is your workforce ready? - tooling u-sme · 3 instructor-led training toolingu.com | 866.706.8665 3...

TOOLINGU.com

Is your workforce

READY?INSTRUCTOR-LED TRAINING CLASS CATALOG

2 Instructor-Led Training

The MosT Flexible soluTion. The most precise training for your people.Tooling u-sMe offers a wide variety of training options in various learning formats, specifically designed to meet corporate training and development needs.

The best training reflects the specific roles in your organization. it’s true that manufacturing knowledge and skills are relatively universal, but at the end of the day, you have your specific processes, and your people have knowledge and skills specific to your organization.

Tooling u-sMe will work with you to customize, create, and tailor a training program to specifically address your group’s needs. start building your own custom workforce development program from the following:

instructor-led classes (traditional and virtual classrooms) online training books and videos (hard copy or digital) that complement your training program

sMe Certifications, self-assessments, and certification review programs

Tell us your problem and we will find your solution.

Call 866.706.8665 or visit us online at toolingu.com.

3 Instructor-Led Training 3ToolingU.com | 866.706.8665

INTRODUCTION

Instructor-Led Training: Tooling U-SME Instructor-Led Training will help develop your team into a knowledgeable

manufacturing workforce that is equipped with relevant, job-focused content. Tooling U-SME has decades of

experience developing technical content and providing expert-led instruction in a variety of key manufacturing areas.

Whether with customized or off-the-shelf training programs, Tooling U-SME’s instructors take complex concepts

and make them easy to grasp. We will work with you to create the right program that meets your company’s specific

objectives and goals.

In the following sections of this catalog, you will find descriptions of our most popular Instructor-Led Training

Courses. We offer a wide variety of courses that can be customized to meet your needs. If you don’t see what you are

looking for on this list, please call your sales representative to inquire.

Our Instructors: Tooling U-SME instructors are professionals in their field. Each of our instructors are hand-picked

based on their experience, passion, and ability to engage students. Our instructors also provide consulting services

when needed to address immediate customer needs or to provide guidance in critical areas for our customers.

Why Tooling U-SME: Our training sessions are turnkey. We can help you if you are starting from scratch or

supplementing an existing program, and whether you need an instructor to come in-house or any of our other training

products and delivery media. We offer the most robust, comprehensive manufacturing training in the market that is

scalable for companies of all sizes. Tooling U-SME has more than 80 years of experience serving the manufacturing

community. We have been working in manufacturing and only manufacturing from the day we were founded, giving us

a unique perspective on the real needs of manufacturing companies.

More Information: If you would like customized training for your company, or more information on a program in this

catalog, please contact your sales representative today or email us at [email protected] or

call us at 866.706.8665.


TABLE OF CONTENTS

Customized Training ...................................................2

Delivery Types ...........................................................5

Virtual Instructor-Led Training .....................................6

Automation & Assembly .............................................7Computer Numerical Control (CNC) Fundamentals ........7

Learning Services ......................................................8

Design & Engineering .................................................9Concurrent Engineering ..............................................9Design for Manufacturability and Assembly (DFM/A) .. 10GD&T Using DFM/A ................................................ 12Geometric Dimensioning & Tolerancing (GD&T) ......... 14Measurement, Inspection, and Gaging ...................... 15Precision Machine Design ........................................ 16

Industrial Maintenance ........................................... 17AC Motor Controls and Relay Ladder Logic ................ 17Hydraulic Conductors-Fittings, Tube, Pipe,

and Hoses............................................................ 18Hydraulic Troubleshooting Using Schematics ............. 20Industrial Electrical Fundamentals ........................... 21Introduction to Lubrication ...................................... 22Level One Industrial Hydraulics Fundamentals .......... 24Level One Programmable Logic Controller (PLC)

Fundamentals ...................................................... 26Level One Pneumatics ............................................. 28Level Two Industrial Hydraulics ................................ 30Mechanical Fundamentals ....................................... 32Troubleshooting Electrical Systems

with Schematics ................................................... 33Variable Frequency Drives ........................................ 34

On-Demand Library ................................................. 23

Lean ...................................................................... 355S: Systematic Organization of the Workplace ........... 35The Human Side of Lean ......................................... 36Integrating Green Manufacturing and Lean ................ 37Introduction to Lean: Overview of the Lean Toolbox .... 38Kaizen Workshop .................................................... 39Kanban/Supermarket Inventory and Demand

Management ........................................................ 40Lean Product Development ...................................... 41Planning Manufacturing Cells .................................. 42Set Up/Changeover Reduction .................................. 43Six Sigma Green Belt .............................................. 44Six Sigma Yellow Belt ............................................. 45Understanding the Tools and Best Practices

of Lean Manufacturing .......................................... 46Value Stream Mapping ............................................ 47

Management .......................................................... 48Computerized Maintenance Management System (CMMS) ................................................... 48Cycle Time Management for Manufacturers ............... 51How to Coach Your People to Think Independently ..... 52Industrial Engineering Fundamentals ........................ 54Manufacturing Technology Fundamentals .................. 56Project Risk Management ........................................ 57Quick Response Quoting and Manufacturing.............. 58Strategic Project Management ................................. 60Walking the Talk: Pathways to Leadership ................. 62

Materials ............................................................... 64Introduction to Composites ...................................... 64Joining and Bonding Composite Structures................ 65Repair of Composite Structures ................................ 66Tooling for Composites ............................................ 67

Process Technologies .............................................. 68Coil Slitting Certificate Program ............................... 68Coil Slitting Fundamentals ...................................... 69High-Speed Endmilling ........................................... 70High-Speed High-Power Machining .......................... 71Industrial Combustion Systems ................................ 72Laser Cutting Certificate Program ............................. 73Machining Process Optimization Program .................. 74Metal Formability Certificate Program ....................... 75Metal Stamping Press ............................................. 76Metalworking Fluid Management .............................. 77Metallurgy Certificate Program ................................. 78Machine Tool Metrology ........................................... 80Modern Grinding Technology .................................... 82Precision Grinding and Abrasive Machining ............... 84Stamping Die Certificate Program ............................. 85Overview of Additive Manufacturing (3D Printing) Technologies ....................................................... 86

Quality & Testing .................................................... 88Advanced Product Quality Planning (APQP) ............... 88Design of Experiments (DOE) ................................... 89APQP/FMEA/Control Plans/Error Proofing (FMEA) ....... 90Failure Mode and Effects Analysis ............................ 92Statistical Process Control Workshop ........................ 94Statistical Process Control (SPC) .............................. 96Tolerance Stack-up Analysis ..................................... 97Total Productive Maintenance (TPM) ........................ 98Value Analysis and Value Engineering (VA/VE) .......... 100

Virtual Instructor-Led Training (VILT) ...................... 102Virtual Instructor-Led Training Sessions .................. 102

5ToolingU.com | 866.706.8665

A VARIETY OF PROVEN INSTRUCTOR-LED METHODS WITH BUILT-IN FLEXIBILITY.Whether you’re starting from scratch or supplementing an existing program, we will work with you to ensure your training

program fits your company’s exact needs. Choose any combination of our off-the-shelf or customized content, and the

following delivery methods, which all include a Certificate of Completion and downloadable materials:

Face-to-Face (Instructors come to you, the most preferred method) • Immediate adaptability

• Hands-on activities

• Dynamic exchange between instructor and participants

• Participants learn from each other

• Networking opportunities

Public Virtual Sessions • Live web-based instructor-led sessions

• Interactive presentations with Q&A period

• Unlimited attendance

• Access to session recordings and post-tests

• Scheduled throughout the year

Private Virtual Sessions • Live web-based instructor-led sessions

• Focused on important areas of knowledge with detailed explanations

• Company-specific customization

• Live streaming video also available

On-Demand Library • Pre-recorded sessions

• 24/7 access

• Access to session post-tests

• Free video preview before purchase

DELIVERY TYPES

> RETURN TO TABLE OF CONTENTS


The BesT experTs. A flexible training solution.

For more information on our VILT program

call 866.706.8665 or visit us online at toolingu.com.

Your team can attend from anywhere.Tooling U-SME developed Virtual Instructor-Led Training (VILT) with one goal in mind: to give you a training method that can be implemented consistently across your organization, around the world. VILT live sessions allow you to access and interact with the best minds in manufacturing – instructors that have been selected for their in-depth knowledge, formidable industry experience and profound passion for teaching.

Virtual Instructor-Led (web-based, online) Access live sessions (Audio and video) Access session recordings and post-tests Unlimited attendance Customizable sessions to focus on specific content Private virtual sessions Live public sessions available


COMPUTER NUMERICAL CONTROL FUNDAMENTALSTwo-Day Course

Description This course covers the knowledge and step-by-step methodology to enable one to troubleshoot electrical systems.

Fundamentals of basic electrical theory along with understanding symbols and circuits will set a foundation

at the beginning of the course. Meters and their use are covered next with lots of hands-on work. The use of

measurement devices combined with knowledge of circuits then becomes the focus of the course. This knowledge

is used to understand and troubleshoot relays and motors, power distribution and quality, motor controls,

electric motor drives, and more.

Audience This introductory course presents the practical basics for learning how to use the latest CNC equipment. By

incorporating a proven “key concepts” approach, it examines the techniques needed for programming and operating a

variety of CNC machine tools with emphasis on CNC machining and turning centers. You will gain a firm understanding

of the basics required to become proficient with this sophisticated and popular form of manufacturing equipment.

Learning Objectives• Learn the six key concepts of manual programming

• Identify special features of manual programming designed to make programming easier and safer

• Find out why formatting the techniques must be used

• Grasp the three basic forms of motion control

• Zero-in on the types of compensation

• Learn how to and when to program tool offsets

• Identify four types of formatting

• Understand simple canned and multiple pass cycles

• Discover sub-programming techniques

• Focus on coordinate system manipulation

Course Outline• Introduction to the Basic Functions of CNC Machines

• Preparation for Programming

• The Three Kinds of Motion

• Types of Compensation

• Program Formatting

• Special Features of Programming Introduction to Machining Center Special Programming Features

AUTOMATION & ASSEMBLY


8 Instructor-Led Training8 Instructor-Led Training

Training only works when a plan is in place. Simply purchasing training does not guarantee results. In fact, training without a plan is the first step to failure.

Work with the best advisors in the industry!

The key to shaping employee performance that delivers desired results involves five best practices that Tooling U-SME has mastered:

Need Analysis: Business objectives that align training with company value.

Job Analysis: Real-world understanding of the specific knowledge and skill for the work.

Competency Modeling: What’s needed for your workforce in your company?

Learning Solution: A plan accurately aligned with your competency needs.

Measure Impact: Competencies that deliver on business objectives.

For more information visit toolingu.com or call us at 866.706.8665

LEARnIng SERvICESThe Right Plan.

ThE RIghT SERvICES to Support Results.

Workerknowledge, skills

and statistcs

WorkPerformanced-based knowledge and skills

PLDPerformance-based

Learning &Development

Businessobjective

JobPerformance

MeasuredImpact

LearningSolution

Competency(knowledgeand Skills)

CoMPeTeNCy


CONCURRENT ENGINEERINGTwo-Day Course

Description The purpose of this course is to practice the techniques of concurrent engineering, and to improve and promote

a unique type of communication between departments during the initial and all succeeding stages of a product

introduction. This course will demonstrate how functional departments can reduce time and money spent in scrap

and rework by uncovering and resolving potential product problems before they occur. It will provide a methodology

that will significantly reduce time from concept to production, create quality, improve product benefits to the end-

consumer, and increase production-line efficiency. The focus of this course is on the communication lines and

implementation of a concurrent engineering program.

Audience This course is designed for team attendance including design engineering, sales, marketing, manufacturing

engineering, quality, production scheduling, and operations. Functional areas that will benefit include: senior project

engineer, director of engineering, manufacturing engineering manager, mechanical engineers quality engineer,

process engineer, production engineer, purchasing, scheduling sales, and marketing. Participants should have a clear

understanding of company operations.

Learning Objectives• Understand the common objectives of concurrent engineering (CE)

• Develop a CE system utilizing guidelines provided

• Determine how to make breakthroughs in time and cost

• Understand the strategic value of concurrent engineering

• Evaluate the potential challenges of reengineering the product design system

• Create a road map to CE success

Course Outline• What Is Concurrent Engineering?

• Developing the Need for Change

• Implementation Steps

• Quality Function Deployment

• Employee Engagement

• Design For Manufacturing

• Design For Assembly

• Concurrent Engineering Metrics

• Concurrent Engineering Tasks

9ToolingU.com | 866.706.8665

DESIGN AND ENGINEERING



DESIGN AND ENGINEERING


DESIGN FOR MANUFACTURABILITY & DESIGN FOR ASSEMBLY (DFM/A) Two-Day Course

Description This workshop will provide you with fundamental knowledge and hands-on practice with Design for Manufacturing and

Design for Assembly (DFM/DFA) and key tools. Topics addressed include the overview and application of DFM and DFA

strategies, Design for Productivity, Process Capability, and Realistic Tolerancing. The program is designed for all levels of

design, product engineering, and manufacturing personnel, as well as more engineering management personnel. It can

be tailored to fit special needs of new product and process development, or can focus on application for existing designs

and manufacturing environments.

Audience This course is designed for individuals with minimal experience with DFM/DFA and its related key tools. However,

many experienced individuals attend the course to refresh their knowledge, gain advanced strategies, and practice

development and application of these tools with an experienced facilitator. Program managers, design-responsible

engineers or managers, and team members such as operators and technicians, quality personnel, and other product

design and manufacturing personnel who are interested in applying DFA, DFM, error proofing, and realistic tolerancing

to their products and processes will all benefit.

Learning Objectives• Key DFX concepts including Design for Manufacturing, Design for Assembly, Design for Lean Design,

and Design for Six Sigma

• Key elements of any component or assembly design that must be considered during DFM/DFA analysis and application

• How to ensure that key stakeholders, including vendors and suppliers, have input to the DFM/DFA activities

• How to structure the DFM/DFA process to facilitate the engineering team through the process for both new products and/or redesigned products/processes

• Step-by-step guidelines for analyzing DFA including design for handling, presentation, orientation, insertion, fastening, and error proofing, mistake proofing, and poka yoke application for design and process elements

• DFM guidelines and general tolerancing recommendation on the most popular manufacturing processes, including injection molding, machining, metal forming, casting, etc.

• How to conduct a variety of capability studies including Cp, Cpk, Pp, and Ppk

• How to calculate and assign appropriate tolerances for new designs

• Five key Geometric Dimensioning and Tolerancing (GD&T) strategies for increasing tolerances and reducing cost without compromising product function

• How to take advantage of GD&T principles without adding GD&T to the drawings

• Step-by-step guidelines for dimensioning, tolerancing, and optimization using both coordinate and geometric tolerancing


Course Outline• Introduction to DFM/DFA

• Design for Assembly

• Error Proofing, Mistake Proofing, and Poka Yoke

• GD&T for DFM

• Design for Metal Forming

• Design for Surface Treatment

• Design for Machining

• Design for Casting

• Design for Plastic and Rubber Parts

• Tolerance Design for Six Sigma

• Small-Group Applications Projects

11ToolingU.com | 866.706.8665



GD&T USING DESIGN FOR MANUFACTURABILITY AND ASSEMBLY (DFM/A) Two-Day Course

Description This course will show how a product’s functional requirements are converted into designs which have the highest level

of functionality, manufacturability, and assembly, but at the lowest cost. This will be accomplished by integrating many

different support tools, the most important of which is geometric dimensioning and tolerancing (GD&T). GD&T will be

demonstrated as the only tool which has the versatility to convey functionality, design intent, fixturing requirements,

and verification techniques, making it the only common language uniting designers, manufacturing engineers, and

quality control personnel.

Audience This course is recommended for anyone involved in product design, manufacturing engineering, and manufacturing

management. This includes design engineers, product engineers, manufacturing engineers, process engineers, quality

engineers, mechanical engineers, cost engineers, and others who are involved in design for manufacture/assembly

(DFM/A).

