Darmstadt | 28.11.2012Darmstadt | 28.11.2012

Learning factories:Excellence in education of manufacturing engineering

Process Learning Factory CiP

Prof. Dr.-Ing. E. AbeleProf. Dr.-Ing. J. MetternichDipl.-Wirtsch.-Ing. Stefan Seifermann

CiPCiP Centre forindustrial

Institute of Production Management,Technology and Machine Tools

www.prozesslernfabrik.de

CiPCiP industrialProductivity

gyTechnische Universität Darmstadt

Welcome to o r Instit te PTWCiPCiP

Welcome to our Institute PTW

Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele / Prof. Dr.-Ing. J. Metternich | 221128Se1 | 1

Initial sit ation for a ne approachCiPCiP

Initial situation for a new approach

Survey among 50 staff managers and directors:

• What are alumni of Technische Universität Darmstadt good at?

Wh i d f i t ?• Where is a need for improvements?

Results

• 70% of the students are going to work within the departments of production development or quality assurance

Results

production, development or quality assurance

• As future employees in production, the alumni lack of:

Knowledge about processes and Lean methods

Skills in the establishment and adaption of production systems

Perception of ideal workflows in manufacturing and enthusiasm for continuous improvement

Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele / Prof. Dr.-Ing. J. Metternich | 221128Se1 | 2

for continuous improvement

Learning by experience on the shopfloor

CiPCiPg y p p

builds lasting knowledge and skills

We keep in mind only a part of the things we perceive:

10% 20% 30%

10% of whatwe read

20% of whatwe hear

30% of whatwe see

50%70% 90%

50% of whatwe hear & see

70% of whatwe say

90% of whatwe do

Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele / Prof. Dr.-Ing. J. Metternich | 221128Se1 | 3

First steps Q estions considered from idea to realisationCiPCiP

First steps: Questions considered from idea to realisation

R f t i ? M d P f i l- Range of topics?- Didactic methods?

- Managers and Professionals from industry?

- Bachelor and Masterstudents?students?

Hardware Realisation

Content Target groups Initial questions(2005)

- Partners?- Products?

Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele / Prof. Dr.-Ing. J. Metternich | 221128Se1 | 4

- Provision of finance?- Used Technologies?

Process learning factory CiP at Technische Universität

CiPCiPExpansionInitial

g yDarmstadt: Milestones in recent years

ExpansionInauguration

ExpansionMachining

Initialsituation

? ??One vision

Award winnerExpansion

Intra-logistics

Start of Expansion

??-Many questions

Trans-EuropeanBuilding concept Education

pIndirect processes

Trans EuropeanDissemination

Reality

Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele / Prof. Dr.-Ing. J. Metternich | 221128Se1 | 5

2005 2006 2007 2008 2009 2010 2011

CiP – the product range is chosen to cover different production

CiPCiPC t e p oduct a ge s c ose to co e d e e t p oduct ocharacteristics

Low Variety Production: Pneumatic Cylinder• Realization of complete value treamincluding machining assembly and indirectincluding machining, assembly and indirectprocesses (order fulfillment)

Pneumatic cylinder

Low Volume, high variety: Gearbox Motor

Chaku Chaku Machining: Key Fob (as give away)

• About 4.000 different variantsare possible

y ( g y)• Flexible Adaption ofMachining Centers toVolume and Product

Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele / Prof. Dr.-Ing. J. Metternich | 221128Se1 | 6

Electric Motorare possible

Key Fob

The hardware in the learning factory represents

CiPCiPg y p

a midsize factory in series production

Turning machine Milling machine Planning Board Assembly lineTurning machineIndex C65

Milling machine Deckel Maho DMC 50H Supermarket Assembly pneumatic cylinder

WZ-

Wag

en1

-NE

/SB

WZ-

Wag

en2

– C

S/B

A

IV-1

IV-4

PB

Mon

tage

PB

SB

A

LernzelleJIT

TUR

N 250

PB Fertig

ung

Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele / Prof. Dr.-Ing. J. Metternich | 221128Se1 | 7

