Offers for professional qualification

The two-day practical seminar on factory planning provides comprehensive basic knowledge about the planning of versatile factories. From factory analysis to structure planning and layout planning, participants in this training course learn how factories are designed today for the future. Practical examples and workshops round off the programme.

During the practical seminar the participants learn ...

• the process model of factory planning,
• how a material flow analysis is carried out,
• how to structure a factory in a sensible way,
• how to develop a layout step by step and
• which means modularity.

Detailed information on the training programme

In the scope of this training course you will be taught in the premises of the newly designed IFA learning factory how to successfully put the theoretical knowledge of factory planning into practice - no matter whether you are planning a new factory or want to reorganise an existing production. Selected methods will be explained in a targeted manner, application possibilities and limits will be shown and then applied by you in a fictitious factory planning project in the learning factory. Here you will follow the factory planning procedure laid down in the VDI guideline 5200 and learn when which method can be used to plan a modern factory efficiently. In addition, you will prepare and moderate various factory planning workshops in the role of factory planner - from the recording of all relevant process data to structure planning and layout workshops. Finally, the layout variants worked out in groups will be compared, jointly evaluated and the best variant implemented in the learning factory in order to get a real impression of proven design guidelines.

Detailed information on the training programme

The training module "Production Controlling" shows you how the logistical performance of a production system can be measured on a model-based basis and how, based on this, a more efficient design of operational production and logistics processes can be achieved. Starting with an introduction to important production-logistic basics and cause-and-effect relationships, models and procedures (throughput diagrams, production characteristics, supply diagrams etc.) are presented, which enable a description and KPI-based analysis of the logistic system behaviour of a production and can be used, for example, to determine capacity bottlenecks or work systems that determine throughput and delivery times. The different approaches and key figures will be discussed together and their possible applications in production controlling will be shown.

In order to provide you not only with theoretical contents but also with practical experience regarding the application and implementation of model-based production controlling, a major focus of the training is on the practical application of the contents learned. For this purpose you will be put into a real operating situation in the IFA Learning Factory and take on the position of a helicopter manufacturer. While you control the incoming customer orders through your production, operating data is continuously recorded, which subsequently enables you to measure and evaluate the logistical performance of your production using the learned procedures and models. Following the first round of the game, a joint evaluation of the realised performance of the production system is carried out by discussing the impressions you have experienced, as well as a model-based analysis and discussion of the recorded operating data. Based on a target/actual comparison regarding the logistical performance towards your customer, you will then analyse the individual work systems of your production in order to identify causes of deviation with the help of the logistical key figures and derive improvement measures to increase the logistical performance. In this context, you will learn, among other things, how to evaluate the inventory and throughput time behaviour of work systems, to check and redefine planning parameters or to define measures with regard to production planning and control (PPC), such as determining batch sizes or sequence rules for the processing of orders. Then, applying the previously defined optimisations, a second round of the game takes place to check whether the changes derived in the course of production controlling can bring about the desired performance of the production system.

Detailed information on the training programme

The module "Production Planning and Control (PPC)" is designed to support you in selecting suitable methods for planning and controlling your production and logistics processes in line with your requirements by first creating a common understanding of production logistics principles and interrelationships as well as relevant key figures. Furthermore, you will get an overview of common planning and control procedures and learn about their individual advantages and disadvantages as well as application requirements.

In addition to the theoretical part, a central focus of our training is on the practical application and implementation of the contents learned. For this purpose you will take over a helicopter production in the IFA Learning Factory and be put into a real operating situation. Confronted with the typical conditions of a production, such as spontaneously occurring rush orders, high stocks in front of individual work systems, time-consuming set-up processes or large batch sizes, customer orders are controlled by the production department and relevant key figures, such as throughput times, capacity utilisation or adherence to delivery dates are analysed. This is followed by a joint evaluation of the realised performance of the production system as well as an analysis and discussion of your experienced impressions and relevant key figures, in order to be able to draw conclusions for the optimisation of the PPC based on the previously learned knowledge. In a second round of the game, the PPC is then optimised according to the improvements made, and a better logistical performance of the production system is achieved by, for example, changed batch sizes, new rules for order release or an adapted processing sequence on the work systems. In this way, you will learn directly how you can influence the performance of your production system through modified parameters or modified control procedures within the PPC.

Detailed information on the training programme

Use digitalisation to keep a permanent eye on your logistics processes and key figures and to ensure precise feedback on current orders! In this training you will become part of a learning factory. You will experience which data and logistic models can be used to analyse production transparently. You will interpret real feedback data and discuss possible applications in your own company within the group.

