a real product
Outcomes Outcomes
• knows the important key figures and understands the interactions • can describe a supply chain and define supply chain management
between production systems • can describe the components of industrial manufacturing
• is able to see the relationship between their managing activities • explains the five production environments and their characteristics
and influence on performance figures • explains the three types of organisation of the production process
• is familiar with the kind of cost calculation used by the company • presents an overview of industrial system planning and control
• knows the conflict between local and process optimum operations
• can differentiate between independent and dependent demand
Article number application
579268 • characterises the concepts of planning priorities and capacities
• issues which drive the three main players in the supply chain
• identifies the four main objectives of management systems for
quality and productivity
• can describe how logistics impacts supply chain management
Article number
578560

Supply chain management Supply chain management
Supply chain processes Warehouse role inside the supply chain
SCM212 SCM221
Contents Contents
• Three level structure of the SCOR Model • The supply chain
• Processes Plan, Deliver, Make, Source, Return • Logistic-Production model and the reference parameters
• The integrated system of performance measurement • The warehouse role and its influence on the service level
• Implementation path • Service level
• Level 1: • Stock versus service
Identify value proposition, specific strategy and macro • Internal and external supply network
measurement of the supply chain business • Planning systems and replenishment
• Level 2:
Geographic mapping and configuration of the physical and Outcomes
information streams of supply chain The participant:
• Level 3: • can map the supply chain
Description, best practices and measurement of the supply chain • is able to measure the warehouse performance according
activities supporting the objectives of the strategy on level 1 and to the right KPIs
the configuration on level 2
Article number
Outcomes 579211
The participant:
• can map, configure, address and measure the performance of a
supply chain
Article number
579209

Managing warehouse levels and purchasing Warehouse planning

policies
SCM231 SCM241
Contents Contents
• Stock and service – management models of stocks and their impact • Dimensioning of structure and resources of the warehouse
on warehouse dimensioning • Warehouse characterization according to stored materials and
• Safety stock and service level automation level
• Evaluation, monitoring and control of stocks • Warehouse types on the distribution network
• Purchasing activities related to logistics agreements • Characteristics of different typologies of warehouses
• Inventory management: report and corrective actions • Dimensioning methodologies
• Layout and allocation
Outcomes • IT systems
The participant: • Material handling
• knows how to balance the warehouse levels according to the • Warehouse performance
costs and service
• can apply the cross-analysis methodology Outcomes
The participant:
Article number • is able to work in a safely and efficient way
579213 • knows the relevant tools and methods for improvement
• is able to create and improve work plans
• is able to communicate failures and problems
Article number
579215

Improving warehouse processes and Transportation management

activities
SCM251 SCM261
Contents Contents
• Value stream mapping • Defining, understanding and communicating problems
• Continuous Improvement Processes • Types of logistics and transportation management
• Different types of transportation: Physical factors and service
Outcomes • Land transportation
The participant: • Transportation role inside the company
• is able to map the value stream inside a warehouse • Import/export and incoterms
• can identify types of waste
• can apply continuous improvement methods Outcomes
The participant:
Article number • is able to describe the logistics and transportation factors critical
579217 to the supply chain
Article number
579219

Supply chain management
Warehouse personnel management
SCM271
Contents
• Warehouse activities organisation
• Needs analysis
• Safety rules in the warehouse
• Warehouse manager role
• Managing staff
• Delegation and goal-oriented management
• Performance measurement and recognition
• Internal and external personnel
• Team work
• Multicultural teams
Outcomes
The participant:
• can define roles and tasks in a team
• is able to manage personnel and knows how to motivate and
how to build harmony
Article number
579221

61
People
The best side of your people
Social skills and effective networks are the key to a

successful organisation.
In the future, both managers and specialists will be

required to continue developing not only their tech-
nical but also their social skills.
Knowing how to overcome difficult situations and

support teams throughout processes of change is
becoming more and more important. Festo will teach
you how to positively design all levels of a process to
achieve a successful overall solution.

Leadership Leadership
Leadership training module 1 Leadership training module 2
LS111 LS242
Contents Contents
• Principles of leadership • Building and managing teams
• Leading is communicating • Roles and group dynamics
• One-on-one leadership skills • Team leadership skills
• Leading yourself • Handling conflict
Outcomes Outcomes
• understands what makes a good leader • can explain what constitutes a team, the team cycle and different
• identifies the changes necessary to become a good leader roles within a team
• understands the principles of management • can match individual needs to roles
• knows the key tasks of a manager • can explain basic time management techniques
• knows different styles of leadership and how and when to • understands the importance of building relationships and alliances
apply them in the business
• knows how and when to delegate • has achieved self-awareness of personal values and behaviour and
understands how others perceive them
Article number • has identified the perception others have of him/her and the
565668 actions necessary to change this, if necessary
• can describe the basic stages of change and the associated feelings
people experience
• can apply techniques to guide individuals through the transition
• has created a plan for development of skills and a specific personal
topic that puts theory into practice
Article number
573633

Leadership training module 3 Leading the maintenance department
LS253 LS261
Contents Contents
• Developing the leadership personality • Requirements for a maintenance and asset manager
• The leader as coach and mentor • Quantitative and qualitative staff planning
• Leading through change • Types of maintenance organisation
• Networking and sparring • Competence requirements for maintenance staff
• Evaluation of current competence profiles
Outcomes • Development of competences
The participant: • Models, style and instruments of leadership
• has completed a personal action plan and the results have been • Leadership close to workplaces – shopfloor management
presented and discussed in small groups • Using Key Performance Indicators (KPIs)
• has reviewed key learning so far based on a personal action plan • Managing conflict
and is committed to future actions • Salary models
• has identified a sparring partner for continued peer coaching • Work motivation and ways of influencing it
• Continuous improvement process in the maintenance department
Article number • Case studies and exercises
573635
Outcomes
The participant:
• is able to successfully lead a maintenance department
• understands their own role and know what is required of them
• is able to plan quantitative and qualitative staff requirements and
create an adequate maintenance organisation
• knows the models, styles and instruments of leadership and can
formulate targets for employees.
• knows competence requirements for their employees, can evaluate
their current status and develop competences
Article number
579243

Competenceweb® concept – High performance coaching for executives

uncontested competences and execution
Contents Contents
• Identify customer values and required competences • Leadership through coaching
• Identify areas for improvement of your company’s value chain • Coaching techniques
• Assess current and future strengths and weaknesses • Managing overall performance
• Plan and execute a strategy • Managing transition, change and cultural complexity
• Career development
Outcomes • Emotional intelligence
The participant:
• has developed a strategy for uncontested competences and Outcomes
activities for profitable growth for their area The participant:
• has drawn up a personal action plan for improving the value chain, • is familiar with basic coaching techniques using tools such as the
for identifying current and future strengths and weaknesses and for Flow model and the GROW model
implementing the chosen strategy • is able – through effective coaching – to manage transition,
change and cultural complexity together with their employees
We offer this course in co-operation with our partner • knows how to support their employees’ career development using
Change International Ltd. methods such as contracting and positive feedback
We offer this course in co-operation with our partner

Change International Ltd.

Managing change Management by travelling around –

remote management
Contents Contents
• Management and leadership theories and skills • What are virtual teams?
• Individual feedback (such as 360°feedback) allowing better • How to manage and lead them
self-guidance and leadership of others • Cultural implications
• Staff development and coaching • Developing and maintaining trust
• Personality development • Virtual team communication
• Self-managed development • Team technologies
• Change management • Performance management and measurement
• Dealing with resistance • How learning occurs in diffuse organisations
• Team-building
• Time management and goal setting Outcomes
• Project management The participant:
• has a basic understanding of virtual teams and how to manage
Outcomes and lead them, including long-distance negotiations and
The participant: problem-solving
• has learned the necessary skills to promote and implement change • knows how to develop and maintain trust with employees who are
in their company physically distant and who stem from other cultures
• knows how to communicate change within their organisation and • can use tools and methods to improve teamwork under the work
cope with difficult decision-making during the change process conditions imposed by virtual collaboration
• has a deeper understanding of how to develop their managers into
global leader We offer this course in co-operation with our partner

Optimal performance at work program Managing Germans in a German organisation

as a non-German
Contents Contents
• Personality theory • Understanding management and work styles
• Personality functioning • Recognizing what is important and what is different
• Myers Briggs Type Indicator® • Understanding German values and ways of thinking and behaviour
• FIRO-B® • Communication patterns
• Stress management • Decision-making and negotiation skills
• Strategic focusing • Leading your team to top performance
• Personal development planning • Winning acceptance
Outcomes Outcomes
• understands the concepts behind and importance of maintaining • understands the foundations of German culture and how they
a healthy work/life balance (such as flow, personality theory, etc.) influence German work culture and communication patterns
• has enhanced self-perception, which leads to better results at work • knows which methods to employ in negotiations and general
• has developed a personal action plan with targets, aspirations and communication with their German employees and colleagues
detailed next steps • is able to successfully lead a virtual or non-virtual team that has
German members
Change International Ltd. We offer this course in co-operation with our partner

Culture Culture
General cultural training Doing business in all parts of the world
Contents Contents
• Gaining the confidence of foreign business partners, • Understanding diversity in different business worlds
customers and staff • Communicating with business partners from all over the world
• Turning cultural differences to your benefit • Intercultural management
• Understanding differences in mentality • Cultural orientation indicators
• Asking the right questions at the right time • Intercultural communication
• Recognizing cultural signals in other business cultures • Working in a virtual team
• Avoiding misunderstandings and delays • Conflict and negotiation
• Preventing unnecessary friction and conflict • Culture shock
• Expanding your own way of thinking and behaving
Outcomes
The participant: • can use the knowledge acquired to run their business in different
• understands differences in cultures across the globe parts of the world
• understands how these differences are reflected in communication • knows the major do’s and don’ts in different cultures
and negotiation styles • can apply different communication techniques for various cultures
• can adapt to different approaches to time management, as required
assertiveness and conflict resolution
We offer this course in co-operation with our partner Change International Ltd.

Culture Culture
Multicultural team development Doing successful business as a woman

in Asian and Oriental cultures
Contents Contents
• Identifying each others’ differences and preferences • Cultural differences
• Expressing expectations and wishes • Rules for proper dress, speech, table manners
• Identifying root causes and solutions, and developing action plans • Negotiation techniques for women
• Harnessing the synergy in multicultural teams
• Creating and refocusing on the common vision and mission Outcomes
statement The participant:
• understands the fundamental differences of Asian and Oriental
Outcomes culture including rules for proper dress, speech and table manners
The participant: • is able to negotiate successfully in an Oriental context using
• understands how cultural differences within the team are reflected appropriate techniques
in communication and work styles • can use tips and tricks for improved working relationships with her
• can adapt to the different approaches to time management, counterparts in Asian and Oriental Countries
assertiveness and conflict resolution within a multicultural team
• is able to use the strengths of the different nationalities within the We offer this course in co-operation with our partner
team to work more productively Change International Ltd.