Learning Objectives• Provide proven guidelines which will help overcome implementation obstacles in DFM/A, producibility,

and tolerancing/dimensioning

• Bring producibility and GD&T together to increase functionality and reduce costs

• Establish clear DFM/A goals and objectives for any organization

• Use provided road maps when integrating a concurrent design and process on existing or new designs

• Justify, select, lead, and follow-up on a team effort

• Identify and define support tools and examine their role in achieving effective DFM/A projects

• Learn the benefits of integrating rapid prototyping into product development

• Provide a checklist which examines whether GD&T is thoroughly or properly integrated into design for functionality, manufacturability, inspectability, and assembly

• Recognize why GD&T is the common language in the transition of products from development to production

• Explain the role that computer-aided process planning (CAPP) and group technology (GT) play in reducing design and process time, along with standardizing parts and materials

• Examine a number of practical applications using all the support tools of DFM/A

DESIGN & ENGINEERING


13 Instructor-Led Training13 Instructor-Led Training 13ToolingU.com | 866.706.8665

Course Outline • Introduction

• DFM Tools and Enabling Technologies

• GD&T Checklists for Production

• DFM/A Teams

• Role of Rapid Prototyping

• Role of Group Technology and Computer-Aided Process Planning

• Road Maps Used to Guide a DFM/A Task

• The Redesign Process Using Producibility and GD&T

• Specific Producibility Recommendations Using GD&T

• Case Study

• How to Publicize Success Stories



GEOMETRIC DIMENSIONING AND TOLERANCING (GD&T) Three-Day Course

Description GD&T provides the basis for designing and applying the industry-accepted design/engineering language. Implementation

of GD&T will improve communication among designers, manufacturing engineers, and quality control inspectors,

resulting in accurate use and interpretation of engineering part drawings. Through examination of the ASME

Y14.5M-2009 standard, group exercises and group discussion, participants will develop the ability to relate drawing

requirements to actual part function and inspect parts defined by GD&T. Participants will also be able to determine the

most appropriate methods of manufacture and inspection.

Audience This course is intended for anyone beginning a new implementation of GD&T, as well as those seeking to refresh

or improve their understanding of the language. Key individuals who will benefit from this course include design

engineers, inspectors, machinists, drafters, manufacturing engineers, tool and die makers, gage designers and makers,

management personnel, and tool designers. Team attendance is encouraged in order to discuss and practice learned

techniques upon returning to the facility.

Learning Objectives• Understand the GD&T language, its purpose and its benefits

• Learn proper use and interpretation of GD&T symbols

• Reduce rejects by eliminating part drawing interpretation errors

• Calculate tolerances to assure interchangeability of parts

• Increase production tolerances

• Relate drawing requirements to actual part function

• Manufacture and inspect parts defined by GD&T

• Take advantage of “bonus tolerances”

• Understand and properly select datums

• Eliminate translation errors with foreign affiliates

• Increase cooperation between all areas of the manufacturing process

Course Outline • Introduction to GD&T and Geometrics

• Form Tolerances

• Datums

• Orientation Tolerances

• Profile Tolerances

• Runout Tolerances

• Locational Tolerances

• Positional Tolerances

• Cylindrical Features

• Positional Tolerances-Noncylindrical Features

• Wrap-Up




MEASUREMENT, INSPECTION AND GAGING Three-Day Course

Audience This course is recommended for anyone involved in product design, manufacturing engineering, and manufacturing

management. This includes design engineers, product engineers, manufacturing engineers, process engineers, quality

engineers, mechanical engineers, cost engineers, and others who are involved in design for manufacture/assembly

(DFM/A).

Course Outline • Introduction and Review

• Measurement, Verification, and Gaging

• Inspection of Form Controls

• Datum Referencing

• Inspection of Profile Controls

• Inspection of Orientation Controls

• Inspection of Location Controls

• Runout Controls

• Gage Dimensioning and Tolerancing

• Paper Gaging

• Metrology Lab Workshop (if available on site)

15ToolingU.com | 866.706.8665



PRECISION MACHINE DESIGNTwo-Day Course

Description A precision machine is an integrated system that relies on the attributes of one component to augment the weaknesses

of another component. In this course emphasis is placed on the design of mechanical and structural precision machine

components and their integration with sensor and control systems to maximize performance. In the discussion of the

design of components and assemblies, emphasis is placed on how the design will affect overall accuracy, repeatability,

and resolution of the machine. Therefore, design engineers will be provided with state-of-the-art information and design

tools needed to design internationally competitive precision machines.

Audience This course assumes that attendees have a professional working knowledge of machine design and is targeted at

manufacturing engineers, machine tool design engineers, and others involved in machine design. The emphasis is on

mechanical components. Sensors and controls will not be covered.

Learning Objectives• Define types of errors and methods for modeling them when predicting machine performance

• Estimate the magnitude of different types of errors

• Understand the importance of damping and how a machine or process can shake itself into ineffectiveness without it

• Analyze methods for estimating the stress and deformation that occur when there is a point or line contact between two bodies

• Design and select sliding, rolling, flexing, or hydrostatic bearings for linear and rotary motion

• Determine the required system and stiffness and transmission ratio in order to specify actuators for a system

• Discuss fundamental properties of rotary motion power transmission elements

Course Outline• Introduction to Precision Machine Design

• Concept Selection Methods

• Assessment of Errors in Precision Machines

• Examples of Errors in Precision Machines

• Error Budgeting

• Introduction to Servo Systems

• Design of the Machine’s Structure

• Damping Systems

• Kinematic Coupling Design

• Sliding Contact Bearings

• Replicated Bearings

• Rolling Element Rotary Bearings

• Rolling Element Liner Bearings

• Hydrostatic Bearings

• Power Transmission Systems Requirements

• Electromagnetic, Piezoelectric Actuators

• Rotary Motion Power Transmission Elements

• Linear Motion Power Transmission Elements




AC MOTOR CONTROLS AND RELAY LADDER LOGICFour-Day Course

Description This course covers the fundamentals of electrical power and theory. The course begins with a review of safety and safe

operation in the electrical industry. Students will review the different types and uses of induction motors, windings

types, motor starters and circuits, motor protection, ladder logic symbols, and diagrams.

Audience Mechanical engineers, electrical engineers, maintenance technicians, instrument technicians, press maintenance,

press design engineers, and project managers.

Learning Objectives• Define safety and safe operation standards

• Name types of induction motor windings and typical uses

• Compare single winding, single phase, split phase

• Explain three phase induction motors

• Examine reversing motors

• Motor starters and starter circuits

• Define motor protection

• Overload relays, operation, and sizing

• Identify motor enclosures

• Read ladder logic

• Compare symbols and abbreviations

• Define logic statements

• Practice diagram generation

Course Outline• Safety Guideline

> PPE

> General electrical safety

> Lock-out/Tag-out

• Induction Motors

> Motor terminology and definitions

> Name plate information

> Types of windings and how they function

> Types of single phase motors and their uses

> Types of three phase motors and their uses

• Motor Starters

> Types of motor starters

> Sizing motor starters

> Motor starter circuits

> Reversing rotation of motors

• Motor Protection

> Types of motor protection

> Placement of motor protection in the start circuit

> Sizing overload protection

> Motor control enclosures and selection

• Ladder Logic

> Symbol recognition

> Using ladder logic

> Developing sound ladder logic

> Troubleshooting motors and motor control logic

17ToolingU.com | 866.706.8665

INDUSTRIAL MAINTENANCE



HYDRAULIC CONDUCTORS, FITTINGS, TUBE, PIPE AND HOSESThree-Day Course

Description This course covers the types of connecting lines and fittings used to carry hydraulic fluid between the various

components of a hydraulic system. Hands-on skills are acquired in tube bending and fittings installation. Students

are also taught how to pick the correct conductor size and type for an application by calculating appropriate values,

then reading the industry standard.



Learning Objectives• State the benefits of the different conductors and when best to use them

• Demonstrate the ability to assemble hoses with permanent and reusable ends

• Construct a flared hydraulic tubing assembly

• Demonstrate how tubing assemblies seal to fittings

• Demonstrate the correct way to install a hose for proper position and alignment

• Demonstrate the ability to properly bend tubing

• Know the advantages and disadvantages of the different types of fittings

• Explain the working pressure, safety factor and burst pressure for hoses

• Read and use conductor inside diameter selection charts

• Calculate the necessary inside diameter of hoses for a given hydraulic circuit

• Explain how pipe size is classified

• State two reasons for fluid conductor supports

• Explain the terms GPM and CFM

• Explain pressure ratings and flow capabilities of tubing and pipe

• Calculate the flow an intake hose can pass, given the inside area and the max

• Be familiar with the guideline for hydraulic hoses, SAE J517 Standard

• Recognize causes of hose failures




Course Outline• Safety

> Safety

• Introduction

> Connectors

> Sizing

> Flow/pressure drop

• Fittings – Adaptors

> Types

> Sealing threads

• Torque valves

> Straight thread/parallel

> SAE Ord/BSPP/ISO/JIS

> Flanges

> SAE ISO Code 61/62

> Metric flanges

> Split flanges

> Static vs. dynamic

> Tube ends 37 degree flare

• Tubing

> Sizes/temperature rating

> Steel/carbon/copper/plastic

> OD/ID/Wall thickness

> Tube flaring/

> Compression ferrules

• Hose/Pipe

> SAE

> Construction/where to use

> How to measure a hose assembly

19ToolingU.com | 866.706.8665




HYDRAULIC TROUBLESHOOTING USING SCHEMATICSThree-Day Course


Description This course begins with a brief review of fundamental fluid power principles and hydraulic schematic symbols. Various

types of hydraulic circuits are covered so students develop a broader understanding of symbol (component) arrangements

and feel comfortable explaining them. Troubleshooting methodology is provided using the hydraulic circuit to group and

isolate potential problems when symptoms such as improper speed, pressure, heat, noise, leaks, and specific failures have

been identified. It also covers the reason for failures.

Audience Mechanical engineers, electrical engineers, maintenance technicians, instrument technicians, press maintenance, press

design engineers, and project managers.

Learning Objectives• Relate fundamental concepts of pressure and flow

• Know basic characteristics of hydraulic fluid

• Review the seven basic symbols

• Introduce assorted symbols and legends

• Learn how to build simple and complex symbols from the basics

• Understand how to read simple and complex circuits

• Draw simple circuits

• Learn troubleshooting techniques

• Learn the divide and conquer technique

• Learn grouping and isolation

• Organizing and sequence of actual diagnostic procedure

• Make economic choices when several possibilities are analyzed

Course Outline• Basic Symbols

> Pumps and motors

> Pressure controls

> Flow controls

> Directional valves

> Proportional valves

> Slip-in cartridges (logic valves)

> Cylinders and actuators

> Fluid conditioners

• Assorted Symbols and Legends

> Transmission line types

> Envelope

> Indicators

• Building Simple and Complex Symbols from the Basics

• Reading Various Simple and Complex Circuits

> Blenders

> Coil tube units

> Injection heads

> Mobile work-over rigs

> Student prints

• Troubleshooting Scenarios

> Troubleshooting techniques

> Grouping and Isolation

> Organizing sequence of actual diagnostic procedure

> Making repair choices

• Hands-on Troubleshooting

> Students build circuits-Instructor introduces problems to troubleshoot


Description This course covers the fundamentals and principles of AC and DC electric. Electrical safety procedures, lock-out/tag-

out, and OSHA compliance are reviewed. The operation and use of relay contacts, input/output devices and measuring

instruments are covered.



Learning Objectives• Review electrical safety

• Explain Lock out/tag out procedures and why they are used

• Know the most common OSHA violations

• Review of electrical fundamentals and symbols

• Work with power formulas

• Know the proper application when using voltmeters, amp meters, and megohm meters

• Explain voltage and current

• Finding resistance and capacitance for parallel and series circuit

• Find difference of normally open and normally closed relay contacts

• Explain differences in limit, proximity, and photo switches

• Review of three different output devices including valves, motors, and fans

Course Outline• Safety Guidelines

> PPE

> General electrical safety practices

> Lock-out/Tag-out

> OSHA requirements

• Electrical Fundamentals

> Ohm’s Law

> Watt’s Law

> Electrical symbols

> Series and parallel resistance and capacitance calculations

> Voltage drop calculations

• Meter Use

> Multi-meter functions

> AMP meters

> Megohm meters

• Electrical Schematics

> Use of symbols in electrical prints

> Reading ladder logic drawings

> Contact arrangements in ladder logic

> Motor start/stop circuits with overload protection

> Types of input devices

> Types of output devices

> Use of input devices as feedback from output devices

> Overload protection in electrical circuits

INDUSTRIAL ELECTRICAL FUNDAMENTALSFour-Day Course

21ToolingU.com | 866.706.8665 21ToolingU.com | 866.706.8665


INTRODUCTION TO LUBRICATIONTwo-Day Course

Description This course examines lubrication systems used in industrial applications. Application of pumping packages, lines,

hoses, monitors, divider blocks, injectors, and lubrication components are reviewed. Proper installation, selection, and

safe troubleshooting practices are discussed. This course includes classroom presentation and hands-on training.



Learning Objectives• Explain the goals of lubrication

• Describe common lubricants used in industry

• Describe the variables used to classify lubricants

• List the advantages and disadvantages of grease and oil

• List the criteria for selecting a specific type and grade of lubricant

• Define the term viscosity and how it relates to oil

• Define the term consistency and how it relates to grease

• Describe common components that require lubrication

• Contrast the various types of lubrication systems (manual and automatic)

• Identify the various types of system components

• Read and interpret a lubrication schedule

• Describe and troubleshoot problems associated with improper lubrication

• Explain how contamination can affect equipment

• State the proper procedures for storing lubricants

• Describe general lubrication “best practices”

• Identify safety concerns associated with lubricants



Course Outline• Principles of Lubrication

> Purpose of lubrication

> Friction and wear

> Dampen and absorb shock

> Temperature

> Corrosion and contaminants

> Oils, greases, and gases

> NGLI grease grades

> Grease thickeners/solids additives

> Viscosity, separation and additives

> Lubricant additives

> Pour Point

> Oil-Soap separation

> Types of Systems

• Centralized Systems

> Manual and mechanical

> Pneumatic, hydraulic, electrical

• System Component

> Pumps and controllers

> Valving and nozzles

> Filtration and indicators

> Monitors

• System Analysis

> Reading and interpreting lubrication prints

• Troubleshooting and Repair

> Tracing and recognizing faults and malfunctions

> How to remove air from systems

> Identifying contamination


23 Instructor-Led Training23 Instructor-Led Training 23ToolingU.com | 866.706.8665 23ToolingU.com | 866.706.8665

Find rich & relevant manuFacturing content in our On-Demand Library.Access the 24/7 On-Demand Library to view high-quality recorded online instructor-led courses. Whether you need a refresher course or to learn completely new concepts, you’ll find it in our library.

Tooling U-SME also offers great flexibility to ensure the content is accessible in the most convenient and meaningful way. On-demand sessions are available for individual purchase or you can plan to attend multiple sessions under a cost-effective subscription model.

Need to train an entire team? Ask us about custom corporate training solutions where you can incorporate access to On-demand sessions.

Registration includes: Access to the same audio and video made available during the live event Downloadable class materials Access to the session post-tests Certificate of Completion to registrants Free video preview before you purchase

Categories include: Design & Engineering Lean Maintenance Management Materials

For more information on our On-Demand Library

visit toolingu.com or call us at 866.706.8665




LEVEL ONE INDUSTRIAL HYDRAULICS FUNDAMENTALSThree- or Five Day Course

Description This course correlates fluid power principles with machine operation and daily maintenance duties. Procedures to

ensure safety of maintenance personnel and prevent damage to machines will be covered. Fluid power symbols will be

compared to the physical components. Location of components in a hydraulic system and proper adjustment procedures

will be identified. Hands-on exercises will reinforce location, proper component connections, and effects of adjustments

on system operation. Elimination of leaks by proper fitting selection and installation will be discussed. Significance of

fluid cleanliness to system longevity and techniques to minimize ingression of contaminants will be presented.

This course is 50 percent hands-on and 50 percent classroom participation.