Our Contents

• What does production controlling involve?
• How can feedback data from production be collected and evaluated in real time?
• Which indicators and target figures are relevant?
• What benefits can you derive from logistics models to control your production?

Your Benefit

• You will get to know the potential of automatic acquisition of feedback data from production.
• You apply logistic models for the evaluation of production data in a practical way.
• You derive conclusions for the production control in your company.

Detailed information on the training programme

In the training course "Basics of Lean Production", the history and significance of Lean Production is explained. As a participant, you will be familiarised with the philosophy and basic idea of lean production. Among other things, you will learn how to recognise the seven types of waste in your own company and then eliminate them in order to only do what your customers are prepared to pay for. Furthermore, you will learn basic methods of Lean Production in a diversified mixture of theory and practice. These include, for example, the Continuous Improvement Process (CIP), so that not a day goes by in your company without improvements, or Visual Management, the consistent application of which brings with it an enormous reduction in search times. Further training contents, which should help you to make the processes in your company highly efficient, are 5S, SMED, Poka Yoke, standardisation, milk run as well as the introduction of a material and production kanban. Especially the implementation of the production kanban as a possibility of pull control in a real assembly system of the IFA learning factory will clearly show you the differences to a system that is controlled according to the push principle. After completing this module, you will have all the necessary knowledge to visit the other modules of our Lean Management offer.   

Detailed information on the training programme

In the training "Lean for executives" you will learn basic methods of Lean Production and apply them directly in practical sessions. Especially by applying these methods, it will be easier for you to design efficient processes in your own company. Among other things, you will be introduced to the seven types of waste and the continuous improvement process (CIP). You will also learn about lean methods and principles such as 5S, SMED, Poka Yoke, standardisation, milk run and visual management. During the course of the training, you will also convert the initial push control of our real assembly system to pull control using Kanban and thus learn the differences between the various types of control, for example with regard to stock and throughput times.

The introduction of lean is always associated with change. Therefore, this training course also focuses on the role of managers and the behaviour of employees in change processes. You as a manager or project manager will learn, among other things, what possibilities there are for motivating employees, how to overcome obstacles faced by employees and how to resolve conflicts between them. Furthermore, the importance of leadership, e.g. by recognising the fears of employees and different leadership styles are emphasised, because even incorrect leadership is a waste.

Detailed information on the training programme

In the "Lean Administration" training course you will learn how to improve your business processes. In a diversified mixture of theory and practice, you will learn basic methods of Lean Administration. First of all, the general principles and objectives behind the Lean Administration approach are conveyed and successful company examples are presented. This is followed by a basic understanding of the various types of waste in the office. These range from the way to the printer to the ineffective moderation of regular meetings.

Other basic methods that will be introduced to you in this context are the 5S in the office, which particularly addresses cleanliness in the workplace; visual management, so that you can immediately see whether everything is in its right place; office Kanban as a way of simple inventory management and orderly storage of office supplies to streamline your procurement processes. Finally, a selection of recommendations will be given to you on how to make both the handling of e-mails and the procedure at meetings more effective and efficient.

In order to be able to initiate changes, you must first get a picture of the current situation. For this reason you will get to know the Makigami methodology. This helps you to visualise your processes and to identify waste and problems. Finally, you will be presented with a procedure for reaching an office in flux based on a detailed analysis of the current situation.

Detailed information on the training programme

The training course "Ergonomics at the workplace" is based on two thematic focuses. In the first part we introduce you theoretically to the challenges of demographic change and its consequences. You will learn what consequences can be derived from this for your performance and that of your employees. In addition, we provide you with the basics and practical measures on how you can ensure your long-term and sustainable performance through ergonomic and age-appropriate workplace design. This includes, among other things, the correct arrangement of work equipment as well as the correct adaptation of workstations to the work task and the respective employee.

In the second section, the content you have worked out is tested together with you in a practical learning environment. In the real assembly system of the institute's own learning factory, we introduce you to the requirements for ergonomic workplace design in production and in the office. Furthermore, we enable you to "age" by using age simulation suits and thus to experience the changed requirements of workplace design, work tasks and the workflow of older employees and thus to better understand them. The experiences and lessons learned are then evaluated together. In addition, by providing you with helpful documents, we enable you to design your own workplace according to ergonomic criteria and to disseminate the topic in your company.  

Detailed information on the training programme