DemonstratorLean Machining

Learning cells Heijunka-Board Machining

Goods receivingsupplier

Assembly linegeared motor

Properties and probable application ranges of learning factoriesCiPCiP

ges

Properties and probable application ranges of learning factoriespl

icat

ion

rang

Education Advanced Training Knowledge platform Network

Pro

babl

e ap

p g g p- Universities- Vocational

schools- Enterprises

- Groups- Small and medium

sized enterprises- Job-seekers

- Innovations- Testing

environment- Application

- Learning factories

- Industry- High schools

factoryLearning

s

- Methodology- Technics- Organisation

- Real products- Machines- Assembly

- Slides- Didactic cells- Demonstrations

- Researcher- Trainer- Factory staff

Pro

perti

es

Didactic Experimental Area Visualization Workforce

Organisation Assembly Demonstrations Factory staff

Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele / Prof. Dr.-Ing. J. Metternich | 221128Se1 | 8

Integration of the process learning factory

CiPCiPg p g y

in the education of mechanical engineering students

HiW

i)

Master thesis

assi

stan

t (H

Tutorial /Advanced Design Projects (ADP)

Res

earc

h a

Mas

ter

Lectures: Management of industrial production, Machine Tools and robots, Automation

or wor

kfor

ce,

Bachelor thesis

Bac

hel

Stu

dent

wLecture: Technology of

f i

Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele / Prof. Dr.-Ing. J. Metternich | 221128Se1 | 9

manufacturing processes

“Learning-Cells” on the shop floor provide

CiPCiPg p p

a short theoretical wrap-up of each method

EXAMPLE SMED / QUICK-CHANGEOVER

„Learning-Cell“:

3 to 6 content tables

H d hibiti Hardware exhibitionsupports the transferto practical application

Step 1 MOTIVATIONDescription problem in manufacturing and its consequence

Step 3 IMPLEMENTATIONDescription of each implementation step

Step 2 FUNCTIONALITYVisualization of functionality and elements

Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele / Prof. Dr.-Ing. J. Metternich | 221128Se1 | 10

Step 4 EFFECTSDemonstration of workflow and process improvement

The CiP curriculum addresses employees

CiPCiPp y

who are involved in the implementation of Lean methods

Phase 1: Lean understanding Phase 2: Lean core elements Phase 3: Lean culture

Lean Material Flow

Lean Basics Just-in-Time**• Pull systems, Kanban, supermarketProduction control**

Lean Thinking

Lean Machining

Basics and diagnosis**• The need for Lean• 7 types of waste• Value stream mapping

OEE

Leadership for continuous improvement processes*• Improvement and leadership

routines

Production control• Heijunka, LevellingFlexible manpower systems**• Yamazumi, flexible line design

Lean Machining• OEE

Value stream design**• Pull principle• Flow production• In-takt production

• Coaching principles

Value added excellence in indirect processes**• Lean Office with 5S

J b t t l i

Quick change-over (SMED)**• Change-over time optimisationMaintenance**• Strategies, TPM

Ability to develop operational excellence in the individual

M i t l i **

Lean Quality

In-takt production• Value stream design

Quality techniques**•Lean quality assurance•Poka Yoke

• Job structure analysis• Value stream analysis and

design

Methods- and transfer- com-petence for Lean trainers*

g ,Cellular Manufacturing*• Selection of Machining Org.

the individual environment

Measuring system analysis**• Capability of measuring systemsMachine capability**•Machine acceptance testProcess capability and SPC**

• Problem solving• Jidoka

petence for Lean trainers•Sensitisation for Lean•Moderation techniques•Workshop development

* 1-day-Workshop

Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele / Prof. Dr.-Ing. J. Metternich | 221128Se1 | 11

•SPC, control chartsTransformation of CiP to a Lean best practice enterprise

** 2-day-Workshop

Pre io s cooperation partners in research and ed cationCiPCiP

Previous cooperation partners in research and education

Research and vocational education with partner companies Management Training

Mahr

Vocational education with regional SME

Mahr

Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele / Prof. Dr.-Ing. J. Metternich | 221128Se1 | 12

In the past 5 years a range of managers and professionals

CiPCiPp y g g p

have been educated at process learning factory CiP

840

120

250

220

16090

LogisticsMachining Production control

Executives, Managers, Directors

Educated managers and professionals

Assembly

Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele / Prof. Dr.-Ing. J. Metternich | 221128Se1 | 13