Learning Objectives• Practice safe procedures to ensure trapped fluids have been relieved internally and suspended loads have been

lowered or properly blocked to permit safe maintenance operations

• Explain hydraulic pressure-force and flow-speed relationships

• Identify and correlate the standard schematic symbols to the hydraulic components and typical locations in a hydraulic system

• Use charts to determine actuator force and speed for given pressure and flow

• Recognize typical cylinder construction and utilize diagnostic procedures

• Identify/classify relief, sequence, unloading, reducing, and counterbalance valves

• Distinguish between meter-in vs. meter-out flow control

• Identify schematic symbol and operational differences of directional control valves

• Identify/classify the different types of hydraulic pumps

• Proper installation of hydraulic components with respect to alignment, connections, and pre-filling with fluids

• Identify and work with the fluid conductors used to carry hydraulic fluid to ensure proper pressure ratings, routing, and to reduce failures

• Implement leak prevention using proper fittings, assembly techniques, and seal materials

• Identify different types of filtration and understand contamination levels

• Recognize fluid requirements for different machines


Course Outline• Safety

• Lock-out/Tag-out

• Confirming de-pressurized hydraulic lines

• Conductors and Connectors

• Hose connectors, construction, sizing, ratings

• Steel tubing

• Hydraulic Fundamentals, Fluids and Reservoirs

• Conductor flows and sizing

• Filter use, locations and sizing, intake, return and pressure

• Actuators (Telescoping, Rams, Single Acting etc)

• Construction, operation and applications

• Regeneration circuits

• Pressure Controls


• Proper use of relief, reducing, sequence, counterbalance, unloading and brake valves

• Pumps and Pumping Principles

• Construction, operation and applications of gear, vane and piston pumps

• Start-up and troubleshooting techniques

• Flow Controls and Flow Dividers

• Construction, theory and operation

• Meter-in verses meter-out, pressure compensated vs non-compensated

• Directional Controls


• Single and pilot operated designs

• Accumulators and Accessories

• Construction, theory and operation

25ToolingU.com | 866.706.8665



LEVEL ONE PROGRAMMABLE LOGIC CONTROLLER (PLC) FUNDAMENTALSFour-Day Course

Description This course covers the fundamentals and principles of Industrial Programmable Logic Controller (PLC). The focus is

on how PLCs work and gives practical information on maintaining PLC systems. Students will examine the control of

systems with a PLC simulator and laptops. Emphasis will be on using the PLC as a diagnostic tool for troubleshooting

the processing system.



Learning Objectives• List the primary functions of a programmable logic controller (PLC)

• Explain the benefits of using PLCs instead of hard-wired relays

• Identify the major components of a PLC and explain their functions

• Describe the function of each of the three types of memory used in a PLC

• Identify different types of programming terminals

• Define such terms as program, address, instruction, program rung, and ladder logic

• Recognize different types of input and output modules

• Explain the basic function of a scan cycle

• Differentiate Boolean AND, OF, NOT functions for multiple devices on a rung

• Identify commonly used numbering systems

• Define the symbols associated with ladder logic

• Explain the relationship between addresses used for field wiring and programming instructions

• Describe a typical I/O address

• Explain why fusing, grounding, and shielding are important when wiring I/O field devices

• Describe how programming instructions interact with the PLC’s memory

• Demonstrate how to wire input and output field devices to a SLC 500 and similar controllers

• Identify how each rung performs the logic functions necessary to determine if the rung is true or false

• Know the importance of maintaining up-to-date documentation

• List the basic steps to troubleshooting PLCs

• Identify the diagnostic and I/O status lights and explain their condition




Course Outline• PLC and Electrical Safety

> Electrical Shock

> Current, Voltage, Resistance

> PLC Enclosures

> PPE

> Electrical Principles and PLCs

> Power Supply Voltage Ratings

> Input and Output Voltage Ratings

> Input and Output Current Ratings

> DC Input Switching

> Current in Series and Parallel Circuits

> Voltage Drops in Series and Parallel Circuits

• Electrical Circuits and PLCs

> Electrical Symbols and Diagrams

> PLC Programming Symbols

> Wiring Diagrams, Ladder Diagrams

> Logic Functions

> Circuit Logic

> Wiring Methods

• PLC Hardware

> Input and Output Sections

> CPUs

> Programming Devices

> Classifications

> Memory

> Operating Cycle

• PLC Programming Instructions

> Processor, Program, Data Table Files

> Addresses-Data Table, Input and Output, Status, Bit File

> Programming Diagram Logic

27ToolingU.com | 866.706.8665


LEVEL ONE PNEUMATICSThree-Day Course

Description This course covers the fundamentals and principles of pneumatics with emphasis on hands-on exercises. Students will

obtain a strong foundation in compressed air production and preparation in pneumatic systems as well as a thorough

look at basic pneumatic components. The course begins with safety followed by basic fluid power principles. Air

compression, preparation, and distribution are then covered. The construction, operation, and specific use of pneumatic

components then become the focus of the class. Specific components covered in this course include compressors, air

motors, flow controls, directional valves, actuators, after coolers, and driers. In addition, seals and gaskets, filtration, and

circuit basics are discussed.



Learning Objectives• Recognize compressed air safety practices

• State advantages and disadvantages of pneumatic systems

• Explain relationship between gauge and absolute pressures

• Identify schematic symbols and be able to read a basic circuit

• Explain the fundamental construction and operation of compressors

• Explain the effect of contaminants in compressed air systems

• Demonstrate where to locate filters

• Explain how pneumatic filters are rated

• State the purpose of a pressure regulator

• Illustrate how an air lubricator works

• Recognize the need to monitor compressor oil level and condition

• Distinguish between venting and non-venting regulators

• Explain the fundamental construction and operation of cylinders

• State how to replace seals and packing in cylinders

• Identify Symptoms of leaking seals in air cylinders

• Explain the fundamental construction and operation of directional valves

• Explain the fundamental construction and operation of flow control valves





> PPE

> Pressure Vessels

> Hoses and Fittings

> Lock-out/Tag-out

• Theory and Principles

> Advantages of Pneumatic systems

> Producing linear and rotary motion

> Principles and properties

• Gas Laws

> Definitions and units of measurement

• Symbols and Intro to Circuits

• Air Production

> Compressor types and functions

> Unloading methods

• Air Preparation/Treatment

> Pressure regulators

> Dryers

> Filtration

> Lubrication

> FRL’s

29ToolingU.com | 866.706.8665



LEVEL TWO INDUSTRIAL HYDRAULICSThree- or Five-Day Course

Description This component and control level course will incorporate component symbols learned in Level one into complete

schematics. Remote control of pressure valves using pilot valves, bleed-off orifices, and proportional controls will

be discussed. Simultaneous control of multiple actuators while maintaining pressure and flow requirements will be

reviewed. Operation and setup of load-sense pumps will be demonstrated. Slip-in and screw-in cartridge valve design

and operation will be presented. Proportional directional control valve function and use will be introduced.

Learning Objectives• Determine pressure required to move load at a given pressure

• Compare area ratios for speed and force output as well as output flows

• Determine actuator speeds for given flow and size

• Use cylinder’s extend and retract to determine flow rates

• Explain remote control techniques for relief, reducing, sequence, counterbalance, and unloading valves

• Compare pressure compensated vs. non-compensated flow control circuits

• Review meter-in versus meter-out operations and learn how to reduce or eliminate pressure intensification problems

• Identify/classify the different types of hydraulic pump controls

• Adjust procedures for pressure-compensating, load-sensing, and power-limiting controls

• Explain diagnostic procedures for variable displacement pumps

• Compare slip-in and screw-in cartridge valves and review circuits

• Use slip-in cartridges and pilot valve to replace a two-stage directional valve

• Demonstrate manifold troubleshooting

• Demonstrate knowledge of hydraulic schematics to aid in diagnostics of machines

• Evaluate machine response and performance with multiple simultaneous operations




Course Outline• Safety Considerations

> Safety equipment

• Hazardous Conditions

• Hydraulic Fundamentals Review Actuators

> Bent rod causes and prevention

> Area ratios for speed and force output flow systems

> Regeneration circuits and pressure intensification

• Pressure Controls

> Remote control of pressure and unloading circuits

> Drain line control techniques

> Control of multiple pressure valves

• Flow Controls

> Meter-in vs. Meter-out

> Pressure compensated vs. non-compensated

> Multiple speed circuits

• Flow Dividers

> Various types and startup problems

• Directional Controls/Slip-In Controls

> Pilot operated check valve ratio problems

> Spool types and transition conditions

> Poppet type no-leak valves/flow control

> Stacking valves, modules and manifolds

> Proper stacking sequence and order

> Drain and tank line considerations

• Proportional Valves/Motor, Pumps, and Pumping Principles

> Directional, flow and pressure types

> Feedback and non-feedback types

> Electronic controls/load sensing

31ToolingU.com | 866.706.8665



MECHANICAL FUNDAMENTALSFour-Day Course

Description

In this course, mechanical elements of power transmission including gears, levers, chains, belts, pulleys, shafts, and

couplings are introduced. Component application and maintenance is included. Safety will be continuously addressed.



Learning Objectives• Distinguish the various types of lines (hidden, object,

dimension, center, extension, and leader) typically found in mechanical drawings

• Locate the “Scale” of a drawing and know how it affects the actual drawing

• Interpret a given drawing and determine the size, and materials required of the drawn part

• Explain the purpose of gaskets, packing, and seals and how they function

• Demonstrate the proper bolting pattern for flange joints containing of gaskets,i.e., torque for proper seal

• List the major types of gaskets, packing and seals

• Define the term friction and the results of it

• Know the difference between plain and antifriction bearings

• Identify the basic function of bearings

• Demonstrate proper procedures for removing, inspecting, and replacing plain bearings

• List the major types of belts used in drive systems

• Identify a given belt by its size

• Demonstrate the procedures for installing belt drive components

• Identify the causes of premature belt wear and determine the proper solution

• Identify the components that make up a roller chain

• Identify the size and type of a given roller chain

• Demonstrate the proper procedure for installing sprockets and chain to OEM specs (alignment and sag)

• Identify the various types of couplings used in industry

• Explain the function of gears

• Identify the major types of gears used in industry

• Describe how gear sets affect power, speed, and torque

• Explain the advantages and limitations of a given gear

• Determine the gear ratio of a given gear set

Course Outline• Mechanical Print Reading

• Gaskets Packing and Seals

• Bearings

• Belt Drives

• Chain Drives

• Couplings

• Gears and Reducers

• Component Alignment




Description This course covers the knowledge and step-by-step methodology to enable one to troubleshoot electrical systems.

Fundamentals of basic electrical theory along with understanding symbols and circuits will set a foundation for the

beginning of the course. Meters and their use are covered next with lots of hands-on exercises. The use of measurement

devices combined with knowledge of circuits then becomes the focus of the course. This knowledge is used to

understand and troubleshoot relays and motors, power distribution and quality, motor controls, electric motor drives,

and more.



Learning Objectives• Review electrical safety

• Examine troubleshooting

• Review basic electrical theory

• Read symbols and circuits

• Review meters

• Examine special meters

• Use basic circuit measurements

• Analyze relays and motor starters

• Troubleshoot relays and starters

• Examine motor electrical problems

• Examine motor mechanical problems

• Troubleshoot DC motors

• Troubleshoot AC motors

• Analyze power distribution

• Troubleshoot power quality

• Troubleshoot motor control circuits

• Review electric motor drives

• Troubleshoot electric motor drives

• Evaluate programmable controllers

Course Outline• Review basic electrical theory

• Review electrical symbols and circuits

• Review meters and their uses

• Voltage drops, current, and resistance measurements

• Relays, contactors, and starters

• Troubleshooting, relays, and starters

• Motor problems, electrical, and mechanical

• Troubleshooting AC and DC motors

• Power distribution

• Troubleshooting power quality problems

• Troubleshooting motor control circuits

• Troubleshooting motor drives

• Programmable controllers

• Troubleshooting IO modules

TROUBLESHOOTING ELECTRICAL SYSTEMS WITH SCHEMATICSThree-Day Course

33ToolingU.com | 866.706.8665



VARIABLE FREQUENCY DRIVESThree-Day Course

Description This course covers the fundamentals of VFDs, electrical safety, AC to DC conversion and PWM for motor controls, the

types of motors and how they are affected by VFDs. Students will troubleshoot a VFD hands-on trainer using parameters,

programming, fault recognition, and fault codes.

Audience Mechanical engineers, electrical engineers, maintenance technicians, instrument technicians, press maintenance, press

design engineers, and project managers.

Learning Objectives• Describe AC induction motors

• Evaluate inverter duty vs. standard duty motors

• Identify basic setup parameters

• Examine operating requirements

• Define safety precautions

• Analyze fault codes

• Discuss common causes of failure

• Troubleshoot drives

• Troubleshoot motors


> PPE

> Review General electrical safety

> Lock-out/Tag-out

• Variable Frequency Drives

> Review AC induction motors

> Inverter duty and standard duty motors

> Power requirements

> Converter section

> DC bus section

> Inverter section

> PWM speed control

> Basic setup parameters

> Operating requirements

> Electrical safety precautions

> Fault codes

> Common failures

> Troubleshooting drives

> Troubleshooting motors




LEAN

5S: SYSTEMATIC ORGANIZATION OF THE WORKPLACEOne-Day Course

Description A hands-on, one-day course providing instruction in how to use the 5S methods to simplify and organize your

workplace to help avoid the seven wastes. It includes classroom instruction where each of the five “S” components

(sort, straighten, shine, standardize, sustain) are explained in detail. Upon completion of the classroom instruction

the participant will move to the work area and apply each of the five ‘S” components in a hands-on manner. The

class provides an excellent foundation for any company in any industry. It is a great class to help a company from

the beginning of their 5S journey or as a refresher for those who are struggling during the implementation phases. It

provides many examples of “best practices” and a very structured SUSTAIN section that attendees can take away and

immediately apply in their own settings.

Audience This class is designed to help any organization learn and apply 5S principles while increasing productivity. All functions

in a company can apply 5S principles to help reduce waste in the workplace. It is designed to give students hands-on

practice and real life examples used in applying 5S methods.

Learning Objectives• Describe each of the 5S components

• Set up a 5S program that can be measured and sustained over time

• Explain how to sustain the newly implemented program

• Describe how 5S is connected to the visual controls needed on the shop floor

• Explain why people are the secret to successful 5S programs

Course Outline• What is 5S and how is it linked to the seven wastes

• The 5S Methodology

• Hands-on practice with workplace organization techniques

35ToolingU.com | 866.706.8665



THE HUMAN SIDE OF LEANTwo-Day Course

Description This course provides a comprehensive journey into how lean manufacturing principles lead to better results when the

people, in any role, have a true appreciation for teamwork and the value of people. Experiential exercises support all

learning points.

Audience All roles in manufacturing (shop floor to C level) and product development. Attendees should have a basic understanding

and experience of lean principles as a prerequisite.

Learning ObjectivesAppreciate the power of people and teams to enable continuous improvement without a tremendous amount of effort.

Course Outline• Introduction

• Value of people and multiplying effect of teams

• Performance measures beyond the traditional one (power of people involvement)

• Implementing lean principle vs. the lean appearance

• Enabling Continuous Improvement to happen

• How to apply this to your own workplace

LEAN



INTEGRATING GREEN MANUFACTURING AND LEAN Two-Day Course

Description Managing resource productivity is key to the greening of manufacturing. Lean can help with proper attention to a

process focus and a systems approach to managing the process improvement effort. Several tools exist that can expand

the lean horizon to accommodate green manufacturing.

Audience Lean practitioners, environmental professionals, health and safety professionals, operations managers, plant managers,

accountants, maintenance managers, quality managers, corporate staff, small business owners, and supply chain

managers.

Learning ObjectivesHelp the students assemble a body of knowledge and identify the skills and attributes (KSAs) necessary to become

competent in the lean-to-green discipline. The emphasis is on understanding the basics and using tried-and-true

methods to make a business case for lean to green programs at their facility. Each student will develop a learning

pathway to develop their competence in the emerging lean-to-green discipline.

Course Outline• Basics of Process Management – Management Systems

• Basics of Resource Productivity – Energy, Water, Materials, People

• Basics of Performance Management – Shingo Model/Eight Quality Management Principles

• Creating a Demand for Lean – Continual Improvement

• Lowering Operational Risk – Monetizing the Improvements

• Creating a Learning Pathway for Demonstrating Lean to Green Competency

37ToolingU.com | 866.706.8665



INTRODUCTION TO LEAN: OVERVIEW OF THE LEAN TOOLBOX One-Day Course

Description This course is designed to teach the basic tools used in a lean culture when problem solving. The course is designed

around a factory simulation where the participants will learn how to apply lean tools in a hands-on manner. Each

participant will be responsible for tracking performance through visual factory methods. As the day progresses, lean

tools are taught and applied to the process. This class is the first stage in an organization’s lean transformation. It is

designed to bring all levels of the organization together in a fun and fast-paced exercise. This class should be used to

help create a hunger and a passion for continuous improvement. Participants will leave excited to go to the next stage of

the transformation.

Audience This introductory course is designed reach all levels of the organization. It is the most effective when cross functional

groups come together for this session. The power of the team is more effective when all disciplines in an organization

can problem solve together.