Culture Culture
Successful purchasing strategy for China Dealing with indirect communication in China
Contents Contents
• Analysis of target groups • Communication styles
• Selection criteria for manufacturers and locations • Indirect communication
• Sending and requesting samples • Nonverbal communication
• Methods of payment • Small talk
• Conflict of interests • Taboo topics
• Negotiating a contract • Written correspondence
• Dealing with invitations
Outcomes • How to say ‘No’ and save face
The participant: • Dealing with compliments
• has the necessary skills to deal with Chinese market conditions
when selecting manufacturers and locations Outcomes
• can handle the lack of market transparency in China with the help The participant:
of practical tools and methods • can use their acquired knowledge of Chinese communication styles
• can overcome the difficulty in establishing contacts using specific and how indirect and nonverbal communication influence the
communication techniques course of a conversation
• has a deeper knowledge of appropriate small talk but also of taboo
We offer this course in co-operation with our partner topics in Chinese society and how to structure spoken and written
Change International Ltd. communication
• knows how to accept or decline invitations, touch on sensitive
issues and let everyone involved keep face at the same time


Culture Culture
Intellectual property – knowledge transfer Fit for India
Contents Contents
• Chinese education system • The paternalistic and task-oriented traditional Indian style of
• Learning methods leadership
• Conflict situations • Status awareness and the tendency to form hierarchies
• Trust law • The perception of time as a potential source of conflict
• Brand orientation • Relationship-building: how to become a member of an
• Benefits of cooperation Indian ‘in-group’
• Patent protection • The creative blend of cultures, traditions, religions,
races and languages
Outcomes • Work practices in business
The participant:
• can make use of their knowledge of the Chinese education system Outcomes
and learning methods to understand intellectual property issues The participant:
when dealing with the Chinese market • has acquired the necessary skills to communicate successfully with
• knows the basic legal framework surrounding intellectual property Indian employees and colleagues, paying special attention to
rights in China and how to this affects their business there issues such as status awareness and the tendency to form
hierarchies
We offer this course in co-operation with our partner • is aware of the appropriate communication style to use in the
Change International Ltd. Indian context as well as of major pitfalls and how to avoid them


Culture Culture
Working with North Americans Successful communication with

Latin America
Contents Contents
• Culture and international business • Customs and national character
• Meetings • Beliefs, culture, values, ethics and social etiquette
• Asking questions and giving feedback • Establishing, nurturing and cementing relationships with
• Negotiating and presenting counterparts
• Inappropriate behaviour in the workplace • Effective communication tools
• Daily life and ‘culture shock’ • Presentations in Latin America
• Time management
Outcomes • Learning about different markets
The participant:
• has the necessary skills to work with North Americans Outcomes
• is aware of the different approaches to time management, The participant:
assertiveness and conflict resolution and how these different • has acquired the necessary skills for a successful business
approaches impact working with North American colleagues relationship with counterparts in South America
• can use appropriate communication, negotiation and presentation • is aware of cultural differences and can communicate effectively
techniques for successful projects in North America or with North and avoid serious misunderstandings because of cultural
American colleagues differences
• feels at home dealing with the South American market and
We offer this course in co-operation with our partner understands the differences between the main Latin American
Change International Ltd. countries


Culture Culture
Intercultural training for the Arab market Working with managers in Eastern Europe
Contents Contents
• Cultural values and their influence on behaviour and ways of • Cultural values in post-socialist economies
thinking • Cultural diversity and differences in behaviour in different countries
• Communication with Arab business partners • Typical attitudes towards Western investors
(greetings, small talk, gaining confidence, • Impact of religious values on business
nonverbal communication) • Managing change in Eastern European countries
• Dealing with time, information, appointments and conflict
• Leadership in the Middle East Outcomes
• Decision-making in companies The participant:
• is able to manage an Eastern European team
Outcomes • knows how to communicate and behave to avoid
The participant: misunderstandings with Eastern European counterparts
• can work successfully across the Middle East, is aware of cultural • can differentiate the various cultures in Eastern European countries
peculiarities and is thus able to avoid faux pas
• is able to use practical strategies for doing business more We offer this course in co-operation with our partner
successfully with Middle Eastern and Arab counterparts Change International Ltd.
• understands and can apply the concepts of what it means to be a
manager in the Arab world, this culture’s approach to time and
priorities, the decision-making process in the Arab world and
preferred communication and negotiation styles


International human resources International human resources
Best practices in international Developing an international

human resources development: human resources strategy
Investors in people
Contents Contents
• Criteria for success critical to international HRD • Updating corporate strategy
• Investors in People • Framework for global alignment
• Details of the Investors in People standard • Mission statement
• Creating alignment through standard evaluating practices • Vision for the future
• International implementation • Building an HR strategy
• Implication for policies
Outcomes • Internationally shared systems and services
The participant: • Implications for the HR org chart and accountability
• is familiar with the concept of Investors in People as well as the
specifics of the standard along with its implications for their Outcomes
company The participant:
• is able to manage and align the human resources function • has gained deeper knowledge of possible frameworks for global
internationally for global corporate success alignment of an HR strategy
• has used techniques such as identifying the mobility pyramid of
We offer this course in co-operation with our partner company employees and identifying leadership capital to develop
Change International Ltd. an international HR strategy
• has drawn up a first draft of an international HR concept with a
concrete action plan for their next steps


Human resources department as a brand Positioning human resources

as a business partner
Contents Contents
• What is a brand? • What is our current image?
• Brand management • Creating strategic alignment
• Why is brand management important? • Marketing the HR function
• What does a good image do for you? • Service level agreements
• How can you achieve this? • The Four HR Roles
• Focus and commonality between behaviour and image • How to bring about change
Outcomes Outcomes
• has acquired knowledge regarding the definition of a brand and • can identify how the business partner approach differs from HR
the basics of managing HR as a brand within their company as an internal consultancy or the role of HR manager or director,
• defines the HR brand in their company and can use this knowledge and can determine whether this is the right approach for their
to assess the compatibility of applicants as well as to ‘sell’ the company
company at job fairs etc. • has devised strategies for influencing line managers
• has developed a personal partnering action plan
Change International Ltd. We offer this course in co-operation with our partner

Employment law Intercultural assessment center
§
Contents Contents
• Constitution of employment law • The assessment center in an international context
• Recruiting process • Understanding intercultural competence
• Contracts of employment • Selecting international candidates
• Statutory framework for the rights of employees • Selecting candidates for international assignments
at their place of work • Identifying development potential for international tasks
• Liability
• Workers’ representatives Outcomes
The participant:
Outcomes • is familiar with assessment centers in an international context
The participant: and which pitfalls to look out for when selecting tasks
• has a deep understanding of employment law and is able to apply it • understands the importance of applicants’ intercultural
• possesses a deeper knowledge of work, health and safety competence and can use it to extend their scope by selecting them
regulations (insurance, minimum wages, working time regulations, for international assignments
maternity rights, etc.) in the specified country • can correctly identify potential for an employee’s development in
• is more skilful in dealing with workers’ representatives such as an international context
unions, work councils etc.
We offer this course in co-operation with our partner Change International Ltd.

The balanced scorecard for The role of human resources in mergers,

international human resources acquisitions and integrations
Contents Contents
• Corporate vision and strategy • Problems with mergers and acquisitions
• The balanced scorecard in HR • Key success factors
• Definition of Key Performance Indicators (KPIs) for HR • Due diligence for cultural and human resources issues
• Gathering data • Post-merger integration
• Planning implementation • Managing change
• BSC project management • Transition tools
• Evaluating success
Outcomes
• uses their acquired knowledge of BSC project management to The participant:
improve both project performance and specifically defined KPIs • has gained the necessary skills for handling problems related to
for their HR department mergers and acquisitions – from the preparation and due diligence
• has developed the first draft of an action plan to implement the phase through to post-merger integration
BSC concept in their HR department • can use different change management methods and tools to ensure
a smooth transition
We offer this course in co-operation with our partner • knows several techniques to evaluate the success of the merger or
Change International Ltd. acquisition process


Human resources development forum Keeping your Chinese co-worker –

in China employee retention
Contents Contents
• Forum discussions • Chinese ‘guanxi’ (networking and relationships)
• Human Resources market specifics • Career development
• Chinese education system • Motivational tools
• Recruitment methods • Creating trust and loyalty
• Employee retention tools • Efficient teamwork
• In-house workshops • Assigning responsibility to the co-worker
• Goal-setting agreements
Outcomes • Social benefit systems
The participant:
• has the necessary skills to deal with Human Resources Outcomes
Development in China The participant:
• understands the Chinese education system and can adapt emplo- • has the necessary skills to deal with HR development in China
yee recruitment and assessment accordingly • knows the philosophical and cultural background of Chinese
• knows the various successful recruiting methods for the Chinese business and can communicate and behave in a manner that avoids
market and can use them effectively conflict
• is aware of the main employee retention tools and special features • is able to build valuable relationships in China by establishing
relating to the Chinese HR market rapport, ties and links with Chinese counterparts
We offer this course in co-operation with our partner We offer this course in co-operation with our partner
Change International Ltd. Change International Ltd.

International human resources Marketing/Communication/Sales
Downsizing – the benefit of outplacement Technical service: customer-oriented

for organisations
CO231
Contents Contents
• Professional career interest exploration • Empowering you and your company
• Aptitude and ability testing • Identifying customer needs and expectations
• Personality assessment • Key skills for ‘setting the stage’
• Resume preparation • The communication cycle
• Job search • Strategic questioning and listening skills
• Interview skills training • Handling potential conflict situations
• Personal organisation
Outcomes • ‘Delivering the result’ – customer focus
The participant: • Achieving customer satisfaction and future commitment
• understands the benefits of outplacement for organisations
and how to cope with its disadvantages Outcomes
• has gained the necessary skills to improve or refresh their The participant:
leadership skills • can explain how their company’s service offering is aligned with a
• has improved self-perception specific customer
• is able to match and apply the right skills to different types of
We offer this course in co-operation with our partner customers and situations
Change International Ltd. • can choose the appropriate appearance and behaviour according to
their company and the customer profile
• can assess and identify the key factors for satisfaction at the
customer level
• can develop a personal action plan to achieve customer satisfaction
Article number
578561

Marketing/Communication/Sales Marketing/Communication/Sales
Blue Ocean – Global key account management

ideas for uncontested market space
Contents Contents
• Learning how to work across industries, with strategic buyers of • Developing key deliverables between both organisations
differing backgrounds, across chains of buyers, and with • Using planning and process tools to set objectives
complementary products and services • Developing strategies and tactics to achieve these objectives
• Leading across diverging functional/emotional appeals and
across several time zones Outcomes
• Prioritizing ideas The participant:
• has acquired the key tools for establishing and deepening the
Outcomes customer-supplier relationship with their chosen key account using
The participant: multi-level selling techniques
• has learned about making the competition irrelevant by creating • can use different information sources such as annual reports,
and capturing new demand, breaking the value-cost trade-off and social networks, blogs and forums to gather more information
aligning the whole system’s activities in pursuit of differentiation about the key account to further improve the relationship with
and low cost them
• can use the Blue Ocean strategies such as Value Innovation, • has put together a list of targets, implementation strategies and a
Six Paths, Strategy Canvas, Tipping Point Leadership etc. preliminary key account management action plan
• has developed a common language for formulating strategies to
maximise project results We offer this course in co-operation with our partner

Marketing/Communication/Sales Marketing/Communication/Sales
International marketing Train-the-Trainer:

Mastering key trainer skills
TTT111
Contents Contents
This 2-day course covers the following topics: This 2x3-day course covers the following topics:
• Knowledge of and skills for the local import/export market • Didactics and training methods
• The 5 Ps of international marketing • Competency-based training, training aims and seminar design
• The impact of culture on marketing and sales • Physiology of learning
• Understanding the buying process • Didactic reduction
• Teaching and learning methods
Outcomes • Progress checks
The participant: • Active listening and asking questions
• is able to cope with cultural differences • Giving and receiving feedback
• understands and can apply value-centered management
• is able to analyse, select and evaluate the appropriate conceptual Outcomes
frameworks to approach international markets The participant:
• knows the classic learning mechanisms and can adapt training
We offer this course in co-operation with our partner content to participants’ needs
Change International Ltd. • knows creative techniques to make technical training engaging
• knows the most important media and knows how they can be used
for a specific training aim or target group
• can communicate effectively with participants
• knows feedback rules and can give and receive feedback
• can structure training content in a clear and appropriate way
• can present complex topics clearly through didactic reduction
Article number
559442

83
84
Competence programs
Tailor-made employee competence development
Jobs are becoming more and more complex.