Directorsprofessionals (total) Professionals / Employees

Research Topics of the CiP TeamCiPCiP

Research Topics of the CiP-Team

Competence Development for Continuous Improvement Processesp p p• Methods for institutionalization of continuous improvement processes in

production environments• Competency development for employees in continuous improvement

processes

• Holistic approach for flexible machining in Germany, especially by Cellular Manufacturing

Flexible Machining

• Productivity improvements via implementing low-cost-automation in machining

Lean Production and Information Technology• Simulation-based analysis and design of lean material and information

flows• Supporting lean production systems through information technology

• Design and optimization of in-house value streams according to „Just-In-Time“ principlesC ti d i l t ti f fl ibl d ti d i t l i ti

Flexible Production and Intralogistic Systems

Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele / Prof. Dr.-Ing. J. Metternich | 221128Se1 | 14

• Conception and implementation of flexible production and intralogisticsystems

2011: Foundation of the „European Initiative on Learning

CiPCiP„ p g

Factories“ with the lead of TUD/PTW

Universities in Europe that

Escola Superior de Tecnologia de

Universities in Europe thatwork with CiP (extract)

• Escola Superior de Tecnologia de Setubal

• Ecole Centrale de Lyon

• Politecnico di Milano

• TU Wien

• University Split

• Hungarian Academy of Science

Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele / Prof. Dr.-Ing. J. Metternich | 221128Se1 | 15

• Stockholm Institute of Education

Our vision for the year 2020:

CiPCiPy

Model company at Technische Universität Darmstadt

Machining Assembly

Engineering Logistics

Machining Assembly

g g g

Administration Traffic

ServicesIntention of the model company

-Enlargement of current education offerfor students and industry employees

- Integration and cooperation of severaldepartments in a common object

Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele / Prof. Dr.-Ing. J. Metternich | 221128Se1 | 16

for students and industry employees-Research in comprehensive processes

departments in a common object-Motivation for multidisciplinary research activities

Yo r contact persons at Process Learning Factor CiPCiPCiP

Your contact persons at Process Learning Factory CiP

Stefan SeifermannEberhard Abele Joachim Metternich

Office: L1|01 230Phone: -75305E-Mail: seifermann@...

Stefan SeifermannDipl.-Wirtsch.-Ing.Team Leader

Office: L1|01 109Phone: -2156E-Mail: abele@...

Eberhard AbeleProf. Dr.-Ing.Head of the Institute

Office: L1|01 106Phone: -2156E-Mail: metternich@...

Joachim Metternich Prof. Dr.-Ing.Deputy Head of the Institute

Office: L1|01 231Phone: -75812E-Mail: czajkowski@...

Stefan CzajkowskiDipl.-Wirtsch.-Ing.

Office: L1|01 233Phone: -6551E-Mail: cachay@...

Jan CachayDipl.-Wirtsch.-Ing.

Office: L1|01 230Phone: -6550E-Mail: boellhoff@...

Jörg BöllhoffDipl.-Wi.-Ing.

E Mail: czajkowski@...a cac ay@

Office: L1|01 231Phone: -6840

Christian HertleM.Sc.

@

Office: L1|01 231Phone: -6622

Michael TischDipl.-Wirtsch.-Ing.

Office: L1|01 233Phone: -75659

Markus RößlerM. Sc.

Office: L1|01 233Ph 75303

Manuel WolffDipl.-Ing.

E-Mail: hertle@...

Office: L1|01 228Ph 6823

Felix WiegelDipl.-Ing.

E-Mail: tisch@...E-Mail: roessler@...

Prof Dr -Ing E Abele

Office: L1|01 107

Annette HebTeam Assistant

Office: L1|07 202

Christoph SchwarzTechnician

Phone: -75303E-Mail: wolff@...

Phone: -6823E-Mail: wiegel@...

Prof. Dr.-Ing. E. AbeleProf. Dr.-Ing. J. MetternichInstitute of Production Management, Technology and Machine Tools Technische Universität Darmstadt

Petersenstr. 30, 64287 Darmstadt, Germany

Phone: (06151) 16 -

Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele / Prof. Dr.-Ing. J. Metternich | 221128Se1 | 17

Office: L1|01 107Phone: -6421E-Mail: heb@...

Office: L1|07 202Phone: -75302E-Mail: schwarz@...

Phone: (06151) 16 - …E-Mail: …@ptw.tu-darmstadt.de

www.prozesslernfabrik.de