Learning Objectives• Understand the basics of lean tools

• Understand the kaizen process

• Understand Takt time

• Understand Lead time

• Understand basic P&L accounting

• Go to the next phase in a lean transformation

Course Outline• Takt Time

• What is Kaizen

• Kanban

• Line Balancing

• Seven Wastes

• Cost of Quality

• Basic P&L

• 5S Principles

LEAN



KAIZEN WORKSHOPThree- to Five-Day Course

Description This multi-day course is designed to have the participant learn how to problem solve in a team environment through the

use of lean thinking. Using the principles of lean, participants will work together to plan and implement improvements

to a defined topic. Scope and boundaries will be established and the team will attack the issues until resolution is

implemented. Most companies do not have enough time to effectively problem-solve, so “band-aid” improvements

are made. In lean, Kaizen is a way to use cross-functional resources in short periods or bursts of dedicated time, to

effectively improve processes. Kaizen is an intense, well-defined event used to help organizations problem-solve with a

systematic approach. The approach utilizes people in a dynamic and fast-paced environment and usually at the origin of

the issue being improved. Kaizen techniques utilize many different lean tools such as line balancing, time observations,

SMED, Value Stream Mapping, 5S techniques, and DMAIC.

Audience Kaizen is the engine in the lean journey. Everyone in the organization should attend Kaizen training. It is the most

important part of the lean philosophy. It is where “things get done.

Learning Objectives• Describe what a Kaizen event is

• Describe the DMAIC process

• Document Kaizen results

• Understand the power of cross-functional teams

Course Outline• What is kaizen

• DMAIC Steps

• Introduction to Value Stream Mapping

• Implementation of Improvements

• Controlling the changes

• Documenting and sharing results

39ToolingU.com | 866.706.8665



KANBAN/SUPERMARKET:INVENTORY AND DEMAND MANAGEMENTOne-Day Course

Description This course is designed to introduce participants to another visual factory tool that helps control the levels of inventory

along with establishing controls used for scheduling work center production. The course will discuss the reasons,

rewards, roadblocks, and challenges of using Kanban signals and supermarket inventory to manage the movement and

storage of material. Each participant will see the importance of synchronizing the information and material flow in the

facility. Key characteristics such as lead time, takt time, inventory valuation, excessive changeover, material shortages,

first time quality, and unbalanced processes will be discussed and the impact shown. The participant will be able to

see the impact of continuous improvement on the material management system. This introductory class will give the

participant enough information to start implementing in their own facility.

Audience This introductory course is appropriate for employees, supervisors, purchasing agents, engineers, and managers who are

considering using visual management tools on the shop floor to help store, move, and replenish material.

Learning Objectives• Describe the elements of a Kanban system

• Describe the elements of a supermarket and when they should be used

• Describe what role demand has on supermarkets and Kanbans

• Describe the impact waste has on the “signaling system”

• Understand how continuous improvement is used to drive inventory levels lower and lower

Course Outline• What is a Kanban System?

• What is a Supermarket?

• What is real demand-Takt Time

• Impact of waste on Kanban and Supermarkets

• Pull Systems: A Case Study

LEAN



LEAN PRODUCT DEVELOPMENTTwo-Day Course

Description Despite an increasing need for speed and efficiency, much of the effort expended by product development teams is often

unnecessary and potentially wasteful. In many cases, only one or two hours of a team member’s work day is actually

spent directly creating value for their customers. The Lean Product Development workshop presents a set of leading-

edge, practical tools for slashing waste and increasing speed and efficiency for any product development process. The

twenty-eight “lean techniques” described in this course enable dramatic reductions in time-to-market while freeing up

valuable resources for additional development work. Firms that have embraced these practical, waste-eliminating tools

have reported up to 50 percent reduction in launch schedules, dramatic improvements in gross margin, and enhanced

customer satisfaction. This hands-on workshop covers all aspects of the subject, including a step-by-step approach for

creating your own lean process that will enable rapid, high-value product development.

Audience Product-line managers, team leaders, task managers, functional managers, six-sigma blackbelts/green belts,

improvement champions, operations managers, process owners, design engineers, and all others with product

development responsibilities.

Learning Objectives• Identify non-value-added tasks and wasteful work

habits on any development project

• Apply 28 lean techniques that provide immediate savings of time and cost

• Use a step-by-step method for prioritizing improvement activities

• Improve the quality and efficiency of customer/team/management communication

• Maximize utilization of scarce human and capital resources

• Support a culture of discipline, value-focus, and intolerance of waste

Course Outline• How You Will Benefit

> Typical sources of waste in product development

> A common-sense, toolbox approach

• A Brief “Lean Thinking” Tutorial

> How the five principles of lean thinking apply to new product development

> Avoiding undershoot and overshoot of customer needs

> Exception management and other fundamental concepts

> The “Continuous Flow” development process

• A Toolbox for Speed and Efficiency

> Testing for Customer Value

> Linked Tasks and the Deliverables Roadmap

> Time Slicing and Stand-up Meetings

> Project Data Management

> The “Waste-Free” Design Review

> Staged-Freeze Specifications

> Value Stream Mapping for Waste Elimination

> Standard Work Methods and Templates

> Risk Buffering and Value Increments

> Resource Prioritization and “Super teams”

> Lean Supplier Management

> Lean Self-Assessment and Kaizen Tools

41ToolingU.com | 866.706.8665



PLANNING MANUFACTURING CELLSTwo-Day Course

Description This course provides an introduction to the planning of manufacturing cells, including the physical, procedural, and

personnel-related aspects of cellular manufacturing. It will provide you with a systematic, step-by-step approach useful

on any cell planning project, from simple manual assembly to automated machining and fabrication.

Audience This course is designed for manufacturing and process engineers, industrial engineers and systems analysts, product

supervisors and team leaders, plant and production managers, materials and production planners, cell-planning and

Just-In-Time (JIT) implementation teams, and program leaders for JIT and TQM.

Learning Objectives• Provide a systematic procedure for planning individual manufacturing cells

• Increase the productivity and effectiveness of those assigned to design and implement manufacturing cells

• Help prepare for plant and company-wide implementation programs

• Understand the strategic benefits and value of cellular manufacturing

Course Outline• Introduction

• Understanding Manufacturing Cells

• How to Plan a Manufacturing Cell

• Systematic Planning Techniques

• Other coupling factors: physical, procedural, people

• Systematic Planning In Action

• Modifying, Selection and Accepting Cell Plans

• Case Problem in Detail Cell Planning

• Principles of Motion Economy and Workplace Design

• Management Issues and Implementation

• Technology and Strategic Issues In Cellular Manufacturing

LEAN



SETUP/CHANGEOVER REDUCTIONOne-Day Course

Description This course is designed to help problem solving teams learn how to identify the features of the non-value-added time

of setting up or changeover equipment used in the manufacturing process. In today’s global market, manufacturers

must be more flexible and have the ability to produce smaller quantities and deliver quicker. They must be able to

utilize equipment for as many different parts as possible. This new way of doing business is driving companies to invest

in capital equipment and inflate their inventories. This course will help participants combat the impact these new

demands are creating. The setups and changeovers are comprised of a series of steps that are performed to prepare

the manufacturing process for a new part. The participant will learn how to define all of the features of a changeover

and learn how to eliminate the waste. The elimination of wasteful activities will free up capacity, lower the need for

inventory, reduce lead time, and help the organization become more flexible.

Audience This class is designed with a hands-on, cross functional team format. It is encouraged to design your teams with several

functions within the organization such as engineering, maintenance, technicians, operators, supervisors etc. This

cross functional mix will give the team the flexibility to make decisions immediately. It also utilizes different levels of

expertise to problem solve creatively.

Learning Objectives• Describe what is meant by setup/changeover time

• Explain the difference between internal and external time

• Understand the impact changeover/setup time has on the organization

• Utilize the changeover template to document a changeover

• Write a new setup/changeover procedure

Course Outline• Definition of Setup/changeover

• Internal vs. External Set-up

• How to document and analyze a set-up/changeover

• Developing and implementing Setup/changeover reduction improvements

• Documenting new standard work procedures

43ToolingU.com | 866.706.8665



SIX SIGMA GREEN BELTFive-Day Course

Description Six Sigma Green Belt – Five-Day Classroom/Workshop: This course teaches specific Lean Six Sigma tools, methods and

techniques for performing business improvement and root cause analysis projects. Six Sigma performance benchmarking

allows organizations to continuously strive towards perfection. Emotional decisions are replaced with logical fact based

decision making tools.

The Six Sigma Green Belt Team Leader is an important part of fostering a Six Sigma Business Culture by providing

direction and vision to the team members as well as people in their organization. This ensures the team’s contributions

make for a successful project. The course links Lean Six Sigma principles with team activities and people development

to enhance measurable results in operational excellence and ensures a thriving business environment.

Six Sigma Green Belt Plus – Up to 16 hours of supplementary Project Coaching /Mentoring: This course activity is in

addition to the Five-Day Classroom/Workshop. It involves providing coaching/mentoring to Six Sigma Green Belt Team

Leaders who want to complete an actual project as part of their Six Sigma Green Belt training certification. This is for

those participants who do not have access to a Six Sigma Black Belt to assist in their organizations development of

a Six Sigma Business Culture.

Audience Project Team Leaders; Process Improvement Managers; Operation Excellence Managers; People involved in Quality

Improvement and Root Cause Analysis.

Learning ObjectivesSix Sigma Green Belt – Five-Day Classroom/Workshop: team leaders will learn how to select a project and perform root

cause analysis to identify the true root cause of an unknown problem. This will allow the Team Leader (Green Belt)

and the team members (Yellow Belts and subject matter experts) to determine the solutions to solve the true problem

(not the symptoms). These solutions will provide significant savings for the organization in terms of costs, increased

efficiency, high-quality products, and increased bottom line figures. By teaching with accelerated learning techniques

(class exercises and hands-on experience), participants can easily grasp and understand the five stages (DMAIC) of

a Six Sigma project. DMAIC stands for: Define-Measure-Analyze-Improve-Control. Each of these topics are explained

thoroughly and used as the basis of a Six Sigma project.

Six Sigma Green Belt Plus – Up to 16 hours of supplementary Project Coaching/Mentoring: This course activity is in

addition to the Five-Day Classroom/Workshop. The team leader completes an actual six sigma project learning through

real life experiences of applying the concepts from the Six Sigma Green Belt five day Classroom/Workshop course.

Additional coaching and mentoring is provided for the participant to receive feedback and encouragement with regard

to the specific project stages and tollgate gate reviews through to the completion.

LEAN



SIX SIGMA YELLOW BELTTwo-Day Course

Description Six Sigma Yellow Belt is an introduction to the Lean Six Sigma principles and methodologies, and how to apply them

to your specific work environment as part of a team. As a team member the tools and techniques taught are vital to the

success of a Six Sigma project, resulting in business improvement and people development.

Audience Project team leaders, process improvement managers, operation excellence managers, and others involved in quality

improvement and root cause analysis.

Learning ObjectivesTeam members will understand the Six Sigma DMAIC principles along with their roles within a project. By teaching with

accelerated learning techniques (class exercises and hands-on experience), participants can easily grasp and understand

the five DMAIC stages of a Six Sigma project. DMAIC stands for: Define-Measure-Analyze-Improve-Control. Having

knowledgeable and trained Team Members (Yellow Belts) on a Six Sigma project is fundamental to its success.

Course Outline• Define

• Project selection

• Roles and Responsibilities

• Team building activities

• Current state process map – Top level

• SIPOC Diagrams – Supplier/Input/Process/Output/Customer

• Quick Wins

• Project Charter

• Tollgate reviews

• Measure:

> Value stream map – Current state

> Swim lane map

> Current state process map – Detailed

> Data collection methods

> Check sheets

> Graphical data display (Scatter plots, Histograms, Box plots, Bar charts, Pareto charts)

• SPC – Control Charts

• Baseline process

• Normal bell curve

• Calculating sigma (Using DPMO method and Overview of z-score method)

• Analyze

• Value-added analysis

• Cause and effect diagrams

• Brainstorming

• Five why’s

• Multi-voting

• Root cause analysis

• Potential root causes problem statement

• Improve

• Lean concepts: seven wastes – TIMWOOD, 5S, Kanban, Pull/Push flow, Poka yoke, Experiment – Windfarm Enterprises

• Develop potential solutions – Idea generating tools

• Future state process map and value stream map

• Solution selection methods

• Control

• Identify similar opportunities

• Control plan

• Transition to process owners

• Lessons learned

• Team recognition

• Project closure Six Sigma Yellow Belt Exam IQnine000 – See instructor listing

45ToolingU.com | 866.706.8665



UNDERSTANDING THE TOOLS AND BEST PRACTICES OF LEAN MANUFACTURINGTwo-Day Course

Description Lean manufacturing is a way of thinking: a culture of eliminating unnecessary activities while responding to

customer needs. Lean concepts have been adopted by many successful manufacturing companies as a way to reduce

costs, satisfy customers, and increase profitability. The process of “becoming lean” may mean a company-wide

transformation from the current operating style. Companies, divisions, even departments, must identify and prioritize the

projects they will undertake to become lean. Overall, this course offers a methodology for linking the goals and metrics

of a project or initiative to a company’s strategic goals and metrics. It provides the basis for tracking the effectiveness of

lean initiatives.

Audience This course is designed for executives, senior staff responsible for initiating and executing significant change projects

within their companies, production managers, plant managers, manufacturing engineers.

Learning Objectives• Become familiar with a technique for establishing and monitoring the value of lean manufacturing initiatives

• Identify lean manufacturing opportunities within the company

• Establish goals and metrics for a lean manufacturing company

• Characterize lean manufacturing initiatives within operational strategies

• Establish goals and metrics for specific lean manufacturing projects

• Prioritize lean manufacturing investments

Course Outline• Defining Lean Manufacturing

• Goals and Metrics for a Lean Manufacturing Company

• Operational Strategies

• Lean Manufacturing Initiatives

• Linking Initiatives to Strategic Goals

• Lean Manufacturing Investment Decisions

• Using Metrics to Track Initiatives

LEAN



VALUE STREAM MAPPINGTwo-Day Course

Description A hands-on course that teaches students how to document and quantify material and information flow within their

organizations using a reliable method known as “Value Stream Mapping.” The course explains how to capture and

document the current material and information flows for a process and provides guidance on how to envision, map, and

plan for improvements to the current flows. A comprehensive case study is used to allow students to practice drawing

value stream maps using a standard set of symbols. As part of the learning key questions are raised to encourage

students to employ continuous improvement thinking and “reliable methods” when developing “future condition”

value stream maps for the case study company. The class provides excellent instruction on how to document and

communicate process flow from a continuous improvement point of view and provides a standard methodology for

moving from the current condition to an improved future condition.

Audience This introductory course is intended for individuals who already have a basic understanding of continuous improvement

and are seeking a proven way to identify, document, and communicate improvement opportunities within their

organization. It is especially relevant for managers or improvement team leaders who would like to learn a simple,

powerful way to “see” and analyze material and information flow in order to help the organization envision and plan for

changes to the current condition.

Learning Objectives• Define value stream and how it relates to material and information flow

• Explain how the value stream map is used to encourage improvement

• Draw a value stream map using a standard set of symbols

• Determine key opportunities from the current condition value stream map

• Develop current, ideal, and future condition value stream maps

• Create an improvement plan to move from the current to the future condition

Course Outline• Key points of Continuous Improvement and their relationship to Value Stream Mapping

• Material and Information Flow using a Value Stream Map – looking at the big picture

• Symbols and Key Metrics of Value Stream Mapping

• Case Study: Developing Current, Ideal and Future condition maps

• Key points to consider when developing Ideal and Future condition maps

47ToolingU.com | 866.706.8665



COMPUTERIZED MAINTENANCE MANAGEMENT SYSTEM (CMMS)Three-Day Course

Description This program will provide a comprehensive overview of the maintenance process with an in-depth look at techniques and

practices that are sure to enhance the reliability of your manufacturing operations. Topics will include Lean Maintenance

Reliability, a CMMS Overview, and how to justify, evaluate, select, implement and optimize your CMMS. You will

increase your depth of knowledge beyond a fundamental understanding of the CMMS process and learn how you can

dramatically improve maintenance efficiency and productivity.