Most employees are not only doing what they origi-
nally learned when they started their job. They also
need to constantly develop their skills and acquire
specialised knowledge related to their current job
profile – both hard skills and soft skills.
That is why we now offer brand-new holistic compe-

tence programs based on industry requirements with
a special focus on role-specific activities.
These programs enable participants to perform more
effectively in their position. They consist of a range of
courses and – in the majority of cases – of a project
work related to tasks in the participant‘s workplace –
all accompanied by our experienced instructors.
This positions the employee to put their newly
acquired skills into practice immediately, making the
ROI clearly visible for their employer, who sees the
improved skills at a glance.
85
Competence programs
Maintenance
Highly efficient production systems based on the Lean Thinking

principle require professional maintenance. This goes far beyond the
reactive approach of troubleshooting, instead pursuing continuous
optimisation of machines and processes. This approach is also called
value-added maintenance. It includes ensuring the highest possible
system availability, low maintenance costs, enhanced energy effici-
ency, and a high level of work safety.
These and other topics form part of our qualification programs for
maintenance technicians, maintenance supervisors und maintenance
managers. They allow measurable development of your employees’
skills and can be certified, if necessary.
86
Overview competence programs maintenance
Courses Competence programs
Maintenance Maintenance and Energy efficiency Energy efficiency

specialist asset manager for operators for managers
Technical communications PLC451

Effective industrial prob- PN142
lem solving techniques
Maintenance and trouble PN121
shooting of EP-systems
Maintenance and trouble- PLC441
shooting of PLC systems
Basics of effective IM181
maintenance
Maintenance strategies PT131
for maintenance operators
Maintenance excellence BM111
Asset management BM121
Maintenance strategies BM131
for maintenance managers
Safety, energy and envi- BM141
ronmental management
Leading the maintenance LS261
department
Energy saving in PN361
pneumatic systems
Energy optimisation in PA281
water and wastewater
treatment plants
Energy market legislative BM151
contest
Energy consumption: BM161
Diagnosis and Analysis
Energy management BM171
system: Design and
implementation
Energy manager: TCM151
Role, competences and
responsibilities
In-company project
87
Maintenance specialist
Competence program Maintenance and troubleshooting of

Maintenance specialist electropneumatic systems using PLC controls
PN121
Modules
• Maintenance and troubleshooting of electropneumatic
Qualification program
systems using PLC control (PN121)
• Effective industrial problem-solving techniques (PN142)
• Technical communications (PLC451)
• Maintenance and troubleshooting of PLC systems (PLC441)
• Basics of effective maintenance (IM181)
• Maintenance strategies for maintenance operators (PT131)
Duration
17 days + 24 hours in-company project
Prerequisites
Fundamentals of mechatronics
Contents
Outcomes This 3-day course covers the following topics:
The participants are able to work as maintenance specialists. • Functional relations between mechanic, pneumatic, electronic
They can maintain machines, and identify faults using problem- and PLC components of a system
solving techniques. They can eliminate causes, document all • Reading and using machine documentation
relevant information and evaluate fault lists. They understand • Set up and commissioning of a system with pneumatics and
and can carry out the various maintenance tasks. PLC control
• Optimising systems using fault documentation
Article number • Methodical approach to find analyse failures in systems
582560 • Applying FMEA technique to prevent failures
• Practical exercises in troubleshooting
Outcomes
The participant:
• can set up and commission a pneumatic system with a PLC control
• can interpret the construction, design features and operation of
components and their relations

Maintenance specialist Maintenance specialist
Effective industrial problem-solving Technical communications

techniques
PN142 PLC451
Contents Contents
• Defining, understanding and communicating problems • Parallel and serial data communication
• Troubleshooting using problem-solving techniques • Fieldbus system overview
• Causes of downtime and how to prepare a fault list • Kinds of networking structures
• Methods/tools for analysing and eliminating root causes • AS interface
(Pareto, cause-effect diagram, brainwriting, FMEA, measure list, • Differences between conventional PLC systems and
measure plan) fieldbus systems
• Master, passive and active slaves
Outcomes • Characteristics of different fieldbus systems
The participant: • Online network diagnostics using host PLC programming software
• can effectively understand and communicate problems • Interfacing between compatible fieldbus systems
• is able to build a team to start the analysis of a major problem that • Network reaction to errors
could not be solved individually • Practical commissioning, installation and configuration of the
• can apply various techniques to identify and eliminate the root following networks: parallel data communication, Profibus DP,
cause of the problem AS-Interface
• can design and analyse a machine fault list for various production • Commissioning, installation and configuration
systems
• can take effective actions and control action plans for a permanent Outcomes
fix of the problem The participant:
• applies basic FMEA analysis on industrial systems • is able to plan networking systems
• can choose the right networking approach
• is able to differentiate between commonly used fieldbus systems

Maintenance and troubleshooting of Basics of effective maintenance

PLC systems
PLC441 IM181
Contents Contents
• Functional correlations between mechanics – pneumatics – • Role of maintenance and technical service
electrics – PLC • The six typical sources of loss in machines and systems
• Commissioning of machines and machine systems • Maintenance, inspection and repair
• Structure and function of PLC • Key indicators for maintenance:
• Using PC for troubleshooting OEE (Overall Equipment Effectiveness), TEEP (Total Equipment
• Troubleshooting as a team Effectiveness Productivity), MTBF (Mean Time Between Failures),
• Using technical documentation MTTR (Mean Time To Repair)
• Process FMEA (Failure Mode and Effect Analysis) as tool for • Structure and design of systematic fault detection
preventive maintenance • Creating maintenance and inspection plans
• Parallel and serial communication between machines • Analysis of weak spots and targeted improvement of machines
• Improving machines using maintenance strategies and systems
• Spare parts management
Outcomes • Maintenance organisation
The participant: • Evaluation of maintenance work
• is able to think in processes and functional correlations • Practical examples and exercises
• can identify and remove failure causes • is familiar with the different areas and roles of maintenance
• can apply FMEA to eliminate faults in a system • is able to identify the six typical kinds of losses on machine and
systems and improve these in a systematic way
• is familiar with typical maintenance documents and be able to use
them in their daily work
• is capable of integrating and optimising their own work in the
processes of the maintenance area

Maintenance strategies for In-company project

PT131
Contents
The in-company project with a duration of 24 hours concludes
the “Maintenance specialist” competence program. Detailed
content is defined in cooperation with the employer. During
these projects, participants will be able put into practice the
subjects they have learned in theory. Each project should focus
on a typical task for a maintenance specialist, for example,
reducing machine downtime, analysing faults, planning spare
parts management, or implementing a maintenance strategy
for a machine.
Outcomes
The participant:
• is able to work as maintenance specialist
Contents • can plan and realize a small project with a maintenance focus
This 2-day course covers the following topics: • can measure the success of projects and present results
• Production systems and their influence on maintenance
• Six typical machine losses
• Roles and self-perception of maintenance department
• Maintenance strategies in comparison:
– Fire-fighting strategy
– Preventive maintenance
– Total Productive Maintenance (TPM)
– Reliability Centered Maintenance (RCM)
– Risk Based Maintenance (RBM)
• Methods to find the right strategy
• Key Performance Indicators for maintenance departments
• Process for implementing maintenance strategies
• Examples and practical exercises
Outcomes
The participant:
• is familiar with different maintenance strategies and their
relationship to production systems
• is able to chose the right strategy for each machine in relation to
the value stream
• knows Key Performance Indicators for maintenance departments
and can use them to measure the success of maintenance
strategies

Maintenance and asset manager
Competence program Maintenance excellence

BM111
Modules
• Maintenance excellence (BM111)
• Asset management (BM121)
• Maintenance strategies for maintenance managers (BM131)
• Safety, energy and environmental management (BM141)
• Leading the maintenance department (LS261)
Duration
Prerequisites
University degree in a relevant technical topic
Outcomes
The participants understand value-add maintenance as impor- Contents
tant element of their company’s production system. Depending This 4-day course covers the following topics:
on the production strategy, they can define the maintenance • From corporate policy to maintenance strategy
strategy, plan and realize the implementation process. They • Creating maintenance targets
can focus on the reliability, availability, maintainability and • Corporate and maintenance figures
safety of all assets. They are able to implement a Continuous • Lean Thinking, Lean Production and Lean Maintenance
Improvement Process (CIP) for higher efficiency, lower energy • Synchro Game
consumption and lower machine operating costs. They can lead • Value streams in the company
the maintenance department. • Value stream analysis and design
• Planning maintenance tasks
Article number • Maintenance budget
582562 • Process fine analysis and design
• Maintenance as an in-house service for business excellence
• Maintenance ROI
• Case studies and practical exercises
Outcomes
The participant:
• knows the strategy of their company and understands which
aspects influence it
• is able to define a strategy for maintenance and asset management
• can plan activities in the maintenance department and develop the
necessary budget
• can analyse current processes and improve them or design
new ones
• knows typical economic data for maintenance department
performance and is able to measure it

Maintenance and asset manager Maintenance and asset manager
Asset management Maintenance strategies for

BM121 BM131
Contents Contents
• Asset management in the company • Production systems and their influence on maintenance tasks
• Life cycle of machines and assets • Six typical machine losses
• Planning of machines and assets • The key figures OEE (Overall Equipment Effectiveness) and
• Failure Mode and Effect Analysis (FMEA) TEEP (Total Effective Equipment Productivity)
• Investment costing and costing methods • Comparison of maintenance strategies:
• Asset-specific maintenance and budget planning • Firefighting, rotational maintenance, TPM, RCM, RBM,
• RAMS analysis condition monitoring (predictive maintenance)
• Project management • Methods for choosing the right maintenance strategy
• Definition of life cycle costs • Key performance indicators
• Identification of weaknesses and issues for machines and assets • Process for the introduction of maintenance strategies
• Problem-solving techniques: • Case studies and exercises
Problem-solving cycle, 5x Why, Ishikawa Pareto, Kepner-Tregoe
• Continuous improvement of machines and assets Outcomes
• Spare parts and warehouse management The participant:
• Case studies and exercises • knows typical maintenance strategies and their influence on
productions systems
Outcomes • can choose them dependent on the machines and processes
The participant: in the factory
• understands the term asset management and is able to support • is able to introduce maintenance strategies, realize them,
their machines and assets and maximise performance for the and measure the results using typical performance data
company
• knows the life cycle and phases of machines and assets
• can plan maintenance tasks for each machine and define
asset-specific budgets
• is able to analyse assets using RAMS analysis, identify weaknesses
and eliminate them with using problem-solving techniques.

