Successful trainings are "Process Control", "Problem Solving" and "Sales"
We offer on-demand training (on site, internet and combined) on a wide range of topics including:
- Auditing * Process Control - Setup and implementation
- Inquiries / orders * Problem solving (with root cause)
- Sales, exporting, Fair participating and visiting * Foundry non-conformity (ferrous alloys)
- Quality requirements and evaluation * Energy saving
- Evaluation of suppliers * Management control setup and implementation
- Final Inspection of products * Designing of foundries
- Design of castings, forgings * Calculations for melting, engineering, moulding... in foundries
Training of the month: scroll down
Process control - Running since April 1st, 2016
New group has started since January 15, 2017
Activities consist of operations / steps and form a process. This process can be production or any other activity as is selling, purchasing, planning, training…
The target is to get a process that is very efficient (lowest cost) and has a short and consistent lead time (production time) with a high and consistent quality (low rejection rate).
Process control is the technique that first will evaluate the actual process concerning effectiveness, use of new techniques, fresh ideas…
Then, after having set / planned this new process, all the current techniques of six sigma, statistical process control, lean manufacturing… will be applied for the choice of the best and affordable process.
The WIP (Work In Progress) can easily be decreased by 30 % within 6 months. Lead time reductions of 50 % are common. Cost reduction of 15 to 20 % can be achieved and rejection can be decreased to 50 % of the actual value in a year.
But the extra benefit will be that it leads to correct and complete instructions for all (difficult first, easy ones later) activities. This will decrease the scrap and repair rate but will also provide the company knowledge and experience on paper (less dependent of operators, leaders and managers).
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The training will be done in 5 steps:
1. Inventory of activities
All activities (operations) are listed as they are performed now in the company. All activities because they all have an influence on the process result.
For this training, one operation is taken for further working out (maybe melting, moulding or another).
The inventory must done by process engineers with department leader and will be stepwise corrected and commented by trainer.
2. Classifying and improving activities
The activities are classified in value adding (paid by customer), non-value adding (not paid by customer) and problem related.
The value adding will be checked for efficiency; the non-value adding must be removed or at least decreased (in time and cost) and the problem related should be temporarily (solved by root cause action). The evaluation is done for two aspects: cost and lead time.
At the end, after proposal discussing with the trainer, the preferred process is set and will be the start of step 3.
3. Setting up FMEA
The FMEA is performed for identifying the “risk”. This can be done (separately) for cost, lead time, environment & safety… In this training, the FMEA is executed (concerning cost and lead time) and checked by all departments: process engineering, quality control, sales and production management. The trainer will guide the process engineers and department leaders how to use the FMEA-system.
The high ranked activities are first in line for further evaluation. The FMEA is a dynamic activity because each change in the process leads to another result.
The result of the FMEA will be the start of step 4.
4. Adding influences on high risk activities
For the high ranked activities, the inventory of influences is setup. These influences are evaluated on how to control them, which working limits are to be put and testing / checking procedure is set. Defining and resetting FMEA per influence.
The influences are completed with the working and rejection limits per activity.
This step will be finalising the influence controlling and start of step 5.
5. Setting up / completing instructions = controlling
The instructions will consist of a clear description of the activity, the influences and how to monitor and control them. The limits will be working limits and rejection limits.
It will contain, as last chapter, the problems from the past and how to act when they re-appear.
The trainee will have learned (used one operation) have to use the PC-methodology for his production process and can apply it on the complete process. The trainee can decide if he wants to share data / answers / comments with other participants or that it will be one on one with the trainer (Gietech BV) and kept secret.
The training is completely given by internet and will, in practice (due to the collecting of data by the trainees), take between 6 and 9 months (depending on the available time of the trainee. The trainee receives the guideline book (how to set up Process Control).
The cost is 750 EUR. Price is net price (excluded VAT if required – not if ordered by a company-, local and international taxes, bank costs) and must be paid before the training starts. In case of subscription, an invoice (with payment details) will be sent.
Training of the year 2017 : Problem solving
How to solve problems permanent?
This training will teach you that the next steps are required:
1. Identify the problem and describe it (why, how frequent, how severe, where....)
2. Explain the problem. If you cannot explain it, you risk that it is incorrect identified and definitely you will not find the root cause
3. Brainstorm for solutions, but identify every potential negative effect of them (on other aspects)
4. Decide about the action and perform it
5. Check the result concerning the problem and potential negative effects
6. Standardise the solution in instructions and guidelines
7. File the history with successful and non-successful actions
The training is by internet – email and will need about 3 months (depending on the time you need). The cost is 250 EUR per company.
Please contact us for more information