Audience • Plant engineers

• Maintenance supervisors and managers

• Industrial and manufacturing engineers

• Directors of operations

• Maintenance planners

• Maintenance schedulers

• Facilities engineers and managers

• Purchasing/store managers

• Inventory-related managers

Learning Objectives• Improve maintenance productivity

• Improve machine quality

• Reduce downtime

• Monitor and improve employee productivity

• Reduce outside contract work

• Provide better service to other departments

• Monitor/control maintenance costs

• Reduce clerical costs

• Increase overall productivity and profits

Course OutlineTurn Maintenance into a Profit Center

• Maintenance image

• Impact of downsizing on maintenance

• Lean Maintenance Reliability (LMR) CMMS Overview Basic Modules

• CMMS Overview

• Advanced Topics

• How to Justify a CMMS

• Specifying a CMMS

• How to Evaluate/Select a CMMS

• How to Implement a CMMS

• Audit/Optimize your CMMS

• Program Review

MANAGEMENT



MANAGEMENT

51ToolingU.com | 866.706.8665

CYCLE-TIME MANAGEMENT FOR MANUFACTURERSTwo-Day Course

Description Total Quality Management, Just-In-Time, Short Cycle Manufacturing, Total Customer Service – they all share the same

principle: to effectively manage both operational and administrative cycle times. Today, time has become the single

largest tactical advantage for successful manufacturers. Why? Simply put, no matter how excellent your products are

or how high the quality of those products, unless you can deliver them faster than your competitors, your customers

will take their business elsewhere. They simply cannot afford to wait. Market dynamics are becoming increasingly

short-cycled, product life cycles shorter, price-point pressures greater, and competition for consumers more intense.

According to recent Commerce Department statistics, the window of opportunity for most domestic products today is

smaller by 30 percent than it was only five years ago. Couple that with the recent movement by most primary and Tier

One manufacturers to reduce their supply bases by 65 percent to 70 percent over the next three years, and you have

the formula for either a significant market share increase, or business failure depending upon how effectively you are

managing your total cycle time.

Audience Manufacturing managers, plant managers, engineering managers, design engineers, manufacturing engineers, process

engineers, industrial engineers, manufacturing supervisors, planning and procurement managers, scheduling managers

and anyone associated with the operations, product development, and scheduling functions within your organization.

Learning Objectives• How to baseline your current operations and processes

• How to establish customer-focused cycle-time metrics and benchmarks

• How to prioritize cycle time opportunities

• How to apply reengineering techniques to safely reduce direct and indirect cycle times

• How to increase quality while reducing cycle time

• How to utilize concurrency to your advantage

• How to measure your current cycle-time costs

• How to identify and quantify customer requirements and expectations

• How to assess current process cycle times

• How to measure the ROI of your cycle-time reduction activities in terms important to management

• How to employ reengineering techniques to setup reduction and change-over activities

• How to involve your supply base in your cycle-time reduction efforts

• How to measure internal risk factors

• How to implement your cycle-time reduction plans

Course Outline• All Work Is a Process

• Where to Begin CTM Activities

• Understanding the Process Completely

• Assessing the Cycle-Time Model

• Developing the New Cycle-Time Baseline

• Implementing the Changes

• Using Metrics to Track Initiatives



HOW TO COACH YOUR PEOPLE TO THINK INDEPENDENTLYOne-Day Course

Description In this one-day course, participants will learn the alternative and highly effective new way to implement teams in their

organization. Participants will learn surprising facts about why teams fail and how to jump-start a team. The instructor

will discuss his own experience with establishing teams and eventual results, including cutting lead time from three

days to ten hours, reducing defects by 78 percent and improving productivity by 31 percent. Most strikingly, morale

(measured by corporate surveys) improved by 210 percent! This course encourages interactive discussions and questions

to inform and inspire participants.

Audience This course is designed for presidents and CEOs, plant managers, engineers, quality professionals, supervisors, and

front-line staff and associates who want to achieve breakthrough results in quality, productivity, and lead time,

and who want to exceed expectations, lead, and contribute.

Learning Objectives• Learn alternatives to traditional team building

• Develop a team that enthusiastically craves hard work

• Design a team that’s the right size

• Teach the team problem-solving techniques

• Learn how to let go of making decisions without losing control

Course Outline• Understand the Proven Path to Teams

• Design Your Teams

• Coach Your Team Members to Think Independently

• Lead Your Team Members to Achieve Together

MANAGEMENT



INDUSTRIAL ENGINEERING FUNDAMENTALSThree-Day Course

Description This course will teach participants how to apply work measurement analysis tools, how to efficiently plan and lay out a

manufacturing operation, and how to improve manufacturing processes through methods-engineering principles. This

course will describe the continually changing role of the industrial engineer. Participants will learn how to use new

engineering tools to improve productivity and efficiency.

Audience This is course is designed for all manufacturing disciplines, including (but not limited to) manufacturing engineers,

industrial engineers, packaging engineers, plant managers, mechanical engineers, ergonomic and simulation specialists,

and anyone else needing fundamental training on industrial engineering.

Learning Objectives• Explore the following as they relate to industrial engineering: methods engineering, work measurement, facilities

planning and design, flexible/continuous flow manufacturing, material handling, plant layout, process improvement

• Learn how to standardize and simplify manufacturing processes and methods

• Incorporate product quality and productivity improvement considerations into these work methods

• Provide cost justification for new methods and equipment

• Document and communicate process plans to the manufacturing floor

• Learn to chart manufacturing operations or processes

• Examine the role and importance of work standards and learn how to establish accurate performance ratings and time studies, apply standard data systems, and plan and design efficient manufacturing operations

MANAGEMENT



Course Outline• Methods Engineering

> Process/operation charting techniques

> Standardize/simplify/eliminate

> Work design for quality

> Documentation/communication of process plans

> Productivity improvement

> Machine/process selection

> Cost justification

• Work Measurement

> Need/use of production standards

> Performance ratings

> Calculation of standard times

• Standard data systems

> Examples using M.O.S.T.

> Class exercise

> Work sampling

> Role/maintenance of incentive systems

• Facilities Planning and Design

> Capacity planning techniques

> Defining the performance objectives

> Material flow concepts

> Types of layouts

> Process layout techniques

> Relationship diagrams and charts

> Product/assembly line balancing

> Evaluating your layout

> “Selling” your layout

• Implementation Tips and Pitfalls

• Cellular/Continuous Flow Manufacturing

> Designing manufacturing workcells

> Workcell simulation

> Computer and software tools

> Just-in-time considerations

• Material Handling

> Twenty principles of material handling

> Selecting material handling methods

> Simplifying/eliminating material handling

> Simple analysis techniques

• Class Workshop on Work Cell Design

> Process Improvement

> Problem identification

> Process capability studies

> Statistical process control techniques

> Simple design of experiment (DOE) techniques

> When to automate

• The Industrial Engineering Function and How It Relates to Other Manufacturing Areas

> Production control scheduling and inventory control

> Manufacturing performance measurement and evaluation

> Production/cost accounting

55ToolingU.com | 866.706.8665



MANUFACTURING TECHNOLOGY FUNDAMENTALSTwo-Day Course

Description The purpose of this course is to provide an overall introduction and review of manufacturing processes, equipment,

and process capabilities, with a strong emphasis on product design, material, process, and equipment selection.

Major issues in modern manufacturing and global competition will also be discussed. Non-engineers who work in a

manufacturing environment will benefit from understanding how a product is manufactured.

Audience This is a fundamental course. Although it is designed with the non-engineer in mind, anyone interested in acquiring a

broad-based understanding of how things are manufactured will benefit from the course.

Learning Objectives• Learn the fundamentals of manufacturing

technologies and processes, and the relevant parameters of each process

• With individual case studies, recognize the importance of the interrelationship among design, material and process selection, and how they impact each other

• Understand the factors that influence product quality and integrity in each of the manufacturing processes

• Evaluate the costs involved in material, process, and equipment selection, and assess return on investment and return on quality

• Appreciate the significance of concurrent design and design for manufacturing and how it impacts a company’s operations

• Understand the significance of environmentally-conscious design and manufacturing and assembly

• Evaluate the impact of computers in all aspects of manufacturing technologies

• Learn recent trends in modern manufacturing technologies and appreciate the significance of current topics in research and development

Course Outline• Mechanical Behavior of Materials

• Structure and Manufacturing Properties of Materials

• Tribology

• Casting

• Bulk Deformation Process

• Sheet Metal Forming Processes

• Metal Cutting

• Abrasive and Non-traditional Machining

• Polymer Processing

• Ceramics and Powder Metals

• Rapid Prototyping

• Joining and Fastening Processes

• Integrated Manufacturing Systems

• Competitive Aspects and Economics of Manufacturing

MANAGEMENT



PROJECT RISK MANAGEMENTTwo-Day Course

Description This course arms project managers with the essential knowledge, skills, and tools to effectively manage and even predict

the effects of the risks on a project. The concept of risk is rarely understood by project managers, thus, it is often

overlooked as a factor in the project manager’s responsibilities. Every project – for that matter every business endeavor

– involves some degree of risk. The project manager must accept the fact that risks exist and learn to deal with them

effectively. For every project, the benefits of the project must be weighed against the potential risks to both the customer

and to the project manager’s own organization. In today’s business climate, both senior management and the customer

have become increasingly adverse to risk, particularly those risks imposed without an offsetting benefit or value.

Audience This course is designed for project managers, program managers in charge of several concurrent projects, and new

managers who want to learn to effectively manage the element of risk in projects.

Learning Objectives• Identify risk in the planning cycle

• Categorize and compare different risks

• Analyze and quantify the risk to the project

• Define risk criteria for projects

• Isolate the opportunities that result from effectively managing risk factors

• Conduct professional risk assessments

• Apply alternate risk assessment methodologies to projects

Course Outline• Overview of Project Risk

Management

• Risk defined

• Differing perspectives on risk in project management

• The need for early identification

• Foundations of Risk Modeling

• Project manager’s view of risk

• Risk analyses – when to use

• Inductive modeling

• Deductive modeling

• Applications and timing

• Decisions that Influence Risk

• Take action or wait

• Risk vs. safety

• Risk vs. emotion

• Present vs. future perspectives

• Risk Modeling

• Qualitative to quantitative conversions

• Inductive risk-modeling techniques

• Criticality assessments

• Case studies

• Risk vs. Cost: Safety concerns

• Tangible cost analysis

• Intangible cost analyses

• Risk-cost calculations

• Case studies

• Legal Considerations

• Legal responsibilities defined

• Failure and defect cost modeling

• Safety standards in various industries

• Deductive Modeling Methodologies

• Fault tree and logic tree analyses

• Costs and probabilities

• How Much Risk Management is Required?

• Risk management safety zone

57ToolingU.com | 866.706.8665



QUICK RESPONSE QUOTING AND MANUFACTURINGThree-Day Course

Description Quick Response Manufacturing (QRM) is a powerful company-wide strategy to cut lead times in all phases of office and

manufacturing operations, while reducing costs and improving quality and productivity. In this three-day program, you

will learn how to significantly reduce your cost estimating, quoting, and manufacturing lead times. In today’s competitive

environment, a company’s ability to respond quickly to a request-for-quotation or a production order can have a

significant impact on getting and keeping customers. Over the last 10 years, dozens of manufacturing companies,

working with the instructor, have successfully applied QRM principles and methods to drastically reduce lead times

in quoting and manufacturing. Your company can be the next one to benefit by applying QRM’s comprehensive and

proven approach. Learn how to reduce cost estimating, quoting, and lead times in all forms of operation – office and

manufacturing. Responding quickly to a customer’s request is an important part of sealing the deal. This course will

show you how to perform quick response quoting and how it can benefit your company.

Audience This program will benefit cost estimators, manufacturing engineers and managers, sales and purchasing personnel

involved in cost estimating, quoting, outsourcing, order processing, production management, etc., as well as senior

executives and managers who are leading efforts to reduce lead times in the office and shopfloor environment. The

program is particularly tailored to small to mid-size companies that manufacture high-variety, low quantity and

custom-engineered products.

Learning Objectives• Implementing rapid, accurate, and consistent cost-estimating and quoting

• Developing feature-based (group technology) cost-estimating models for modified-standard products

• Applying operation-level parametric cost-estimating methodology for custom-made products

• Performing activity driver-based estimating of time/effort for non-manufacturing activities such as CAD drafting, engineering, software development, etc.

• Avoiding the pitfalls of traditional quoting practices and replace them with QRM quoting practices

• Reorganizing office workflow processes for lead time reduction in quoting and order processing

• Implementing cells to achieve quick-response production

• Applying QRM techniques for materials planning and control

• Incorporating QRM strategies for customer and supplier relations management

• Monitoring and managing performance metrics that support QRM

MANAGEMENT



Course Outline• Introduction to Quick Response Manufacturing (QRM) Strategy

• Rapid, Accurate and Consistent Cost Estimating and Quoting: Is It Possible?

• What Causes Quoting Variability and Inaccuracies?

• Pitfalls of Traditional Cost Estimating and Overhead Allocation Practices

• Quick Response Cost Estimating Methodologies: Part One

• Common Beliefs and Myths Regarding Cost Estimating and Quoting

• Quick Response Cost Estimating Methodologies: Part Two

• Issues and Challenges in Developing Quick Response Cost Estimating Models

• Principles for Redesigning Office Operations for Quick Response

• Creating an Action Plan for Improving Your Company’s Office Operations

• Activity-Based Costing (ABC)

• Introduction to QRM Principles for the Shop Floor

• QRM Strategies for Materials Planning and Production Control

• QRM Strategies for Customer and Supplier Relationship Management

• Financial Impact of QRM

• Developing a QRM Strategy and Implementation Plan for Improving Your Shop Floor Operations

59ToolingU.com | 866.706.8665



STRATEGIC PROJECT MANAGEMENTThree-Day Course

Description Project management in today’s global markets requires an entirely new set of leadership, management, and

technological skills because many of today’s projects are critical to the strategic direction and vision of the organization.

As a consequence, project management is no longer merely a low profile, fill-in activity. It requires a high degree

of commitment to both operational and fiscal results, an acceptance of accountability for conformance to project

stakeholder requirements, and exceptional leadership skills with which to forge a synergistic chemistry between diverse

functional groups. Success in today’s dynamic, complex business environments is predicated on:

• The ability to accurately understand the complexities of the business and project environment, create a project plan that considers the lowest risk, lowest cost, and lowest impact approach to implementation, and the tactical skills to ensure successful implementation through effective control and risk management.

• The marketing, soft-selling, and negotiating skills to accurately assess stakeholder requirements and expectations, and then to effectively balance them against the actual capabilities of the project team to ensure the critical strategic alignment.

• The organizational skills to select, develop, and motivate personnel from diverse organizational and functional groups to ensure that they can and will work together to attain defined project objectives.

• The ability to develop and implement project management control processes to ensure that the project remains on schedule and within budget, while consistently controlling the internal and external risk factors that could derail the project during both planning and implementation processes.

• The follow-through to ensure that corrective actions are taken quickly and decisively, thus guaranteeing that the project objectives are never compromised.

Audience This program was designed for experienced and novice project managers alike from diverse industry segments.

Business and product managers at all levels will also find this an ideal seminar to isolate methodologies to better

monitor and control their projects.

MANAGEMENT



Learning Objectives• Identify the tools and techniques used by effective project managers from a wide array of industries

• Explain how to establish a project scope that is aligned with both stakeholder expectation and organizational capabilities

• Identify how to establish results-oriented stage gate performance metrics to guide your project throughout implementation

• Describe essential project management tools including project planning, risk management, procurement management, stakeholder management, budget and control, communication management, quality and compliance management, situational assessments, decision analysis, root cause analysis, critical-path and critical-chain techniques, resource leveling, earned value management and forecasting techniques, Gantt, PERT and many more

• Describe how to select the best members for your project team, motivate, and discipline them

• Recall the secrets of trade-off analyses to ensure that the project is never compromised in the eyes of the stakeholders

• Explain the importance of project documentation and lessons learned

Course Outline• Project Management Evolution – Overview of PM Tools, Processes, and Techniques

• Acceptance of Responsibility

• Project Scope Management – Alignment of the Customer’s Expectations and Requirements

• Project Human Resource Management – Organizing for Success through Closed-Loop Management

• Project Communications Management – Managing Perception

• Project Analysis – Situational Assessment, Preliminary Failure Analysis, Decision Analysis

• Project Time Management – Building the Project Plan to Reflect Real Constraints

• Project Cost Management – Building the Project Budget, Financial Controls, and Forecasting Tools

• Project Quality Management – Satisfying Expectations and Compliance Requirements

• Project Procurement Management – Managing Critical Acquisition Processes

• Project Risk Management – Controlling the Downside Effectively Through Quantitative Analysis

• Project Stakeholder Management – Ensuring Project Alignment

61ToolingU.com | 866.706.8665



WALKING THE TALK: PATHWAYS TO LEADERSHIPFive-Day Course

Description There is a significant difference between being an excellent individual contributor and in being an excellent leader.