Maintenance and asset manager Maintenance and asset manager
Safety, energy and environmental Leading the maintenance department

management
BM141 LS261
Contents Contents
• European laws, regulations and standards for work safety, • Requirements for a maintenance and asset manager
fire prevention, environmental safety and safe machine operation • Quantitative and qualitative staff planning
• Technical standards: ATEX, PED • Types of maintenance organisation
• European Machine Directive • Competence requirements for maintenance staff
• Danger and risk analysis • Evaluation of current competence profiles
• Typical energy sources in the company: electrical energy, oil, • Development of competences
water, gases, compressed air ... • Models, style and instruments of leadership
• Energy consumption and losses • Leadership close to workplaces – shopfloor management
• Evaluation of efficiency of various types of energy • Using Key Performance Indicators (KPIs)
• Energy value stream analysis and design • Managing conflict
• Planning alternative sources of energy • Salary models
• Typical emissions: waste, water, CO2, contaminated air • Work motivation and ways of influencing it
• Carbon audits • Continuous improvement process in the maintenance department
• Handling hazardous substances • Case studies and exercises
• Case studies and exercises
Outcomes
The participant: • is able to successfully lead a maintenance department
• is able to cut energy costs, minimize machine operation risk and • understands their own role and know what is required of them
comply with EU and national legislative requirements • is able to plan quantitative and qualitative staff requirements and
• knows the European laws, regulations and standards for work create an adequate maintenance organisation
safety, fire prevention and safe machine operation • knows the models, styles and instruments of leadership and can
• can analyse plant energy consumption and identify and eliminate formulate targets for employees.
energy losses • knows competence requirements for their employees, can evaluate
• can plan and implement alternative sources of energy their current status and develop competences
• knows how to identify plant emissions and is able to develop
carbon audits

In-company project
Contents
the “Maintenance and asset manager” competence program.
Detailed content is defined in cooperation with the employer.
During these projects, participants will be able put into practice
the subjects they have learned in theory. Each project should
focus on a typical task for a maintenance and asset manager,
for example, planning maintenance tasks, definition of asset-
specific budgets or a danger and risk analysis.
Outcomes
The participant:
• is able to work as maintenance and asset manager
• can plan and realize a small project with a maintenance and
asset management focus
• can measure the success of projects and present results

Energy efficiency for operators
Competence program Energy saving in pneumatic systems

Energy efficiency for operators
PN361
Modules
• Energy saving in pneumatic systems (PN361)
• Energy optimisation in water and wastewater treatment
plants (PA281)
Duration
Prerequisites
Vocational training in a technical field
Outcomes
The participants know the different types of energy used in
their plant. They can analyse energy consumption, define los-
ses and weaknesses, and make systematic improvements. Contents
They can calculate energy costs and develop proposals for This 1-day course covers the following topics:
energy substitution. They can implement these and present the • Costs of compressed air with measurements
results of their work. • Costs of leaks
• Compressed air consumption of various circuits
Article number • The cost of oversizing and undersizing components
582561 • Rightsizing for efficiency
• Energy efficient circuits
• Correcting the faults that cause efficiency waste
Outcomes
The participant:
• understands the relationship between consumption and costs
of energy sources
• can apply efficiency measures in the preparation, distribution
and consumption of compressed air
• is able to correct faults that cause efficiency waste
• can apply efficiency measures in pneumatic circuits
• can select efficient components for various applications
• is able to measure the air consumption of various
pneumatic applications
• can improve the lifetime of various pneumatic components

Energy efficiency for operators Energy efficiency for operators
Energy optimisation in water and In-company project

wastewater treatment plants
PA281
Contents
the “Energy efficiency for operators” competence program.
focus on a typical task for a energy efficiency technician, for
example, measurement of compressed air preparation, distri-
bution and consumption or evaluation of the costs of energy
sources.
Outcomes
The participant:
• is able to work as technician in the field of energy efficiency
Contents • can plan and realize a small project with an energy efficiency
This 2-day course covers the following topics: focus
• Forms of energy and its sources • can measure the success of projects and present results
• Energy consumption in water and wastewater treatment
• Optimisation of energy consumption for aeration
• Energy efficiency
• Cost impact of ineffective systems
• Causes of energy waste
• Energy management systems
Outcomes
The participant:
• is able to evaluate detailed energy consumption and the costs of
energy sources
• can determine main consumers in a plant
• can detect faults that cause waste of energy
• can define and supervise quality goals related to energy
consumption
• can compare the efficiency of systems (for example, pumps)
• is able to optimise energy demand of control strategies
(automated close-loop control), such as fill level, flow control or
aeration
• can evaluate measures for energy saving
• can develop an energy management system
• can estimate the potential for energy production in a wastewater
treatment plant

Energy efficiency for managers
Competence program Effective industrial problem-solving

Energy efficiency for managers techniques
PN142
Modules
systems using PLC controls (PN121)
• Energy market legislative contest (BM151)
• Energy consumption: Diagnosis and analysis (BM161)
• Energy Management System: Design and implementation
(BM171)
• Energy manager: Role, competences and responsibilities
(TCM151)
Duration
Prerequisites Contents
Advanced technical knowledge This 2-day course covers the following topics:
• Defining, understanding and communicating problems
Outcomes • Troubleshooting using problem-solving techniques
The participants know the importance of energy efficiency and • Causes of downtime and how to prepare a fault list
of the Energy Management System (EMS). They understand the • Methods/tools for analysing and eliminating root causes
requirements of ISO 50001 and are able to integrate the above (Pareto, cause-effect diagram, brainwriting, FMEA, measure list,
into ISO managing systems and plan tasks for an energy mana- measure plan)
ger. They know the regulatory requirements, can control the
energy audit process and undertake diagnosis and analysis Outcomes
processes. They can design and implement an Energy Manage- The participant:
ment System. They are able to fulfill the role, tasks and respon- • can effectively understand and communicate problems
sibilities of an energy manager. • is able to build a team to start the analysis of a major problem that
could not be solved individually
Article number • can apply various techniques to identify and eliminate the root
582563 cause of the problem
• can design and analyse a machine fault list for various production
systems
• can take effective actions and control action plans for a permanent
fix of the problem

Energy efficiency for managers Energy efficiency for managers
Maintenance and troubleshooting of Energy market legislative contest

electropneumatic systems using PLC controls
PN121 BM151
Contents Contents
• Functional relations between mechanic, pneumatic, electronic • Importance of the energy efficiency
and PLC components of a system • Energy performance indicators
• Reading and using machine documentation • Purpose of an Energy Management System (EMS)
• Set up and commissioning of a system with pneumatics and • Benefits of a systemic energy management
PLC control • Requirements of ISO 50001
• Optimising systems using fault documentation • Integrated approach to ISO managing systems
• Methodical approach to find analyse failures in systems • Environmental management:
• Applying FMEA technique to prevent failures comparison with different standards (EN ISO 14001, EMAS)
• Practical exercises in troubleshooting • Tools for implementation and improvement of EMS
• Challenges and risks related to the implementation of EMS
Outcomes • Success factors for EMS
The participant: • Compulsory appointment of the energy manager, their competence
• can set up and commission a pneumatic system with a PLC control • Person in charge of energy in the residential and industrial fields
• can interpret the documentation of the system • Electricity and gas markets, rates and current prices, various supply
• can interpret the construction, design features and operation of possibilities
components and their relations • „White certificates“ (TEE)
• can design and analyse a machine fault list • Identifying and eliminating waste
the failures and take actions Outcomes
• can apply FMEA to prevent failures on a system The participant:
• knows the importance of energy efficiency and of
Energy Management System (EMS)
• understands the requirements of ISO 50001 and there integration
at ISO managing systems
• can deduce the consequences for the company
• knows the important steps for implementation of ISO 50001
• is able to plan tasks for an energy manager

Energy consumption: Energy Management System:

Diagnosis and analysis Design and implementation
BM161 BM171
Contents Contents
• Regulatory requirements for the energy efficiency of final • Fundamentals of company organisation
electricity consumers • Project management, risk assessment and planning techniques
• Legal requirements and standards for energy consumption • Problem solving to handle critical situations
diagnosis • Contractual conditions in energy sector
• Energy auditing process (project financing, Energy Performance Contracting..)
• Techniques for energy data capture • Renewable energy sources and their incentives
• Energy performance indicators and consumption analysis • Heating and cooling systems
• Industrial plant & building • Thermal regulation and supply
• Measuring of the energy efficiency of an industrial process • Compressed air distribution and lighting
• Identification of opportunities: • Cogeneration, trigeneration and district heating
analysis charts, energy signature and control papers • Technical and economic comparison of alternative solutions and
• Analysis of costs/benefits, evaluation of interventions definition of the funding strategy
• Writing of an energy diagnosis report • Draft, review and governance of the action plan
• Defining and monitoring an energy improvement plan • Forecasting and reporting on targets
• Critical factors for investments and company profitability • Effect of behaviours on energy performances
• Internal communication and awareness
Outcomes • External communication and Green Marketing
The participant:
• knows the regulatory requirements for the diagnosis and analysis Outcomes
of energy systems The participant:
• can control the energy audit process • can design and implement an Energy Management System
• can realize diagnosis and analysis processes • knows the different kinds of energy and opportunities for
• can document the results optimisation
• knows critical factors for investments and company profitability • knows types of renewable energy and their advantages
• can compare types of energy and make the right choices for the
company
• is able to plan the implementation process
• can realize and evaluate the process

Energy manager: In-company project

Role, competences and responsibilities
TCM151
Contents
the “Energy efficiency for mangers” competence program.
focus on a typical task for an energy manager, for example, the
preparation of the implementation of ISO 5001 or design and
implementation of an Energy Management System.
Outcomes
The participant:
• is able to fulfil the role of an energy manager
• can design and implement an Energy Management System
Contents • can measure the success of projects and present results
• Role and responsibilities of the energy manager
• Tasks and activities as energy manager
• Necessary competences
• Competence profile of energy manager
• Structures and processes for efficient energy management
• The maintenance manager as energy manager
• Integration of energy management into daily maintenance work
• The impact of maintenance on energy saving
• Continuous improvement of systems efficiency
• Choosing software to monitor the essential parameters
Outcomes
The participant:
• knows the role, tasks and responsibilities of an energy manager
• knows the competence profile of an energy manager and is able
themself to meet requirements
• can analyse, improve and design internal processes for energy
optimisation
• is able to plan, realize and evaluate projects for energy efficiency
• can involve energy efficiency issues in the Continuous Improvement
Process

Competence Programs
Mechatronics
Mechatronics is the combination of mechanical engineering, electro-

nics and information technology – to a single technology, product or
qualification. Such qualifications are urgently needed by companies
to plan, build, operate and maintain mechatronic systems.
On the following pages we offer role-specific training programs based

on the syllabuses for mechatronic technicians. These focus on tasks
involving mechatronics, such as maintenance, PLC programming and
the assembly of mechatronic systems. They allow measurable deve-
lopment of your employees’ skills and can be certified, if necessary.
102
Overview competence programs mechatronics
Courses Competence programs
Assembly Fluidics Maintenance PLC and robotics Process improvement

specialist specialist specialist specialist specialist
Material transport with PT161

crane and forklift
Assembly and installation PT171
Work organisation LP271
Technical communications PLC451
Commissioning of PT181
mechatronic systems
Maintenance and trouble- PN121
shooting of electro-
pneumatic systems using
PLC controls
Maintenance strategies PT131
for maintenance operators
Maintenance and trouble- HY521
shooting of hydraulic
systems
Systematic safety impro- PN351
vement in pneumatic
systems
Proportional hydraulics HY132
Vacuum in handling PN381
technology
Valve terminal CPX – PN163
Commissioning, modifica-
tion and fault elimination
Maintenance and trouble- PLC441
shooting of PLC systems
maintenance
Maintenance strategies for BM131
Simatic S7 analogue and PLC471
PID control
S7 workshop PLC481
Robotics fundamentals ROB111
Motion control solutions ROB121
SYNCHRO – Introduction to LP111
Lean Production and VSM
Analysing and designing LP161
value streams
Systematically designing LP261
value added processes
Technical service: CO231
customer-oriented
In-company project
103
Assembly specialist
Competence program Material transport with crane and forklift

Assembly specialist
PT161
Modules
• Material transport with cranes and forklifts (PT161)
• Assembly and installation (PT171)
• Work organisation (LP271)
• Commissioning of mechatronic systems (PT181)
Duration
Prerequisites
Outcomes Contents
The participants are able to work as assembly specialists for This 2-day course covers the following topics:
mechatronic systems. They can install mechanic components in • Use of cranes and forklifts
machines or systems and install pneumatic tubing and electri- • Accident prevention and work safety
cal wiring. They can select and configure appropriate pneuma- • Operating with cranes and forklifts
tic and electrical components. They can commission, test and • Drive types
demonstrate the function and use of machines and mechatro- • Stability
nic systems to customers. They are able to work systematically • Regular inspections
and efficiently. In the event of problems, they can use problem- • Handling of products and loads
solving techniques to systematically identify and eliminate • Traffic rules and traffic routes
faults. • Driving manoeuvres
• Theoretical and practical test
Article number
582557 Outcomes
The participant:
• is able to operate cranes
• can drive forklifts
• is able to transport product in a safe manner
• knows and observes the relevant safety regulations

Assembly specialist Assembly specialist
Assembly and installation Work organisation
PT171 LP271
Contents Contents
• Mechanical assembly of elements and components • Occupational safety
• Fastening technologies • Energy efficiency
• Configuration, installation and marking of pneumatic components • Order and cleanliness at the workplace (5C)
• Connecting of pneumatic and electrical components • Planning and designing of work plans
• Installing networks and fieldbus systems • Communication in working processes
• Testing components • Documentation of problems and failures
• Correction • Continues improvement processes
Outcomes Outcomes
• can read technical documentation and is able to correct these • is able to work in a safe and efficient way
• can choose, configure and assemble mechatronic components and • knows the relevant tools and methods for improvement
systems on the basis of technical documentation • is able to create and improve work plans
• can install pneumatic tubes and electrical cables and wires • is able to communicate failures and problems
• can test mechatronic components
• is able to find and eliminate faults and document the correct status
in the technical documentation

Technical communications Effective industrial problem-solving

techniques
PLC451 PN142
Contents Contents
• Parallel and serial data communication • Defining, understanding and communicating problems
• Fieldbus system overview • Troubleshooting using problem-solving techniques
• Kinds of networking structures • Causes of downtime and how to prepare a fault list
• AS interface • Methods/tools for analysing and eliminating root causes
• Differences between conventional PLC systems and (Pareto, cause-effect diagram, brainwriting, FMEA, measure list,
fieldbus systems measure plan)
• Characteristics of different fieldbus systems Outcomes
• Online network diagnostics using host PLC programming software The participant:
• Interfacing between compatible fieldbus systems • can effectively understand and communicate problems
• Network reaction to errors • is able to build a team to start the analysis of a major problem that
• Practical commissioning, installation and configuration of the could not be solved individually
following networks: parallel data communication, Profibus DP, • can apply various techniques to identify and eliminate the root
AS-Interface cause of the problem
• Commissioning, installation and configuration • can design and analyse a machine fault list for various production
systems
Outcomes • can take effective actions and control action plans for a permanent
The participant: fix of the problem
• is able to plan networking systems • applies basic FMEA analysis on industrial systems

Commissioning of mechatronic systems In-company project
PT181
Contents
the “Assembling specialist” competence program. Detailed
on a typical task for an assembly specialist, such as final
assembly of mechatronic system or commissioning a system.
Outcomes
The participant:
• is able to work as assembly specialist
• can plan and implement the assembly and commissioning of
a mechatronic system
Contents • can measure the success of projects and present results
• Planning commissioning
• Connecting mechatronic system to the power supply
• Testing protection measures
• Testing modules
• Load and testing software
• Safety check of whole machine
• Machine documentation and necessary corrections
• Documentation of commissioning
• Introducing customers to the function and operation of the
mechatronic system
Outcomes
The participant:
• is able to commission and test mechatronic systems
• can do all necessary safety checks
• can check the complete function of mechatronic system
• can document the process of commissioning
• is able to introduce customer employees to the function and
operation of the system
• can explain and present the documentation of machine

Fluidics specialist
Competence program Effective industrial problem-solving

Fluidics specialist techniques
PN142
Modules
systems using PLC controls (PN121)
• Maintenance and troubleshooting of hydraulic systems
(HY521)
• Systematic safety improvement in pneumatic systems
(PN351)
• Proportional hydraulics (HY132)
• Vacuum in handling technology (PN381)
• Valve terminal CPX – Commissioning, modification and fault
elimination (PN163)
Duration
15 days + 24 hours in-company project Contents
Prerequisites • Defining, understanding and communicating problems
Fundamentals of mechatronics • Troubleshooting using problem-solving techniques
• Causes of downtime and how to prepare a fault list
Outcomes • Methods/tools for analysing and eliminating root causes
The participants are able to work as fluidics specialists. They (Pareto, cause-effect diagram, brainwriting, FMEA, measure list,
can identify customer requirements, design an appropriate sys- measure plan)
tem with regard to quality and cost, and present the results to
the customer. They can work with pneumatic and hydraulic sys- Outcomes
tems, identify weaknesses and implement improvements. They The participant:
understand and can configure and operate valve terminals. In • can effectively understand and communicate problems
the event of problems, they can use problem-solving tech- • is able to build a team to start the analysis of a major problem that
niques to systematically identify and eliminate faults. could not be solved individually
• can apply various techniques to identify and eliminate the root
Article number cause of the problem
582558 • can design and analyse a machine fault list for various production
systems
fix of the problem
Article number
559417

Fluidics specialist Fluidics specialist
Maintenance and troubleshooting of Maintenance and troubleshooting of

electropneumatic systems using PLC controls hydraulic systems
PN121 HY521
Contents Contents
• Functional relations between mechanic, pneumatic, electronic • Important hydraulic components
and PLC components of a system • Circuit design and reading circuit diagrams
• Reading and using machine documentation • Hydraulic troubleshooting techniques
• Set up and commissioning of a system with pneumatics and • Analysing circuits for troubleshooting
PLC control • Hydraulic maintenance approach
• Optimising systems using fault documentation • Troubleshooting guides
• Methodical approach to find analyse failures in systems
• Applying FMEA technique to prevent failures Outcomes
• Practical exercises in troubleshooting The participant:
• knows the features of important hydraulic components
Outcomes • can interpret the technical data of the component
The participant: • understands how availability of production equipment
• can set up and commission a pneumatic system with a PLC control can be improved
• can interpret the documentation of the system • knows the efficient maintenance methods
• can interpret the construction, design features and operation of • can read and analyse hydraulic circuit diagrams
components and their relations • can effectively troubleshoot hydraulic circuits
• can design and analyse a machine fault list • can safely commission the system
the failures and take actions Article number
• can apply FMEA to prevent failures on a system 559449
Article number
559396

Systematic safety improvement in Proportional hydraulics

pneumatic systems
PN351 HY132
Contents Contents
• Correct dimensioning • Structure, function and characteristic data of proportional, way,
• Operation modes pressure and flow control valves
• Safe designing example • Generation of set points
– Hazardous areas • Adapting amplifier electronics to required conditions
– Risk analyses • Development and interpretation of proportional hydraulics circuit
– Safety measures diagrams
• 10 technical safety functions • Intensive practical training through setup of circuits according to
• Emergency stop circuit diagrams and setting parameters for optimal commissioning
• Pneumatic safety tips • Procedures for maintenance, troubleshooting and commissioning
• Open- and closed-loop control
Outcomes • Servo valve technology and control
The participant:
• can recognise the hazards in pneumatic processes Outcomes
• is able to analyse the risk factors of simple pneumatic designs The participant:
• can apply safety measures and safety circuits • can explain the structure and mode of operation of proportional,
• understands the principles of emergency and safety solutions way, pressure and flow control valves
• can raise the safety of simple pneumatic designs • is able to interpret the characteristic data of proportional valves
• can choose the right proportional or servo solution for the
application
• is able to develop, read and interpret proportional hydraulics circuit
diagrams
• can explain the principles of servo valve technology and control
• can explain the difference between open- and closed-loop controls
• is able to identify and solve the most common faults in proportional
and servo hydraulics systems

Vacuum in handling technology Valve terminal CPX –

Commissioning, modification and
fault elimination
PN381 PN163
Contents Contents
• Introduction to vacuum technology • Design and function of three different CPX valve terminal series
• Vacuum generation in handling technology – MPA
• Vacuum components in handling technology – Midi
• Component selection criteria – VTSA
• Valve functions
Outcomes • Creating pressure zones
The participant: • Drawing and reading pneumatic circuit diagrams
• understands the generation and provision of vacuum • Functional relationships between pneumatics and
• is able to describe the fundamentals of vacuum electrical engineering
• can select and dimensions suction cups • Terminal configuration and spare parts ordering
• can interpret the material properties of handling with vacuum • Modification and replacement of parts
• can interpret the vacuum generator properties • Versatile electrical connection technology
• can design simple vacuum circuits • Adjustable failsafe behaviour
• Detection and elimination of pneumatic and electric controls
• Diagnosis via fault LEDs at the Profibus node
• Creating a Profibus configuration using STEP7
• Testing and diagnosis via Profibus using a programming unit
• Programmed diagnosis
Outcomes
The participant:
• is familiar with the CPX valve terminals and operation principles
• can interact with the CPX interface
• can diagnose failures of CPX valve terminals
• can make a diagnosis via Profibus

Fluidics specialist
In-company project
Contents
the “Fluidics specialist” competence program. Detailed content
is defined in cooperation with the employer. During these pro-
jects, participants will be able put into practice the subjects
they have learned in theory. Each project should focus on a
typical task for a fluidics specialist, for example, maintenance
of fluidic systems or the operation of valve terminals.
Outcomes
The participant:
• is able to work as fluidics specialist
• can plan and realize a small project with a fluidics focus

Competence program Maintenance and troubleshooting of

Maintenance specialist electropneumatic systems using PLC controls
PN121
Modules
Qualification program
systems using PLC control (PN121)
• Maintenance and troubleshooting of PLC systems (PLC441)
• Maintenance strategies for maintenance operators (PT131)
Duration
Prerequisites
Contents
The participants are able to work as maintenance specialists. • Functional relations between mechanic, pneumatic, electronic
They can maintain machines, and identify faults using problem- and PLC components of a system
solving techniques. They can eliminate causes, document all • Reading and using machine documentation
relevant information and evaluate fault lists. They understand • Set up and commissioning of a system with pneumatics and
and can carry out the various maintenance tasks. PLC control
• Optimising systems using fault documentation
Article number • Methodical approach to find analyse failures in systems
582560 • Applying FMEA technique to prevent failures
• Practical exercises in troubleshooting
Outcomes
The participant:
• can set up and commission a pneumatic system with a PLC control
• can interpret the construction, design features and operation of
components and their relations

Effective industrial problem-solving Technical communications

techniques
PN142 PLC451
Contents Contents
• Defining, understanding and communicating problems • Parallel and serial data communication
• Troubleshooting using problem-solving techniques • Fieldbus system overview
• Causes of downtime and how to prepare a fault list • Kinds of networking structures
• Methods/tools for analysing and eliminating root causes • AS interface
(Pareto, cause-effect diagram, brainwriting, FMEA, measure list, • Differences between conventional PLC systems and
measure plan) fieldbus systems
Outcomes • Characteristics of different fieldbus systems
The participant: • Online network diagnostics using host PLC programming software
• can effectively understand and communicate problems • Interfacing between compatible fieldbus systems
• is able to build a team to start the analysis of a major problem that • Network reaction to errors
could not be solved individually • Practical commissioning, installation and configuration of the
• can apply various techniques to identify and eliminate the root following networks: parallel data communication, Profibus DP,
cause of the problem AS-Interface
• can design and analyse a machine fault list for various production • Commissioning, installation and configuration
systems
• can take effective actions and control action plans for a permanent Outcomes
fix of the problem The participant:
• applies basic FMEA analysis on industrial systems • is able to plan networking systems

Maintenance and troubleshooting of Basics of effective maintenance

PLC systems
PLC441 IM181
Contents Contents
• Functional correlations between mechanics – pneumatics – • Role of maintenance and technical service
electrics – PLC • The six typical sources of loss in machines and systems
• Commissioning of machines and machine systems • Maintenance, inspection and repair
• Structure and function of PLC • Key indicators for maintenance:
• Using PC for troubleshooting OEE (Overall Equipment Effectiveness), TEEP (Total Equipment
• Troubleshooting as a team Effectiveness Productivity), MTBF (Mean Time Between Failures),
• Using technical documentation MTTR (Mean Time To Repair)
• Process FMEA (Failure Mode and Effect Analysis) as tool for • Structure and design of systematic fault detection
preventive maintenance • Creating maintenance and inspection plans
• Parallel and serial communication between machines • Analysis of weak spots and targeted improvement of machines
• Improving machines using maintenance strategies and systems
Outcomes • Maintenance organisation
The participant: • Evaluation of maintenance work
• is able to think in processes and functional correlations • Practical examples and exercises
• can identify and remove failure causes • is familiar with the different areas and roles of maintenance
• can apply FMEA to eliminate faults in a system • is able to identify the six typical kinds of losses on machine and