Leadership and management skills do not come naturally in all but a few cases, but rather must be learned—ideally

before a new assignment or promotion is awarded. Certainly, an individual may have some of the basic natural talents

to be a good leader, but many of the nuances of effective leadership must be learned either through experience or

mentoring from someone who has made the transition successfully.

This course was designed for both experienced and new managers, those preparing for that promotion into the

management ranks, or those adjusting to new circumstances. It is also an excellent course for those anticipating a move

into management in the future, as well as those interested in making themselves eminently more upwardly mobile. And

for those who have been managers for some time, this is an excellent refresher to keep you from becoming stale, or to

help you break some of the common paradigms that come with tenure.

Audience This course was designed for both experienced and new managers, those preparing for that promotion into the

management ranks, or those adjusting to new circumstances. It is also an excellent course for those anticipating a move

into management in the future, as well as those interested in making themselves eminently more upwardly mobile. And

for those who have been managers for some time, this is an excellent refresher to keep you from becoming stale, or to

help you break some of the common paradigms that come with tenure.

Learning Objectives• Identify the steps necessary to enhance the probability of success for every career transition

• Relate how to develop an enlightened leadership style suited to your business environment and your own personality.

• Describe the critical differences between management and leadership, and how those differences separate the few truly successful leaders from the many managers who just struggle along or fail

• Describe how to leverage your technical and operational expertise into a powerful leadership style

• Explain how to manage the risks that can arise from poor decisions, misaligned organizational structures, or ineffective management actions/inactions.

• Describe the way to lead, earn the respect of your peers and employees, and create a successful organization

MANAGEMENT



Course Outline• Introduction – Management vs. Leadership

• The Transition from Individual Contributor to Manager, then Organizational Leader

• Leadership in Perspective

• The Complexity of Today’s Employment and Labor Laws

• Management and Leadership Skill-Building Scenarios and Case Studies

• Employee Selection, Direction, Motivation, Development, and Discipline – A Focus on Results Versus Effort

• Building Organizational Alignment and Balance to Maximize Capability

• Base-Lining Organizational Competencies and Capacities

• Quantitative Problem-Solving and Decision-Making Techniques to Eliminate Bias and Emotion

• Turning Your Vision for Change Into Reality – Organizational Change Management

• Recognizing and Controlling Organizational Politics

• Organizational Risk Management: Maximizing the Upside While Controlling the Downside

63ToolingU.com | 866.706.8665



INTRODUCTION TO COMPOSITESTwo-Day Course

Description This course is designed for the student that has little or no prior experience with composite materials and processes.

It is also an excellent refresher for those that have some experience in this area. In this course we introduce a variety of

composite materials, forms, processes, laminate design ideas, and basic construction and manufacturing principles.

Audience Composite technicians, engineers, quality assurance inspectors, procurement personnel, and anyone interested in

advanced composites.

Learning ObjectivesTo provide a fundamental understanding of advanced composite materials, properties, and manufacturing processes and

methods used in fabricating and inspecting these types of structures.

Course Outline• Composite technology overview – history, recent developments, and an introduction to industry terminology

• Advantages and disadvantages of composite materials

• Health and safety concerns

• Fibers – properties of glass, carbon, Kevlar,® boron, and quartz fibers

• Fiber forms: non-woven, unidirectional, bidirectional, and multi-axial fabrics and forms

• Resins – thermoset and thermoplastic resin matrices

• Laminate design fundamentals: quasi-isotropic, balanced, and symmetric laminate properties

• Core materials – foam, honeycomb, and balsa core materials

• Molding methods – contact molding (wet and prepreg hand layup), resin/film infusion processing, pultrusion, filament winding, tape laying, and fiber placement technologies

• Vacuum bagging materials and techniques: oven vs. autoclave issues

• Curing thermoset resins: understanding viscoelastic properties and determining cure of thermoset resins

• Service environment concerns – lightning strike protection, corrosion concerns, chemical and environmental exposure issues

• Non-destructive inspection methods and techniques – visual inspection, tap testing, radiography, thermography, holographic laser interferometry, laser shearography, and ultrasonic A and C scans

MATERIALS



JOINING AND BONDING COMPOSITE STRUCTURESOne-Day Course

Description This course is designed for the attendee to learn more about joining and bonding advanced composite structures. This

course assumes that the attendee has some experience with composites materials or has attended the Introduction to

Composites course as a prerequisite. In this course, different materials, methods, hardware, and techniques employed in

bonding and fastening composite structures are examined.

Audience Composite technicians, engineers, quality assurance inspectors, procurement personnel, and anyone interested in

bonding advanced composite structures.

Learning ObjectivesTo provide the student with a fundamental understanding of adhesive bonding principles, methods, and techniques

employed in the advanced composite industry.

Course Outline• Bonding vs. fastening a composite structure: examining the pros and cons

• Typical joint designs

• Drilling composite structures – tools and techniques

• Fasteners/fastening composites

• Structural adhesives – properties and characteristics of different chemistries and forms

• Failure modes of adhesively bonded joints

• Surface preparation – metals vs. plastics, peel ply surfaces and abrasion techniques

• Cleaning freshly energized composite surfaces

• Bondline thickness control – using carriers and microbeads

• Methods for obtaining uniform clamping pressure at the joint

• Curing the adhesive: fundamentals of time and temperature processing

65ToolingU.com | 866.706.8665



MATERIALS


REPAIR OF COMPOSITE STRUCTURESOne-Day Course

Description This course covers the basic requirements for assessing damage and repairing advanced composite structures. It is

designed for the student that has some experience with composites materials or has attended the Introduction to

Composites course as a prerequisite. This course examines different materials, methods, and techniques employed in

damage assessment, removal, and permanent reconstruction of damaged composite structures.

Audience Composite repair technicians, engineers, quality assurance inspectors, and anyone else that may be interested in

advanced composite repairs.

Learning ObjectivesTo provide the student with a fundamental understanding of damage assessment, damage removal, and common repair

processes utilized in the repair of advanced composite structures.

Course Outline• Types of damage and other defects – understanding the terminology

• Damage assessment/determination of extent of damage

• Damage/defect removal

• Dealing with contamination in the structure

• Drying moisture contaminated structures

• Types of repairs – comparison of tapered-scarf vs. stepped vs. doubler repairs

• Paint or gel-coat removal requirements and concerns

• Identification of unknown structures – material form recognition, determining ply count and ply orientation, and establishing an adequate repair scheme

• Composite material replacement and orientation requirements

• Repair materials and methods – wet-layup, prepreg, and bonded or bolted doubler repairs

• Replacing lightning strike materials in repairs

• Using hot-bond equipment – understanding different heating methods and techniques


TOOLING FOR COMPOSITESTwo-Day Course

Description This course is designed for the student that is interested in designing or building tooling for composites. The course

assumes that the attendee has some experience with composite materials or has previously attended the Introduction to

Composites course as a prerequisite. In this course we explore the many types of tools used for manufacturing composite

panels (and assemblies), as well as those used in the fabrication of the tools themselves. A thorough examination of tooling

materials and properties is addressed.

Audience Composite technicians, tool fabricators, tool designers/engineers, quality assurance inspectors, procurement personnel,

and anyone interested in advanced composite tooling.

Learning ObjectivesTo provide the student with a fundamental understanding of composite tool design, tooling materials and properties,

as well as tool fabrication and maintenance methodologies.

Course Outline• Types of tools, tool designations, and tool function

• Prototype vs. rate-production tooling

• Model requirements and limitations – virtual (CAD) vs. physical models

• Fundamentals of tool design – meeting application and service requirements

• Composite vs. metal molds and fixtures – pros and cons

• Tooling materials/material properties and characteristics

• Fabricating composite tool-laminates – materials, methods, and tricks of the trade

• Tool proofing and thermal mapping/categorization

• Tool maintenance and repair requirements

• Initial tool-surface preparation and semi-permanent release agents


PROCESS TECHNOLOGIES


Description This certificate program provides a comprehensive overview of the coil-splitting process with an in-depth look at

techniques and practices that are sure to enhance the slitting operations. You will be shown several operational

features that, if included on your lines, could dramatically improve product quality and productivity.

Get the recognition you deserve. The purpose of this certificate program is to provide a standard achievement to

improve your knowledge and understanding of the coil slitting process, correct tooling setups, proper use of stripper

rings, remedies to common slitting mistakes, teamwork, quality, productivity, line concepts, power requirements and

more. By achieving this certificate, you will have documentation of your knowledge that you can take to current and

future employers to validate your expertise. This comprehensive professional training will give you the knowledge,

skills, study materials and an examination of understanding for the coil slitting process. You benefit by getting the

recognition you deserve for your knowledge and skills, your company benefits by having you as a recognized, trained

professional and the industry benefits with the quality products you produce. The certificate program is not a license

or a certification from SME, but recognition of your knowledge, skills and experience in forging press operations. If you

have taken The Fundamentals of Coil Slitting, this program is the next step.

Audience Slitter owners, slitting line operators, slitting line setup personnel, slitting line helpers, slitting production managers,

slitter maintenance personnel, quality control personnel, area engineers, plant engineers, and plant managers.

Learning Objectives• Quality Considerations

• Defining Gauge Ranges

• Types of Coil Slitting

• Line Productivity

• Coil Storage and Handling

Course Outline• What is Coil Slitting?

• Program Expectations

• Quality Considerations

• Defining Gauge Ranges

• Types of Coil Slitting

• Line Productivity

• Coil Storage and Handling

• Equipment Considerations

• Dealing with Shape Problems

• Fracture Mechanics

• Slitter Capacity

• Slitter Tooling

• Packing the Arbors

• Know Your Slitter

• Understanding Setups

• Edge Trim Disposal

• Edge Trim Considerations

• Threading Aids

• Strip Separators

• The Recoiling Process

• Slit Coil Packaging

• Drive Concepts

• Presentation Wrap-Up

COIL SLITTING CERTIFICATE PROGRAM Three-Day Course


COIL SLITTING FUNDAMENTALSTwo-Day Course

Description This course will provide a basic overview of coil processing with an in-depth look at the specific slitting process. The

focus is on slitting for light, medium, and heavy gauge steel (steel gauge ranging from: .015 to .615). In addition to

the technical areas, the course will address important day-to-day work issues such as teamwork, increasing productivity

through increasing uptime, and quality as relates to coil slitting.

Audience This course is designed for slitter owners, slitting line operators, slitting line setup personnel, slitting line helpers,

slitting production managers, slitter maintenance personnel, quality control personnel, area engineers, plant engineers,

and plant managers.

Learning Objectives• Realize how quality and teamwork effect coil slitting operations

• Resolve shape challenges

• Understand the language of slitting

• Improve setup procedures

• Learn proper separator alignment

Course Outline• Quality and Teamwork Issues

• Understanding Line Concepts

• Increasing Uptime and Productivity

• Exploring Tensioning Systems

• Tackling Shape Problems

• Slitting Language and Terminology

• Fundamentals of Fracture Mechanics

• Stripper Ring Systems

• Determining Slitter Capacity

• Tooling Setup Procedures

• How to Check Your Slitter Tolerances

• Edge Trim Disposal

• Separator Alignment and Set-Up

• Line Drive Considerations





HIGH-SPEED END MILLINGTwo-Day Course

Description The dynamics of end milling are not taught in machining or basic metal-cutting classes; however, as speed and

horsepower increase, it is common for endmills to vibrate or chatter. Machinists can typically eliminate chatter from

their processes, but most often at the expense of cycle time (25-200 percent lost productivity). This course teaches

how to improve quality while machining parts faster by testing and understanding the tool-toolholder-spindle-machine

structure. These techniques have been used by industry for more than 20 years and have become more mainstream as

high-speed CNC machines have spread through the industry.

Audience Machinists, CAD/CAM Programmers, Manufacturing Engineers, Shop Supervisors, and Business Owners.

Learning Objectives• Attendees will learn how to manage and perform the latest techniques in optimizing endmills for improved productivity

and quality.

• These five-to-ten minute analysis techniques can save hours and days of tool testing by quickly steering the machinist to the optimal speeds, depth of cuts, and feeds for their system.

• The content builds upon basic metal-cutting knowledge taught in trade school, undergraduate engineering, and machinery handbooks.

Course Outline• Experimental Vibration

• Tap Test

• Compare endmill structures

• Mode Shape

• Cutting Dynamics and Stability Diagrams

• Review cutting mechanics

• Self-Excited Vibration

• Stability Diagram

• Review Endmill Optimization Techniques

• Machine Shop Demo – Testing Endmills

• Analyzing Endmills – Stability Diagrams

• Machine Shop Demo – Cutting tests

• Managing Parameters in CAD/CAM

• Course Wrap-up


HIGH-SPEED HIGH-POWER MACHININGOne-Day Course

Description This course will teach you advanced techniques in metal cutting through awareness of machine dynamics. Research

has generated a vast amount of knowledge over the years. However, extensive application or distribution of this

information to the manufacturing engineering community has not occurred. This course will supply you with

the practical background you need to apply much of this knowledge to several areas in production engineering:

specifications and acquisition of machine tools; machine tool testing, proper use, and maintenance, process planning,

and NC programming.

Audience Engineers involved in the design, improvement, and maintenance of machine tools; specifying, purchasing, and testing,

or programming machining operations should attend. This course is designed for engineers with a background in the

problems of vibrations and the lack of stiffness of structures, spindles, tool holders, and fixtures. Production engineers

that are concerned with maximizing the effectiveness of metal removal operations, both stability and accuracy. Process

planners-NC programmers interested in learning how existing data bases for speed and feeds can be expanded to

include width and depth-of-cut to improve accuracy and metal removal rates and avoid chatter for specific machines

and operations. Machine tool builders and users will benefit from this course.

Learning Objectives• Study chip formation and tool wear

• Review dynamic characteristics of machine tools

• Evaluate chatter and methods of combating it

• Discover errors due to cutting forces and methods of minimizing them

Course Outline• Introduction and overview

• Review of mechanical vibration theory

• Chatter theory

• Simulation of chatter and errors of the machined surface

• Sensors for high speed machining

• Control of chatter

• Evaluation of Machine Tool Cutting Performance

• Process planning

• Spindle modeling (if time permits)

• Specification and comparison of high-speed spindles (if time permits)





INDUSTRIAL COMBUSTION SYSTEMSTwo-Day Course

Description The purpose of this clinic is to provide a complete overview of industrial combustion systems principles, operation, and

troubleshooting so as to improve your expertise in this area.

The use of industrial combustion systems in the manufacturing process, including forging, metal heat treating, painting,

curing, ceramics, etc. has increased. However, as plants downsize, the expertise needed to use these systems correctly

and most effectively has diminished. This exceptional, two-day program addresses the needs of the manufacturing

professional responsible for operating, setting up and troubleshooting combustion systems, as well as those interested in

learning more about them.

Audience If you’re interested in learning more about the proper operation, setup and troubleshooting of combustion systems in the

manufacturing process, this course is a must-see for: Maintenance technicians responsible for burner and combustion

systems. Furnace, oven, and kiln operators who tune and maintain their burner systems. Plant engineers and quality

supervisors with an interest in furnace productivity, product quality and fuel economy. Start-up and service technicians

for process heating equipment manufacturers. Sales and customer service reps whose ability to assist their customers

will be enhanced by a basic understanding of how burner systems work.

Learning Objectives• Gain an understanding of the basics of combustion

systems and how they operate

• Learn how to properly set up these systems for efficient operation

• Learn preventive maintenance techniques to avoid common problems

• Develop skills for troubleshooting these systems when problems occur

Course Outline• The Combustion Process

• Basics of Fuel-Air Ratios

• Heat Transfer

• Heat Balances in Industrial Furnaces, Ovens and Kilns

• Wall, Radiation and Conveyor Losses

• Heat Storage, Insulating Materials and Production Scheduling

• Available Heat

• Fluid Flow – Relationship between Flow and Pressure Drop

• Flow Control Systems

• Basics of Flow Control Systems

• Air Flow Controls

• Gas Flow Controls

• Burner Control Systems

• Setting Up Burners – By the Numbers

• Pressure and Flow Measurement

• Preheated Air–How It Affects Control System Operation

• Preventive Maintenance – Setting Up a Checklist

• Troubleshooting

> Philosophy – How to Approach Equipment and System Problems

> The Troubleshooting Guide – How to Use It


LASER CUTTING CERTIFICATE PROGRAMThree-Day Course

Description This program builds on fundamental knowledge of CNC operations and part design for CO2 laser cutting. Attendees will

apply this information in a uniquely designed interactive and hands-on demonstration optimizing the operation of a CNC

laser cutting machine. Safety and ISO standards are included in this program, and each attendee will learn how to work

in compliance with the parameters of CNC laser cutting machines.

Audience Laser operators, laser technicians, laser OEMs, laser integrators, product designers, and manufacturing engineers.

Learning Objectives• Laser Safety

• Fundamentals

• Applied Laser Technology

• Laser Cutting Machine Operations

• Maintenance

• Creating a Work Plan

Course Outline• Understanding the effects industrial lasers have

on the eye and skin.

• Becoming familiar with control measures used to prevent hazardous laser exposure.

• Awareness of laser safety standards and regulations.

• Knowing the importance and role of the Laser Safety Officer

• Blueprint reading

• Geometry of parts (three dimensional thinking, optimizing part layout)

• Laser to material interaction (laser friendly materials and impact of surface conditions on downtime)

• Process gas requirements and selection (gas delivery systems and gas dynamics-critical

• Systems applications (on blanks)

• Nozzle adjustments and cutting speed (types, gas flow, alignment, geometry, height, standoff and venture effect)

• Laser Machine set up

• Laser nozzle adjustment

• Approach Reference Point

• Manual Traverse Exercises

• Position tool (nozzle)

• Set Zero point

• Understanding why maintenance is critical

• Preventive maintenance and consumables

• Layout of a part process cutting sequence sigma nest

• Test Abilities of a Part Process





MACHINING PROCESS OPTIMIZATION PROGRAMOne-Day Course

Description Application of the techniques presented in this program will improve your machining process efficiency by at least

20 percent. These techniques have delivered four-fold increases in tool life, elimination of scrap, and increases in

profitability. It enhances manufacturing efforts in all lean enterprises.

Audience Machining process engineers, tool designers and programmers, sales and technical service representatives, machinists,

chemists, chemical managers, metalworking fluid sales personnel and technical service representatives, Six Sigma

practitioners, and quality managers.

Learning ObjectivesThis program focuses on understanding chip formation during machining, how to read the tool wear patterns for insight

to continuous improvement activities. Key points of the program:

• Solve any machining problem

• Improve profitability any machining process

• Identify and document sub-optimized practices for continuous improvement

• Read the process issues by understanding tool wear and failure modes

• Use a ‘Deep Dive” into a process as a training opportunit

• Address sub-optimized conditions with world-class techniques

• Capture process data and analyze it properly

• Understand all cost components of the manufacturing process

• Recognize the nine elements that impact the cost components

• Address the five disciplines that impact the efficiency of the process

Course OutlineThe course is broken into explaining the nine elements of manufacturing and the five disciplines that are impacted

by the nine elements.

• Nine elements:

> Part Design/Part Processing

> Part Material and Hardness

> Blank Manufacturing quality

> Tool Design and Manufacture (including Regrind)

> Fixture Design and Manufacture

> Machine Condition (including filtration)

> Gauges and Technique

> Lubricant Chemistry, Condition and Application

> The Machinist (operator, skilled trades, cutter grind, all managers)

• Five disciplines:

> Filtration

> Tools

> Coolants

> Metallurgy

> Machine


METAL FORMABILITY CERTIFICATE PROGRAMThree-Day Course

Description This program provides a basic overview of the metal formability process with an in-depth look at techniques and

practices that are sure to enhance your operations.

Audience Tool and die makers and designers, die engineers, sheet metal product designers, sheet metal product release engineers,

operators, managers, purchasing, stamping manufacturers, plant managers, and anyone who is a practitioner of

formability measurements for formability improvement.

Learning Objectives• Identify the differences between feasibility, manufacturability, and capability

• Read and interpret Formability plots from FEA applications

• Read and interpret Forming Limit Diagrams

• Effectively record and report on stamping formability

• Determine potential corrective actions to address formability issues

• Apply a formability analysis systems that addresses product design through tooling launch

Course Outline• Identify Critical Process Outputs

• Identify Critical Process Inputs

• Define Measurement Strategies and tracking methods

• Formability Measurement

• Define and perform Strain Analysis

• Identify FLD (forming limit diagram)

• Define Thinning Strain Analysis

• Formability Analysis

• Identify Common Tools

• Plan for Product Feasibility

• Plan for Manufacturing Feasibility

• Plan for Die Verification

• Failures, Variability and Corrective Actions

• Formability System Process Control





METAL STAMPING PRESS MAINTENANCE AND TROUBLESHOOTINGOne-Day Course

Description This program will train attendees in the following areas: How to maximize uptime, even with less than perfect machinery,

The Theory of the Box, safe metal stamping press operations, each participant will fully understand the design and

usage of metal stamping presses, and efficient and practical preventative maintenance inspection procedures.

Audience All press maintenance personnel.

Course Outline• Press Operator/Die Setting/Basic Maintenance Training

• Terminology Overview

• Clutches and Brakes

• Frame Design

• Drive Train Designs

• Slide Assembly

• Die Cushions

• Bolster Plates

• Importance of Proper Level and Alignment of the Press Bed and or Frame

• Counterbalance Cylinders

• Troubleshooting

• Design and implement your own Press Preventative Maintenance Program


METALWORKING FLUID MANAGEMENTCERTIFICATE COURSEThree-Day Course

Description This course provides a comprehensive overview of metalworking fluids and is led by industry-renowned experts.

The course is tailored to provide a comprehensive look at the latest techniques and practices that are sure to improve

your metalworking fluid operation. The course gives you the opportunity to review the various operations that use

metalworking fluids, explore the fundamentals of fluid and additive chemistry, analyze factors that affect the quality of

metalworking fluids and the work environment, learn about the unique aspects of metalworking fluid microbiology and

toxicology, and review a broad range of condition monitoring tests, learning how to use condition monitoring to manage

metalworking fluids in individual sumps and large central systems.

Audience This course was designed for those involved in developing additives for, formulating and using or maintaining

metalworking fluids. Including:

• Metalworking fluid end users – typically maintenance

engineers and those responsible for dealing with health

and safety issues

• Metalworking fluid formulators – chemists, sales

representatives and fluid maintenance engineers

• Metalworking fluid additive suppliers – chemists and

sales representatives handling the variety of additives

used in metalworking fluids

• Distributors of metalworking fluids – attending will enable

you to provide better support to your end user customers

• Chemical process operators

• Health and safety personnel

• Laboratory and technical personnel

• Machinists

• Metalworking plant managers and supervisors

Learning Objectives• Explore the fundamentals of fluid and additive chemistry

• Analyze factors that affect the quality of MWFs and work environment

• Learn about the unique aspects of MWF microbiology and toxicology

• Review a broad range of condition monitoring tests

• Improve knowledge and understanding of MWF management

• Find solutions to common MWF problems

• Understand the various types of metalworking operations

• Recognize the primary types of metalworking fluids

• Identify chemicals used to formulate metalworking fluids

• Become aware of metalworking fluid microbiology fundamentals

• Identify antimicrobial additives used to control microbial contamination in metalworking fluids

• Understand fundamental concepts of metalworking fluid toxicology

• Understand industrial hygiene for metalworking facilities

• Use test data to manage metalworking fluid systems

• View and apply the information through a variety of case studies

• Obtain documentation and validate expertise with an optional post-exam at the end of the course (Please note: this is different than STLE’s certification exams – the CLS, CMFS, OMA I and OMA II.)





METALLURGY CERTIFICATE PROGRAMThree-Day Course

Description This certificate program will provide you with a basic understanding of the properties of metals and their alloys as well

as an introduction to the science of forming alloys. In addition, common manufacturing flaws and the modes of common

failure of engineering alloys will be introduced, allowing you to identify processes and techniques that will help you

improve your product quality and reliability. Real-world examples will amplify key points in the program. The certificate

program pre- and post- exams allow for the examination of proven information gained by participants. Successful

candidates receive: SME Certificate of Completion.

Audience This program is designed for anyone interested in metallurgy, including fabricators, design engineers, quality control

personnel, supervisors, metallurgy professionals, and product developers.

Learning Objectives• Fundamental aspects of metallic properties

> Atomic makeup of metals and alloys

> Relation of crystal defects and strength

> Ductility

> Heat treatment

> Alloying

• Failure modes in terms of causes and characteristics

> Ductile overload failure

> Brittle failure

> Fatigue

> Friction wear

> Additional forms of corrosion

• Manufacturing techniques for alloys

> Casting

> Mechanical forming

> Welding

> Powder metallurgy techniques

> Heat treatments

> Metallurgical surface treatments


Course OutlineDay One — Pre Exam

• Introduction to Metals and Alloys

• Fundamental Properties of Metals and Their Alloys

• Metals and the nonmetallic elements

• Characteristic physical properties of metals

• Characteristic chemical properties of metals

• Metal crystal structures

• Metal crystal defects that determine properties

> Diffusion

> Ductility

> Strength

> Fracture

Day Two

• Microstructure and Properties of Metals and Alloys

• Effects of Microstructure on Properties and the Control of Microstructure

• Introduction to phases of metals and alloys

• Casting structures

• Wrought structures

> Work hardening

• Annealing

• Steel and aluminum alloys

• Heat treating

• Forming techniques and flaw state

• Surface treatments

Day Three

• Specification and Durability of Alloys

• Examine the Modes of Damage, Origin of Flaws and Types of Nonconformances that are seen in Engineering Applications of Alloys

• Specifications and requirements for alloys

• Modes of damage

> Overload

> Brittle fracture

> Fatigue

> Corrosion

> Wear

• Flaw State

> Measurement testing and control

• Review

• Post Exam

79ToolingU.com | 866.706.8665





MACHINE TOOL METROLOGY PRACTICAL APPLICATIONSThree-Day Course

Description This course is designed for manufacturing engineers and technicians looking to assess, characterize, and understand the

accuracy errors of a machine tool and perform the necessary tests for specific applications. It provides a comprehensive

review of the latest national and international standards for CNC machine tool evaluation. Current metrology instruments

are reviewed including newly developed systems including autocollimators, electronic levels and compliance systems,

telescoping ball-bars, spindle analysis systems, and 5-D laser measurement systems. Geometric, thermal, and dynamic

machine tool errors are identified and discussed as well as machine tool error mapping and correction. Where practical,

demonstrations on electronic gages, levels, laser, and telescoping ballbar are part of this comprehensive training program.

Audience This course is designed for concerned with machine tool productivity and purchasing specifications. It is also appropriate

for managers, engineers, and technicians engaged in plant management and supervision, manufacturing operations,

quality assurance, control, and maintenance, machine tool builders and designers, machine tool rebuilders and

distributors machine tool sales, service, and testing representatives, technology educators, factory, assembly, and field

service technicians and machinists.

Learning Objectives• Understand, assess, and characterize the accuracy

errors of machine tools

• Perform the appropriate tests for error evaluation

• Create specifications based on standards

• Communicate in terms used and understood by the machine tool community

• Become familiar with the use of recently developed metrology instruments

• Identify machine tool accuracy error sources

• Compare the accuracy of similar machines

• Make informed purchase decisions

• Effect machine tool error corrections

• Plan maintenance action

Course Outline• Fundamentals of Machine Tool Metrology

• Introduction to the ASME B5.54 Standard

• Metrology Instruments – Principles, Applications, and Utility

• On-Machine Demonstration – Level and Compliance Measurements

• Geometric Errors and Their Measurement

• On-Machine Demonstration – Geometric Error Mapping with the 5-D Laser Measurement System and Cold Tests with the Spindle Analyzer System

• Dynamic and Thermal Error and their Measurement Methods

• On-Machine Demonstration – Telescoping Ballbar Spindle Dynamic and Thermal Analyzer System (Warm Tests)


MODERN GRINDING TECHNOLOGYTwo-Day Course

Description This course will acquaint participants with modern-day grinding processes and practices. Using “real world” production

situations, the course dispels the myths of grinding and provides an easily understood and comprehensive view of the

abrasive machining process technology available for today and tomorrow’s industry. This course will equip participants

with the necessary understanding to choose abrasive type, grinding wheel grade, the dressing system and process

parameters with guidelines on what to look for when purchasing a grinding machine or what to expect when using one of

given design. For those who have hands-on experience, this course will challenge participants to understand the process

theory thoroughly and adopt a different, more comfortable, attitude toward the technology. For those with little to no

experience in grinding, this course will open up a whole new world of machining technology. Participants will complete

the course with the knowledge that grinding is a powerful process directly aimed at the next generation of materials

and the demands of a precision material removal industry.

Audience This course is designed for anyone who operates grinding machines, is currently using abrasives, is machining next

generation materials (composites, ceramics), and has a working knowledge of basic grinding technology.

Learning Objectives• Learn how various abrasives work and their effect on workpiece surface integrity

• Select the correct abrasive for specific grinding applications

• Properly and consistently true and dress any grinding wheel

• Discover how grinding can now displace milling, broaching, and some turning applications

• Learn how to economically machine next generation materials, like ceramics, where grinding is a must

• Gain a thorough understanding of grinding machine design, including CNC, to assist in identifying both positive and negative aspects of existing machine tools and learn what to look for when purchasing new grinding equipment




Course Outline• The Manufacture and Use of Abrasives and Their Effect on the Workpiece

> The properties of conventional and superabrasives

> Grinding wheel bond systems

> Manufacture and applications of coated abrasives

> The selection of the proper abrasive system for a given application

• Truing, Dressing and Coolant Methods

> Single point dressing

> Crush dressing

> Diamond roll dressing

> Continuous dressing

> EDM dressing metal bond systems

> Types of cutting fluid

> The role and proper application of the cutting fluid

> Filtration of the cutting fluid

• New Applications for Cylindrical Grinding and Surface Grinding

> Creep-feed grinding

> High speed grinding

> Speed feed grinding

> In-process gaging

> Applications of adaptive control

> New guidelines for surface finish measurement

• Grinding Machine Tool Design

> Structure and dynamics of grinding machine tool design

> Choice of materials in machine tool construction

> CNC controls

> What to look for when purchasing new grinding equipment

> Next generation grinding machine tool concept

83ToolingU.com | 866.706.8665





PRECISION GRINDING AND ABRASIVE MACHINING CERTIFICATE PROGRAMThree-Day Course

Description This new certificate program provides a basic overview of the precision grinding and abrasive machining process with an

in-depth look at techniques and practices that are sure to enhance your abrasive operation. You will be shown several

processes that could dramatically improve product quality and productivity.

The objective of the Precision Grinding and Abrasive Machining Certificate Program is to increase your understanding

and expertise of how to successfully and safely use abrasive processes. This comprehensive professional training will

assess your knowledge and skills of the abrasive and grinding process. You benefit by getting the recognition you deserve

for you knowledge and skills, your company benefits by having you as a recognized, trained professional and the industry

benefits with the quality products you produce.

Audience This course is designed for anyone who is operating or familiar with grinding machines, currently using or working with

abrasives, machining next generation materials (composites, ceramics), currently milling or broaching, or thinking of

purchasing a milling, broaching, or grinding machine.

Learning Objectives• The mechanism and theory of the abrasive process

• Abrasive types and their properties

• Grinding wheel bond systems

• How to specify the wheel for the job

• How to properly mount a grinding wheel

• How to properly true and dress a grinding wheel

• Effects of wheel speed

• Super abrasive grinding

• Types of grinding fluid

• The proper application of grinding fluid

• Understanding surface finish

• Grinding machine design

• Understanding the effects of vibration in grinding

• Material (Grinding is a materials driven process)

• Surface grinding processes

• Cylindrical grinding processes

• Contour grinding processes

• Troubleshooting the process

• Case studies

Course Outline• The mechanism and theory of the abrasive process

• Abrasive types and their properties

• Grinding wheel bond systems

• How to specify the wheel for the job

• How to properly mount a grinding wheel

• How to properly true and dress a grinding wheel

• Effects of wheel speed

• Super abrasive grinding

• Types of grinding fluid

• The proper application of grinding fluid

• Understanding surface finish

• Grinding machine design

• Understanding the effects of vibration in grinding

• Material (Grinding is a materials driven process)

• Surface grinding processes

• Cylindrical grinding processes

• Contour grinding processes

• Trouble-shooting the process

• Case studies


STAMPING DIE CERTIFICATE PROGRAMThree-Day Course

Description

The Stamping Die Certificate Program is an intensive and comprehensive training and recognition program designed

to develop the knowledge skill set relating to your work specialty: stamping dies. Earning a stamping die certificate is

not easy. First, participants sit for a pre-exam to pinpoint challenge areas. Then use the next three days of intensive

stamping die training to address these challenge areas. On the last day, take a voluntary 50 question final exam that,

when passed, qualifies you to receive your SME Stamping Die Certificate.