Maintenance strategies for In-company project

PT131
Contents
the “Maintenance specialist” competence program. Detailed
on a typical task for a maintenance specialist, for example,
reducing machine downtime, analysing faults, planning spare
parts management, or implementing a maintenance strategy
for a machine.
Outcomes
The participant:
• is able to work as maintenance specialist
Contents • can plan and realize a small project with a maintenance focus
This 2-day course covers the following topics: • can measure the success of projects and present results
• Production systems and their influence on maintenance
• Roles and self-perception of maintenance department
• Maintenance strategies in comparison:
• Fire-fighting strategy
• Preventive maintenance
• Total Productive Maintenance (TPM)
• Reliability Centered Maintenance (RCM)
• Risk Based Maintenance (RBM)
• Methods to find the right strategy
• Key Performance Indicators for maintenance departments
• Process for implementing maintenance strategies
• Examples and practical exercises
Outcomes
The participant:
• is familiar with different maintenance strategies and their
relationship to production systems
• is able to choose the right strategy for each machine in relation to
the value stream
• knows Key Performance Indicators for maintenance departments
and can use them to measure the success of maintenance
strategies

PLC and robotics specialist
Competence program Technical communications

PLC and robotics specialist
PLC451
Modules
• Simatic S7 analogue and PID control (PLC471)
• S7 workshop (PLC481)
• Robotics fundamentals (ROB111)
• Motion control solutions (ROB121)
Duration
Prerequisites
Outcomes
The participants are able to work as PLC and robotics specia- Contents
lists. They can identify customer requirements, design an This 5-day course covers the following topics:
appropriate system with regard to quality and cost, and pre- • Parallel and serial data communication
sent the results to the customer. They can work with PLC and • Fieldbus system overview
robotic systems and various program languages. They can ana- • Kinds of networking structures
lyse existing programs, identify weaknesses and implement • AS interface
improvements. In the event of problems, they can use problem- • Differences between conventional PLC systems and
solving techniques to systematically identify and eliminate fieldbus systems
faults. • Master, passive and active slaves
• Characteristics of different fieldbus systems
Article number • Online network diagnostics using host PLC programming software
582559 • Interfacing between compatible fieldbus systems
• Network reaction to errors
• Practical commissioning, installation and configuration of the
following networks: parallel data communication, Profibus DP,
AS-Interface
• Commissioning, installation and configuration
Outcomes
The participant:
• is able to plan networking systems

PLC and robotics specialist PLC and robotics specialist
Simatic S7 analogue and PID control S7 workshop
PLC471 PLC481
Contents Contents
• Analogue value processing • Complex hardware tests
• A/D converter and D/A converter • Further exploration of STEP 7
• Standardisation of analogue input values • Sequence programming in FUC
• Frequency measurement • Application of organisational modules
• Maximum and minimum limits of an analogue value • Declaration of variables in function modules and functions
• Difference between local and global variables • Application of standard and system function modules
• 16/32-bit converter • Application of IEC modules from the library
• Current input, voltage output • Operation modes: setup, automatic, single step, emergency stop
• Analogue sensors • Analysis of necessary communication between modules
• I/O-components in machines
• Data and tool transfer
Outcomes
• can plan and program a task that requires analogue value The participant:
processing • understands and can create complex program structures
• can integrate an analogue unit into a PLC program • is able to plan, realize and evaluate complex PLC programs
• can read and handle output analogue values • is able to commission modules and machines
• can connect analogue components correctly • can undertake structured programming
• can address and parameterize analogue components • can work with and generate data modules
• can commission and test the system • can find errors in complex programs quickly and efficiently
• can integrate analogue value processing into a program • can spot the reasons for machine breakdowns with the aid of the
PLC program
• makes changes and additions to programs developed by others

PLC and robotics specialist PLC and robotics specialist
Robotics – Motion control solution CMCA

Fundamentals
ROB111 ROB121
Contents Contents
• Handling devices • Motion functions
– Fundamentals, types and applications, advantages and – Positioning
disadvantages – Synchronisation
– End effectors – Homing
• Mechanics • Dynamics
– Degrees of freedom, joints – Distance, speed, acceleration and jerk
– Linear motion, circular motion • Handling systems architecture
• Coordinate systems – Festo kinematics
– World, reference • CMXR
• Movement vs. speed – Overview and performance
– Drives, servo and induction motors • Teach pendant and Festo Teach Language (FTL)
– Feedback – Overview, programming
• Motion control – Integrated Codesys PLC
– Basic blocks • Applications
– Typical data of a motion control system – Examples
• Applications – “Hands-on”
– Examples – Pick and Place
– “Hands-on” – Optimising
Outcomes Outcomes
• is able to identify the different types of handling systems • can identify the different pieces of equipment that are part of the
• can describe the mechanics behind robotics systems motion control systems
• can describe the working principles behind the control of • can commission a motion control system
movement and speed • masters standard programs of handling (Pick and Place) with FTL
• is able to explain what a coordinate system is language for the Festo Electrical Handling Systems and the Teach
• can enunciate the principles of a motion control system pendant
• can optimise the program to achieve the maximum performance

PLC Robotic specialist
In-company project
Contents
the “PLC and robotics Specialist” competence program.
focus on a typical task for a PLC and robotics specialist, such as
realizing a small PLC or robotic program, or improving or exten-
ding a program.
Outcomes
The participant:
• is able to work as PLC and robotics specialist
• can plan and realize smaller projects

Process improvement specialist
Competence program SYNCHRO –

Process improvement specialist Introduction to Lean Production and VSM
LP111
Modules
• SYNCHRO – Introduction to Lean Production and VSM
(LP111)
• Analysing and designing value streams (LP161)
• Systematically designing value added processes (LP261)
• Maintenance strategies for maintenance managers (BM131)
• Technical service: customer-oriented (CO231)
Duration
Prerequisites
No prerequisites Contents
Outcomes • Inventory minimisation as an important basis for increased
The participants are able to work as process improvement spe- productivity
cialists. They understand the Lean Thinking approach and • The principle of pull production control
identify waste in production processes. They can explore the • Advantages compared to conventional production control methods
causes of waste, and plan and implement improvements. They • Types and function of different pull production control methods
assist a Lean Change Agent, support them in their activities • Application of methods
and are responsible for practical realization of improvements. • Kanban – the classic pull principle
• SMED – Optimisation of setup processes with Single Minute
Article number Exchange of Die
582555 • CIP as part of the business game
• Introduction to Value Stream Mapping (VSM)
Outcomes
The participant:
• is able to understand the principles of lean thinking
• knows fundamental methods for improvement
• can develop and implement ideas for meeting customer
requirements and process improvements

Process improvement specialist Process improvement specialist

processes
LP161 LP261
Contents Contents
Outcomes Outcomes
• knows which factors must be taken into account in order to use
value stream mapping in their company

Basics of effective maintenance Effective industrial problem-solving

techniques
IM181 PN142
Contents Contents
• Role of maintenance and technical service • Defining, understanding and communicating problems
• The six typical sources of loss in machines and systems • Troubleshooting using problem-solving techniques
• Maintenance, inspection and repair • Causes of downtime and how to prepare a fault list
• Key indicators for maintenance: • Methods/tools for analysing and eliminating root causes
OEE (Overall Equipment Effectiveness), TEEP (Total Equipment (Pareto, cause-effect diagram, brainwriting, FMEA, measure list,
Effectiveness Productivity), MTBF (Mean Time Between Failures), measure plan)
MTTR (Mean Time To Repair)
• Structure and design of systematic fault detection Outcomes
• Creating maintenance and inspection plans The participant:
• Analysis of weak spots and targeted improvement of machines • can effectively understand and communicate problems
and systems • is able to build a team to start the analysis of a major problem that
• Spare parts management could not be solved individually
• Maintenance organisation • can apply various techniques to identify and eliminate the root
• Evaluation of maintenance work cause of the problem
• Practical examples and exercises • can design and analyse a machine fault list for various production
systems
• is familiar with the different areas and roles of maintenance • applies basic FMEA analysis on industrial systems
• is able to identify the six typical kinds of losses on machine and

Maintenance strategies for Technical service: customer-oriented

BM131 CO231
Contents Contents
• Production systems and their influence on maintenance tasks • Empowering you and your company
• Six typical machine losses • Identifying customer needs and expectations
• The key figures OEE (Overall Equipment Effectiveness) and • Key skills for ‘setting the stage’
TEEP (Total Effective Equipment Productivity) • The communication cycle
• Comparison of maintenance strategies: • Strategic questioning and listening skills
• Firefighting, rotational maintenance, TPM, RCM, RBM, • Handling potential conflict situations
condition monitoring (predictive maintenance) • Personal organisation
• Methods for choosing the right maintenance strategy • ‘Delivering the result’ – customer focus
• Key performance indicators • Achieving customer satisfaction and future commitment
• Process for the introduction of maintenance strategies
• Case studies and exercises Outcomes
The participant:
Outcomes • can explain how their company’s service offering is aligned with a
The participant: specific customer
• knows typical maintenance strategies and their influence on • is able to match and apply the right skills to different types of
productions systems customers and situations
• can choose them dependent on the machines and processes • can choose the appropriate appearance and behaviour according to
in the factory their company and the customer profile
• is able to introduce maintenance strategies, realize them, • can assess and identify the key factors for satisfaction at the
and measure the results using typical performance data customer level

In-company project
Contents
the “Process improvement specialist” competence program.
focus on a typical task for a process improvement specialist,
such as value stream analysis for a selected product, value
stream design, or workplace optimisation.
Outcomes
The participant:
• is able to work as process improvement specialist
• can plan and realize a small Lean Production project

Competence programs
Supply chain management
Divided in two parts, the competence program supply chain manage-

ment starts from fundamentals, and can lead to certification for job-
specific positions.
The first part focuses on fundamentals and covers best practices and
tools while taking a global view of the supply chain. It demonstrates
the importance of an overall outcome rather than the sum of indivi-
dual results.
The second part is dedicated to job-specific learning: It focuses

mainly on role-specific activities, enabling the participant to perform
effectively in a specific position as part of the supply chain.
126
Overview competence programs supply chain management
Courses Competence programs supply chain management fundamentals
Production Production control Process improvement

supervisor specialist specialist Tool setter Warehouse manager
Introduction to supply SCM201

chain management
Supply chain processes SCM212
Courses Competence programs supply chain management
Production Production control Process improvement

supervisor specialist pecialist Tool setter Warehouse manager
Leadership training LS111

module 1
SYNCHRO – Introduction to LP111
Lean Production and VSM
Analysing and designing LP161
value streams
module 2
Systematically designing LP261
value added processes
Business administration BM181
compact
module 3
Production control LP211
methods
SMED – LP131
Reducing setup time
Pull: Kanban and CONWIP LP311
Heijunka: LP301
Levelling and smoothing
TOC: Theory of Constraint LP291
in practical use
maintenance
Maintenance strategies BM131
for maintenance managers
Technical service: CO231
customer-oriented
Fundamentals of Total Pro- LP281
ductive Maintenance
Warehouse role inside the SCM221
supply chain
Managing warehouse lev- SCM231
els and purchasing policies
Warehouse planning SCM241
Improving warehouse pro- SCM251
cesses and activities
Transportation SCM261
management
Warehouse personnel SCM271
management
In-company project
127
Supply chain management fundamentals
Competence program Introduction to supply chain management

SCM201
Modules
• Introduction to supply chain management (SCM201)
• Supply chain processes (SCM212)
Duration
4 days
Prerequisites
Basic knowledge and understanding about the structure of
companies and the roles of functional units
Outcomes
The participants are able to choose the right supply chain strat-
egy to measure and identify priorities. They can recognise the
importance of every department and its influences on the sup- Contents
ply chain. They are familiar with KPIs of every department in This 2-day course covers the following topics:
the supply chain and know how to improve efficiency of the • Introduction
supply chain by a KPI system. They understand the complexi- • Definition, importance and current trends of
ties and risks of global supply chains. They are able to use supply chain management
basic tools in order to optimise a supply chain. • The fundamentals of supply chain management
• Supply chain – Views
Article number • Operations – Manufacturing, MRP, ERP, Inventory, Lean/JIT, TQM
582551 • Distribution – Logistics
• Integration – “Theory of Constraints”
• Game experience – three rounds of a simulation to produce and
distribute a real product
Outcomes
The participant:
• can describe a supply chain and define supply chain management
• can describe the components of industrial manufacturing
• explains the five production environments and their characteristics
• explains the three types of organisation of the production process
• presents an overview of industrial system planning and control
operations
• can differentiate between independent and dependent demand
application
• characterises the concepts of planning priorities and capacities
• issues which drive the three main players in the supply chain
• identifies the four main objectives of management systems for
quality and productivity
• can describe how logistics impacts supply chain management

Supply chain processes
SCM212
Contents
• Three level structure of the SCOR Model
• Processes Plan, Deliver, Make, Source, Return
• The integrated system of performance measurement
• Implementation path
• Level 1:
Identify value proposition, specific strategy and macro
measurement of the supply chain business
• Level 2:
Geographic mapping and configuration of the physical and
information streams of supply chain
• Level 3:
Description, best practices and measurement of the supply chain
activities supporting the objectives of the strategy on level 1 and
the configuration on level 2
Outcomes
The participant:
• can map, configure, address and measure the performance of a
supply chain

Production supervisor
Competence program Leadership training module 1

LS111
Modules
• Leadership training module 1 (LS111)
(LP111)
• Business administration compact (BM181)
Duration
Prerequisites
Vocational qualification Contents
Outcomes • Principles of leadership
The participants are able to work as production supervisor. • Leading is communicating
They understand what makes a good leader and identify the • One-on-one leadership skills
changes necessary to become a good leader. They know their • Leading yourself
role as manager of a team and their tasks. They are familiar
with lean manufacturing and use tools in their production. They Outcomes
are able to lead and manage their team in an efficient way. The participant:
• understands what makes a good leader
Article number • identifies the changes necessary to become a good leader
582553 • understands the principles of management
• knows the key tasks of a manager
• knows different styles of leadership and how and when to
apply them
• knows how and when to delegate

Production supervisor Production supervisor
SYNCHRO – Analysing and designing value streams

Introduction to Lean Production and VSM
LP111 LP161
Contents Contents
• Inventory minimisation as an important basis for increased • Lean thinking as the basis for recording value streams
productivity • Preparatory steps for value stream analysis
• The principle of pull production control • The SIPOC method (Source – Input – People – Output – Customer)
• Advantages compared to conventional production control methods for delineating processes
• Types and function of different pull production control methods • The stages of current state value stream analysis
• Application of methods • Practical implementation of current-state value stream mapping
• Kanban – the classic pull principle using a concrete example
• SMED – Optimisation of setup processes with Single Minute • Stages and restrictions when mapping a new, efficient value stream
Exchange of Die • Customer takt as key performance indicator for designing new
• CIP as part of the business game processes
• Introduction to Value Stream Mapping (VSM) • Practical implementation of future value stream mapping using a
concrete example
Outcomes • Deriving a project plan
The participant: • Fundamental aspects of introducing value stream mapping
• knows fundamental methods for improvement Outcomes
• can analyse the causes of delivery problems and low productivity The participant:
• can develop and implement ideas for meeting customer • is familiar with the method of value stream mapping and will be
requirements and process improvements able to apply it
• can record and present the value-added process and is able to use
the current-state value stream map to identify waste, weak points
and deficits
• understands the design of processes that are lean yet still robust
and stable processes, and is able to apply value stream mapping

Leadership training module 2 Systematically designing value added

processes
LS242 LP261
Contents Contents
• Building and managing teams • Structuring value-added systems and principles of their design
• Roles and group dynamics • Basic principles of value-added systems:
• Team leadership skills flow, pull, reduction of waste
• Handling conflict • Methods and tools for designing flows within the company:
production lines, U-cells
Outcomes • Methods and tools for eliminating bottlenecks: reducing setup
The participant: times with the SMED method, maximum machine availability with
• can explain what constitutes a team, the team cycle and different TPM, ensuring quality failure production
roles within a team • Methods and tools for controlling production according to
• can match individual needs to roles customer demand: Kanban, Heijunka, Just In Time, Just In Sequence
• can explain basic time management techniques • Methods and tools for measuring success:
• understands the importance of building relationships and alliances Key Performance Indicators (processing time, quality rate,
in the business productivity, capital tied up in inventories, and on-time delivery)
• has achieved self-awareness of personal values and behaviour and • Practical examples and case studies
understands how others perceive them
• has identified the perception others have of him/her and the Outcomes
actions necessary to change this, if necessary The participant:
• can describe the basic stages of change and the associated feelings • understands the basic structure of value-added systems, how they
people experience are adapted to specific companies, and the important methods and
• can apply techniques to guide individuals through the transition tools
• has created a plan for development of skills and a specific personal • can apply the basic principles of lean production and is capable of
topic that puts theory into practice determining which methods are important for their company
• has acquired a comprehensive understanding of the application of
the tools and instruments through various practical examples

Business administration compact Leadership training module 3
BM181 LS253
Contents Contents
• First level business indicators: turnover, cost and profit • Developing the leadership personality
• Relationship between business indicators and Key Performance • The leader as coach and mentor
Indicators • Leading through change
• Different kinds of cost: variable, fixed and stepped fixed • Networking and sparring
• How lean manufacturing can help
• Kinds of cost calculation and their consequences for process Outcomes
improvement The participant:
• Process-oriented performance figures • has completed a personal action plan and the results have been
• Case studies presented and discussed in small groups
• Practical exercises and examples • has reviewed key learning so far based on a personal action plan
and is committed to future actions
Outcomes • has identified a sparring partner for continued peer coaching
The participant:
• knows the important key figures and understands the interactions
between production systems
• is able to see the relationship between their managing activities
and influence on performance figures
• is familiar with the kind of cost calculation used by the company
• knows the conflict between local and process optimum

In-company project
Contents
the “Production supervisor” competence program. Detailed
on a typical task for a production supervisor, for example,
shopfloor management, definition of key performance indidca-
tors or conflict management.
Outcomes
The participant:
• is able to operate as production supervisor
• can plan and realize a smaller project with focus leadership
• can present the results and measure the success of project

Production control specialist

Production control specialist Introduction to Lean Production and VSM
LP111
Modules
(LP111)
• Production control methods (LP211)
• SMED – Reducing setup time with SMED (LP131)
• Pull: Kanban and CONWIP (LP311)
• Heijunka: Levelling and smoothing (LP301)
• TOC: Theory of constraint in practical use (LP291)
Duration
Prerequisites
No prerequisites
Contents
The participants are able to work as production control specia- • Inventory minimisation as an important basis for increased
lists. They can plan make-to-order, customer-specific and series productivity
production. They know the criteria for excellent production con- • The principle of pull production control
trol and can handle the conflict between short delivery times, • Advantages compared to conventional production control methods
low inventories and high capacity utilization. They are able to • Types and function of different pull production control methods
choose and implement the appropriate production control • Application of methods
method to suit the specific situation in their company. • Kanban – the classic pull principle
Outcomes
The participant:

Production control specialist Production control specialist
Production control methods SMED –

Reducing setup time with SMED
LP211 LP131
Contents Contents
• Main features, design and structure of efficient value-added • Relationship between batch size and setup time
systems • Reducing setup times as the only way to reduce batch sizes and
• The role, significance and responsibilities of production control inventories in production
in efficient value-added systems • The SMED (Single Minute Exchange of Die) method and its phases
• Production control and the balance between ability to deliver, • The OTED (One Touch Exchange of Die) method
inventory reduction and capacity utilisation • Constructive solutions for fast setup processes
• Criteria and conditions for the control and planning of production • Work organisation options for fast setup processes
• Basic principles and important variables of control and planning: • Influence on production control
replenishment time, min/max-control, safety stock, re-order points, • Practical implementation of methods in a model plant
lot sizes for ordering
• Selected production control concepts summarised and compared: Outcomes
load-dependent order release, cumulative quantity concept, The participant:
Kanban, Theory of Constraints (constraint-focused production), • is able to recognise waste
levelling and smoothing (Heijunka), CONWIP (Constant WIP) • knows the importance of short setup times for fast and economical
• Practical exercises order processing, flexible production and low inventories
• can apply and teach the SMED method
Outcomes
The participant:
• is familiar with typical parameters and manipulated variables in the
production control process
• is able to apply them to strike a balance between ability to deliver,
inventory reduction and capacity utilisation
• is familiar with common methods of production control and their
scenarios and conditions of application
• can select suitable methods for their company

Pull – Heijunka –
Kanban and CONWIP Levelling and smoothing
LP311 LP301
Contents Contents
• Low inventories and high reliability of delivery as basis for • Heijunka – a system for production control and process
excellent productivity improvement
• Function of Pull principle • The principle of levelling and smoothing: from batch production to
• Kinds of Pull: Kanban and CONWIP One-Piece-Flow
• Design of control cycles • EPEI – Every Part Every Interval
• Calculation of control cycles • Typical process interruptions and errors: long setup times,
• Communication in control cycles low machine efficiency, different shift models, distances,
• The process of implementation quality problems
• Case studies • Levelling and smoothing in practice
• Practical exercises • Combination of Heijunka and Kanban
• Application possibilities and limits
Outcomes • Case studies
The participant: • Practical Exercises
• is familiar with the pull principle, its functions and advantages
• knows in which production types Kanban and CONWIP can be Outcomes
applied The participant:
• can design Kanban and CONWIP control cycles • is familiar with the approach of levelling and smoothing
• is able to calculate replenishment times and inventories in buffers • knows in which production types Heijunka can be applied
• can plan processes for implementation of Kanban or CONWIP • can design and calculate Heijunka
• can plan implementation processes for Heijunka

TOC – In-company project

Theory of constraint in practical use
LP291
Contents
the “Production control specialist” competence program.
focus on a typical task for a production control specialist, for
example, design of a Kanban cycle, identification of the right
production control approaches or the implementation of
Heijunka.
Outcomes
The participant:
Contents • is able to operate as production control specialist
This 2-day course covers the following topics: • can plan and realize a smaller project with focus production
• TOC: fundamentals and function control
• The interaction between gating, replenishment and • can present the results and measure the success of project
buffer management
• Influences of inventories: statistical fluctuation of dependent
occurrences – effects of fortune; inventory as function of
replenishment time
• First dimensioning of stock and dynamical modification
• The economical stock and the system of priorities by order release
• Structure and function of gating: protection of bottlenecks,
avoiding overflow in production, correct time for order release
• Sequence control of production orders: How can a very complex
production environment be controlled? How can bottlenecks be
identified?
• EOO in practical using
• Practical exercises
Outcomes
The participant:
• is familiar with the principles, the advantages and disadvantages
of Theory of constraint
• knows in which production types TOC can be applied
• knows the elements and the function of TOC
• can calculate TOC orders


Process improvement specialist Introduction to Lean Production and VSM
LP111
Modules
(LP111)
• Maintenance strategies for maintenance managers(BM131)
• Technical service: customer-oriented (CO231)
Duration
Prerequisites
No prerequisites Contents
Outcomes • Inventory minimisation as an important basis for increased
The participants are able to work as process improvement spe- productivity
cialists. They understand the Lean Thinking approach and • The principle of pull production control
identify waste in production processes. They can explore the • Advantages compared to conventional production control methods
causes of waste, and plan and implement improvements. They • Types and function of different pull production control methods
assist a Lean Change Agent, support them in their activities • Application of methods
and are responsible for practical realization of improvements. • Kanban – the classic pull principle
Outcomes
The participant:


processes
LP161 LP261
Contents Contents
Outcomes Outcomes

Basics of effective maintenance Effective industrial problem-solving

techniques
IM181 PN142
Contents Contents
• Role of maintenance and technical service • Defining, understanding and communicating problems
• The six typical sources of loss in machines and systems • Troubleshooting using problem-solving techniques
• Maintenance, inspection and repair • Causes of downtime and how to prepare a fault list
• Key indicators for maintenance: • Methods/tools for analysing and eliminating root causes
OEE (Overall Equipment Effectiveness), TEEP (Total Equipment (Pareto, cause-effect diagram, brainwriting, FMEA, measure list,
Effectiveness Productivity), MTBF (Mean Time Between Failures), measure plan)
MTTR (Mean Time To Repair)
• Structure and design of systematic fault detection Outcomes
• Creating maintenance and inspection plans The participant:
• Analysis of weak spots and targeted improvement of machines • can effectively understand and communicate problems
and systems • is able to build a team to start the analysis of a major problem that
• Spare parts management could not be solved individually
• Maintenance organisation • can apply various techniques to identify and eliminate the root
• Evaluation of maintenance work cause of the problem
• Practical examples and exercises • can design and analyse a machine fault list for various production
systems
• is familiar with the different areas and roles of maintenance • applies basic FMEA analysis on industrial systems

Maintenance strategies for Technical service: customer-oriented

BM131 CO231
Contents Contents
• Production systems and their influence on maintenance tasks • Empowering you and your company
• Six typical machine losses • Identifying customer needs and expectations
• The key figures OEE (Overall Equipment Effectiveness) and • Key skills for ‘setting the stage’
TEEP (Total Effective Equipment Productivity) • The communication cycle
• Comparison of maintenance strategies: • Strategic questioning and listening skills
• Firefighting, rotational maintenance, TPM, RCM, RBM, • Handling potential conflict situations
condition monitoring (predictive maintenance) • Personal organisation
• Methods for choosing the right maintenance strategy • ‘Delivering the result’ – customer focus
• Key performance indicators • Achieving customer satisfaction and future commitment
• Process for the introduction of maintenance strategies
• Case studies and exercises Outcomes
The participant:
Outcomes • can explain how their company’s service offering is aligned with a
The participant: specific customer
• knows typical maintenance strategies and their influence on • is able to match and apply the right skills to different types of
productions systems customers and situations
• can choose them dependent on the machines and processes • can choose the appropriate appearance and behaviour according to
in the factory their company and the customer profile
• is able to introduce maintenance strategies, realize them, • can assess and identify the key factors for satisfaction at the
and measure the results using typical performance data customer level

In-company project
Contents
the “Process improvement specialist” competence program.
focus on a typical task for a process improvement specialist,
such as value stream analysis for a selected product, value
stream design, or workplace optimisation.
Outcomes
The participant:
• is able to work as process improvement specialist
• can plan and realize a small Lean Production project

Tool setter
Competence program Basics of effective maintenance

Tool setter
IM181
Modules
• SMED – Reducing setup time with SMED (LP131)
• Fundamentals of Total Productive Maintenance (TPM)
(LP281)
Duration
7 days
Prerequisites
No prerequisites
Outcomes
The participants are able to work as tool setters. They know the Contents
importance of high machine efficiency. They can measure the This 2-day course covers the following topics:
efficiency of their machines, and can identify and eliminate loss • Role of maintenance and technical service
and waste using problem-solving techniques. They know the • The six typical sources of loss in machines and systems
important elements of an efficient maintenance program and • Maintenance, inspection and repair
can implement these for their machines. • Key indicators for maintenance:
OEE (Overall Equipment Effectiveness), TEEP (Total Equipment
Article number Effectiveness Productivity), MTBF (Mean Time Between Failures),
582556 MTTR (Mean Time To Repair)
• Structure and design of systematic fault detection
• Creating maintenance and inspection plans
• Analysis of weak spots and targeted improvement of machines
and systems
• Maintenance organisation
• Evaluation of maintenance work
• Practical examples and exercises
Outcomes
The participant:
• is familiar with the different areas and roles of maintenance

Tool setter Tool setter
Effective industrial problem-solving SMED –

techniques Reducing setup time with SMED
PN142 LP131
Contents Contents
• Defining, understanding and communicating problems • Relationship between batch size and setup time
• Troubleshooting using problem-solving techniques • Reducing setup times as the only way to reduce batch sizes and
• Causes of downtime and how to prepare a fault list inventories in production
• Methods/tools for analysing and eliminating root causes • The SMED (Single Minute Exchange of Die) method and its phases
(Pareto, cause-effect diagram, brainwriting, FMEA, measure list, • The OTED (One Touch Exchange of Die) method
measure plan) • Constructive solutions for fast setup processes
• Work organisation options for fast setup processes
Outcomes • Influence on production control
The participant: • Practical implementation of methods in a model plant
• can effectively understand and communicate problems
• is able to build a team to start the analysis of a major problem that Outcomes
could not be solved individually The participant:
• can apply various techniques to identify and eliminate the root • is able to recognise waste
cause of the problem • knows the importance of short setup times for fast and economical
• can design and analyse a machine fault list for various production order processing, flexible production and low inventories
systems • can apply and teach the SMED method
fix of the problem

Tool setter
Fundamentals of Total Productive

Maintenance
LP281
Contents
• Lean Manufacturing and TPM
• The OEE (Overall Equipment Effectiveness)
• Total Productive Maintenance: Targets and elements
• TPM as part of production systems
• Measuring and analysing of machine losses
• The important implementation steps
• TPM as a holistic concept with influences and interactions to the
whole company
• Case studies and practical exercises
Outcomes
The participant:
• knows the maintenance strategy TPM, its elements and targets
• recognises the need of TPM
• are able to implement parts of TPM
• can help colleagues to apply TPM

Warehouse manager
Competence program Warehouse role inside the supply chain

Warehouse manager
SCM221
Modules
• Warehouse role inside the supply chain (SCM221)
• Managing warehouse levels and purchasing policies
(SCM231)
• Warehouse planning (SCM241)
• Improving warehouse processes and activities (SCM251)
• Transportation management (SCM261)
• Warehouse personnel management (SCM271)
Duration
8 days
Prerequisites
Introduction to supply chain management
Contents
The participants are able to work as warehouse managers. • The supply chain
They can identify opportunities for improvement. • Logistic-Production model and the reference parameters
They are able to recognise the impact of actions taken at the • The warehouse role and its influence on the service level
warehouse level on the supply chain. They increase the analy- • Service level
sis capability of the overall impact on the business. They can • Stock versus service
use appropriate tools and processes to maximise the • Internal and external supply network
warehouse performance. They can define goals and lead a • Planning systems and replenishment
team.
Outcomes
Article number The participant:
582552 • can map the supply chain
• is able to measure the warehouse performance according
to the right KPIs

Warehouse manager Warehouse manager
Managing warehouse levels and Warehouse planning

purchasing policies
SCM231 SCM241
Contents Contents
• Stock and service - management models of stocks and their impact • Dimensioning of structure and resources of the warehouse
on warehouse dimensioning • Warehouse characterization according to stored materials and
• Safety stock and service level automation level
• Evaluation, monitoring and control of stocks • Warehouse types on the distribution network
• Purchasing activities related to logistics agreements • Characteristics of different typologies of warehouses
• Inventory management: report and corrective actions • Dimensioning methodologies
• Layout and allocation
Outcomes • IT systems
The participant: • Material handling
• knows how to balance the warehouse levels according to the • Warehouse performance
costs and service
• can apply the cross-analysis methodology Outcomes
The participant:
• is able to work in a safe and efficient way
• knows the relevant tools and methods for improvement
• is able to create and improve work plans
• is able to communicate failures and problems

Warehouse manager Warehouse manager
Improving warehouse processes and Transportation management

activities
SCM251 SCM261
Contents Contents
• Value stream mapping • Defining, understanding and communicating problems
• Continuous Improvement Processes • Types of logistics and transportation management
• Different types of transportation: Physical factors and service
Outcomes • Land transportation
The participant: • Transportation role inside the company
• is able to map the value stream inside a warehouse • Import/export and incoterms
• can identify types of waste
• can apply continuous improvement methods Outcomes
The participant:
• is able to describe the logistics and transportation factors critical
to the supply chain

Warehouse manager
Warehouse personnel management
SCM271
Contents
• Warehouse activities organisation
• Needs analysis
• Safety rules in the warehouse
• Warehouse Manager role
• Managing staff
• Delegation and goal-oriented management
• Performance measurement and recognition
• Internal and external personnel
• Team work
• Multicultural teams
Outcomes
The participant:
• can define roles and tasks in a team
• is able to manage personnel and knows how to motivate and
how to build harmony

Festo worldwide
Argentina Finland Latvia Slovakia
Festo S.A. Festo Oy Festo SIA Festo spol. s r.o.
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Festo, UAB Slovenia
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Partizanų 63M
Festo Pty. Ltd. Festo Eurl IC Trzin, Blatnica 8
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Course Catalog TaC International 2015 - EN

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Course Catalog TaC International 2015 - EN

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Training and Consulting

Course catalogue 2015

Are you satisfied with your current productivity?

Festo is a global engineering and manufacturing company that maintains its

Our portfolio combines training courses with tailor-made Knowledge Checks,

Dr. Daniel Boese Dr. Theodor Niehaus

18 PN111 Modern industrial pneumatics

46 LP111 SYNCHRO – Introduction to Lean Production and VSM

64 LS111 Leadership training module 1

86 Competence programs maintenance

102 Competence programs mechatronics

126 Competence programs supply chain management

What makes us engineers of productivity?

In a word, this makes us engineers of productivity.

Security Simplicity Facts & figures:

at any time and in any situation, you can

We give our all for you – in customer sup-

this increases one thing: your productivity. of our collaboration.

Training in technology and

Manufacturing know-how Globally qualified trainers Methods and formats

And we can use this experience

Our approach is competency-

What we train Technology How we train

Our training formats and

Improving specific Key Per-

Optimising production Principles Benefits and results

Profound technical expertise

For over 40 years, we have been providing support

We set the highest standards for our training.

Our trainers know the areas of work of your partici-

Modern industrial pneumatics Modern industrial pneumatics for operators

18 More information: www.festo-tac.com

Systematic safety improvement in Modern industrial hydraulics

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Mastering mobile hydraulics Proportional hydraulics

20 More information: www.festo-tac.com

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CODESYS version 2 – CODESYS version 2 –

Article number Article number

22 More information: www.festo-tac.com

CODESYS version 3 – CODESYS version 3 –

Article number Article number

More information: www.festo-tac.com 23

Maintenance and troubleshooting of Technical communications

24 More information: www.festo-tac.com

Simatic S7 analogue and PID control S7 workshop

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26 More information: www.festo-tac.com

Valves in process automation Principles of industrial measurement

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Practical mastery of closed-loop control Fundamentals of closed-loop control

28 More information: www.festo-tac.com

Water purification processes Safe and efficient water transport

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Key processes of wastewater transport Fundamentals of modern

30 More information: www.festo-tac.com

Monitoring, controlling and optimising Energy optimisation in water and

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Fundamentals of water technology Operating membrane filtration processes

32 More information: www.festo-tac.com

Mastering rapid sand filtration Pneumatics for water management

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Robotics – Motion control solution CMCA

34 More information: www.festo-tac.com