Audience This certificate program is designed for any manager, manufacturing and process engineer, tool and die designer, tool

and die engineer and technician, estimator, tool and die room supervisor who is an:

• Experienced stamping die professional ready for the next step in stamping die design

• Experienced stamping die professional who wants to increase promotion opportunities

• Experienced “resident expert” who has the knowledge and wants to prove it

• Experienced stamping die professional seeking the recognition you deserve from a professional organization

Learning Objectives• Various nuances of sheet metal

• Press types and mechanical limitations

• Cutting and methods to increase punch life and establish correct cutting clearance

• All facets of progressive and draw die

• Sequencing methods, model aids and forming simulation for die development

• CNC, assembly, tryout, and troubleshooting for the manufacturing process

• Cost estimating of stamping dies

Course Outline• Stamping Die Fundamentals

• Understanding Sheet Metal

• Understanding the Press

• Progressive Dies

• Draw Dies

• Basic Die Development/Manufacturing Process

• Cost Estimating of Stamping Dies

85ToolingU.com | 866.706.8665



OVERVIEW OF ADDITIVE MANUFACTURING (3D PRINTING) TECHNOLOGIESTwo-Day Course

DescriptionAdditive manufacturing or commonly referred to as 3D Printing is a manufacturing process that supports all aspects of

the product development cycle; from prototype to end-use production parts. It reduces your time to market, improves

product quality, enhances collaboration and streamlines parts integration. In this multi-level program, you will learn

about the current technologies, how they work, and how best to use them to improve your operations.

AudienceEngineers: mechanical, tooling, quality, materials, and process, new product designers, VP of design and engineering,

and management.

Learning ObjectivesParticipants will gain a solid understanding of the current technologies and primary applications. In addition,

participants will gain a clear comprehension of the manufacturing process and available material choices.

The course will also help them understand the landscape of the industry and the business and economics of adopting

these technologies.

Course Outline • Additive Manufacturing Overview

• Definition of additive manufacturing (AM) per ASTM International?

• Benefits of AM compared to other technologies

• General build/flow process in additive manufacturing

• Additive Manufacturing Processes

• What are Additive Manufacturing processes and why use them?

> Binder jetting

> Directed energy deposition

> Material jetting

> Material extrusion

> Powder bed fusion

> Sheet lamination

> Vat photopolymerization




• Key systems and features from OEMs (3D Systems, Stratasys, EOS, etc.)

• Additive manufacturing terminology – DMLS, FDM, SLA, etc

• Additive manufacturing materials – plaster, plastics, sand, metals, etc.

• Introduction to secondary processes using additive manufacturing

• Processes and technologies enhanced through Additive Manufacturing technologies

• Additive manufacturing Inputs

> Introduction to 3D Imaging, reverse engineering and inspections

> Additive manufacturing file (AMF) file format

> What to expect from CAD files

> Potential problems with bad files

> Software to fix and adjust bad files

> Outputting STL files

• Design for Additive Manufacturing

> Freedom-of-design using additive manufacturing

> Design for additive manufacturing

> Select which process or technology to use

> Complexity is free

• Business and Economics of AM

> Economics of outsourcing vs. in-house

> ROI of selected systems

> Economics of concept modelers and large frame AM systems

> Additional Resources and Information

> Order parts effectively

> Purchase equipment, materials and services

> Utilization of standards for qualification

87ToolingU.com | 866.706.8665



ADVANCED PRODUCT QUALITY PLANNING (APQP)Two-Day Course

DescriptionThis course provides general guidelines for preparing plans and checklists for ensuring that advanced product quality

planning is successfully implemented. Participants will learn the fundamentals of APQP and will be able to apply them

when working with component teams. Hands-on team exercises are used throughout the course to enhance the

learning process.

AudienceThis course is designed for any supplier applying for or certified in QS-9000 as well as any manufacturer anxious

to develop, update, or maintain a relevant quality plan.

Learning Objectives• Understand the benefits of APQP implementation

• Review the elements of APQP

• Acknowledge the voice of the customer

• Define reliability and quality goals

• Secure management support

• Apply DFMEA and DFMA concepts

• Review PFMEA, process flow, and layout challenges

• Assess customer feedback and use information

Course Outline • Product Quality Planning Responsibility Matrix

• Plan and Define Program

• Voice of the Customer

• Business Plan/Marketing Strategy

• Reliability and Quality Goals

• Product Assurance Plan

• Management Support

• Product Design and Development

• Product and Process Validation

• Feedback, Assessment and Corrective Action

QUALITY AND TESTING



DESIGN OF EXPERIMENTS (DOE)Two-Day Course

DescriptionThis two-day course will provide participants with fundamental knowledge and hands-on practice with the Design

of Experiments (DOE) and key concepts. Topics addressed include the overview and application of basic statistical

concepts, basic problem solving and guidelines for designing experiments, full factorial designs, fractional factorials

designs, analysis of effects, response surface methodology, and Taguchi techniques. The program is designed for

all levels of design and manufacturing personnel. It can be tailored to fit special needs of new product and process

development, or can focus on the application for existing manufacturing environments.

AudienceThis course is designed for individuals with minimal experience with the DOE and its related concepts and methods.

Program managers, design-responsible engineers or managers, and team members such as operators and technicians,

quality personnel, and other product design and manufacturing personnel who are interested in applying DOE to their

products and processes will all benefit.

Learning Objectives• Key concepts of variation, statistics, and probability used in DOE

• How to select and apply the correct type of design with the appropriate factors and levels

• How to determine controllable, uncontrollable, and noise factors

• Step-by-step guidelines for designing, conducting, and analyzing experiments

• How to conduct factor screening and process characterization and optimization

Course Outline • Module 1 – Basic Statistical Concepts

• Module 2 – DOE Basics

• Module 3 – Full Factorial Designs

• Module 4 – Fractional Factorial Experiments

• Module 5 – Optimization Techniques

• Product Design and Development

• Product and Process Validation

• Feedback, Assessment and Corrective Action



QUALITY AND TESTING


APQP/FMEA/CONTROL PLANS/ERROR PROOFINGFour-Day Course

DescriptionThis workshop will provide participants with fundamental knowledge and hands-on practice with the Advanced Product

Quality Planning (APQP) process and key tools of failure mode and effects analysis (FMEA), control plans, and error

proofing. The program is designed for all levels of design and manufacturing personnel as well as experienced engineering

and management personnel, especially those involved in developing new products or processes. Why all four topics

together? APQP, FMEAs, control plans, and error proofing are all interrelated and build on each other. Training that focuses

only on one of these subjects at a time cannot show how these tools work together to minimize effort, improve quality, and

complete programs more quickly with less headaches before, during, and after launch. Participants will apply these key

tools together to bring a product from concept to production during this comprehensive, start-to-finish workshop.

AudienceThis course is designed for individuals with minimal experience with the APQP process and its related key tools.

However, many experienced individuals attend the course to refresh their knowledge, gain advanced strategies, and

practice development and application of these tools with an experienced facilitator. Program managers, design-

responsible engineers or managers, potential APQP or FMEA team members such as operators and technicians, quality

personnel, and other product design and manufacturing personnel who are interested in continuous improvement

strategies will all benefit.

Learning Objectives• APQP phases, milestones, and deliverables

• The relationship between APQP, PPAP, FMEAs, control plans, and error proofing

• Step-by-step instructions for completing design and process FMEAs

• How to avoid some of the most common FMEA pitfalls

• How to use FMEAs and other inputs to complete Control Plans easily and quickly

• Error proofing and mistake proofing concepts, applications, and opportunities throughout the APQP process


Course Outline • Advanced Product Quality Planning

> Pre-Assessment

> Product Quality Planning Responsibility Matrix

> Fundamentals of Product Quality Planning

> Product Quality Planning Timing Chart

> Plan and Define Program

> Voice of the customer

> Design goals

> Reliability and quality goals

> Product assurance plan

> Management support

> Product Design and Development

> Process Design and Development

> Product and Process Validation

> Feedback, Assessment and Corrective Action

> Failure Mode and Effects Analysis

> Pre-assessment

> Instructor-led development of a sample FMEA

> FMEA definition, questions, purpose, and benefits

> Types of FMEAs, their focus, and their relationship with QS-9000

> Timing of FMEA development and revisions

> FMEA team composition and data inputs

> Design FMEA Development

> Process FMEA Development

> FMEA Application Workshop

> FMEA Summary and Advanced Strategies

• Control Plans

> Pre-Assessment

> What is a Control Plan?

> How is a Control Plan Developed?

> The Benefits of a Control Plan

> Control Plans and the Product Life Cycle

> Control Plan Inputs

> The Control Plan Team (Process Team)

> Process Flow and Characteristics

> Standardization and Continuous Improvement

• Error Proofing and Workshop Summary

> Pre-assessment

> The philosophy of process-focused quality

> What is Error Proofing and Mistake Proofing?

> Everyday examples of Error Proofing

> Manufacturing examples of Error Proofing

> Purpose and Benefits of Error Proofing

> The Key Elements of Error Proofing

> Error Proofing Case Studies

> Error Proofing, QS-9000, and the APQP process

> Error Proofing Case Study Workshop

> Error Proofing Summary and Advanced Strategy

91ToolingU.com | 866.706.8665



FAILURE MODE AND EFFECTS ANALYSIS (FMEA) ANALYSISTwo-Day Course

DescriptionThis two-day course will provide participants with fundamental knowledge and practice on design and process failure

mode and effects analysis (FMEA). Participants will learn the purpose and benefits of FMEA, the different types of

FMEAs and their focus, QS-9000 FMEA requirements and guidelines, FMEA timing and inputs, and steps required for

developing FMEA.

AudienceThe course is designed for all levels of design and manufacturing personnel, including first time practitioners as well

as experienced engineering and management personnel. Experienced individuals will attend to refresh their FMEA

knowledge, examine advanced strategies, and practice FMEA development with an experienced facilitator. Design-

responsible engineers or managers, potential FMEA team members such as operators and technicians, quality personnel,

and other product design and manufacturing personnel who are interested in continuous improvement strategies

will all benefit.

Learning Objectives• Explore key assumptions required for different types of FMEAs

• Study severity, occurrence, and detection ranking interpretation and application

• Consider the differences between requirements, failures, effects, causes, and controls

• Learn how to avoid the common pitfalls

• Understand links between FMEAs and other key documents

• Use step-by-step procedures for completing FMEAs

Course Outline • Introduction

> Pre-Assessment

> Instructor-Lead Development of a Sample FMEA

> FMEA Definition, Questions, Purpose, and Benefits

> Types Of FMEAs, their Focus, and their Relationship with QS-9000

> Timing Of FMEA Development and Revisions

> FMEA Team Composition and Data Inputs

• Design FMEA Development

> DFMEA Candidates, Timing, and Inputs

> Prepare the Form for Traceability

> Item/Function, Failure Modes, and DFMEA Assumptions

> Effects and Severity – Worst Case Scenarios

> Causes and Occurrence – Warranty Data vs. Test Data

> Current Design Controls and Detection – Ranking Criteria Weaknesses

> Risk Priority Number – One of Several Indicators

> Recommended Action Do’s and Don’ts

> DFMEA Group Exercises

QUALITY AND TESTING



• Process FMEA Development

> PFMEA Candidates, Timing, and Inputs

> Process Requirements, Failure Modes, and PFMEA Assumptions

> Effects and Severity: The Five Categories of Effects

> Causes and Occurrence – The link with Cpk and the Five Whys

> Current Design Controls and Detection: The Case for Error Proofing

> Risk Priority Number – Proper RPN Calculation

> Recommended Action – What if There Isn’t One?

> PFMEA Group Exercises

• FMEA Application Workshop

> Participant-lead Review of Day One Content

> Brainstorming, Selection, and Practice on a Sample FMEA Project

> Guided Small Group FMEA Development

> Small Group FMEA Presentations

• FMEA Summary and Advanced Strategies

> Characteristics of Good FMEAs

> Concurrent Development of PFMEAs and DFMEAs– Benefits and Sources of Confusion

> Data-Gathering Strategies and Related Quality Tools

> Cost/Benefits Analysis and Cost of Changes

> Potential Problems, Pitfalls, and Areas of Confusion– Beware of RPN Thresholds

> FMEA Maintenance and Control Plan Links

> Mining for Gold Using FMEAs

> Group Summary Exercises

> Post-Assessment

93ToolingU.com | 866.706.8665



QUALITY AND TESTING


STATISTICAL PROCESS CONTROL (SPC) WORKSHOPTwo-Day Course

DescriptionThis workshop will provide you with fundamental knowledge and hands-on practice with the Statistical Process Control

(SPC) and key tools. Topics addressed include the overview and application of Basic Statistical Concepts, Basic Problem

Solving and Quality Tools, Variable Control Charts, Attribute Control Charts, Measurement Systems Analysis (MSA),

Gage R&R, Capability Analysis, Dimensional Management, and Statistical Tolerancing. The program is designed for all

levels of design and manufacturing personnel, as well as more experienced engineering and management personnel. It

can be tailored to fit special needs of new product and process development, or can focus on application for existing

manufacturing environments.

SPC is really a collection of related tools that can be used for a variety of situations. Training that focuses only on one of

these subjects at a time cannot show how these tools work together to understand, monitor, control, and eliminate variation

in products and processes before, during, and after launch. Workshop participants apply the various tools in an integrated

fashion to experience the start-to-finish effects of an effective SPC program using actual product and process data

simulating the various phases of a product life cycle.

AudienceThis course is designed for individuals with minimal experience with the SPC and its related key tools. However,




design and manufacturing personnel who are interested in applying SPC, MSA, and Statistical Tolerancing to their

products and processes will all benefit.

Learning Objectives• Key concepts of variation, statistics, and probability used in SPC

• How to select and apply the seven traditional quality and problem-solving tools

• Analysis of time series data, types of variation, types of data, and the power of control charts

• How to select, develop, and analyze variables control charts, including the X-bar and R chart

• How to select, develop, and analyze attributes control charts

• Key Measurement Systems Analysis concepts, including Bias, Stability, Repeatability, and Reproducibility

• How to conduct a variety of Gage R&R studies for both variable and attribute data

• How to conduct a variety of capability studies including Cp, Cpk, Pp, Ppk, and Cpm

• Functional dimensioning and tolerancing concepts and applications

• Design for manufacturing applications for dimensioning and tolerancing

• Step-by-step guidelines for dimensioning, tolerancing, and optimization

• Statistical tolerancing options based on probability, statistics, and capability indices


Course Outline • Basic Statistical Concepts

• Problem Solving Tools

• Control Charts

• X-bar and R Charts

• Other Variable Charts

• Attribute Control Charts

• Measurement Systems Analysis (MSA) Concepts

• Gage Repeatability and Reproducibility Studies (Gage R&R)

• Capability Analysis

• Dimensional Management Fundamentals

• Statistical Tolerancing Fundamentals



QUALITY AND TESTING


STATISTICAL PROCESS CONTROL (SPC) MEASUREMENT SYSTEMS ANALYSIS/GAGE R&R (MSA AND GRR), CAPABILITY ANALYSIS (CP, CPK, PP)Five-Day Course

DescriptionThis five-day workshop will provide you with fundamental knowledge and hands-on practice with the Statistical Process

Control (SPC) and key tools. Topics addressed include the overview and application of Basic Statistical Concepts, Basic

Problem Solving and Quality Tools, Variable Control Charts, Attribute Control Charts, Measurement Systems Analysis

(MSA), Gage R&R, and Capability Analysis. The program is designed for all levels of design and manufacturing personnel,

as well as more experienced engineering and management personnel who need a working knowledge of X-bar and R

charting, variable Gage R&R studies, and calculation of statistical process capability, and how the three are interrelated.

AudienceThis course is designed for individuals with minimal experience with the SPC and its related key tools. However,




design and manufacturing personnel who are interested in applying SPC, MSA, and Capability Analysis to their products

and processes will all benefit.

Learning Objectives• Key concepts of variation, statistics, and probability used in SPC

• Analysis of time series data, types of variation, types of data, and the power of control charts

• How to select, develop, and analyze variables control charts, including the X-bar and R chart

• Key Measurement Systems Analysis concepts, including Bias, Stability, Repeatability, and Reproducibility

• How to conduct a variety of Gage R&R studies for both variable and attribute data

• How to conduct a variety of capability studies including Cp, Cpk, Pp, and Ppk

Course Outline • Basic Statistical Concepts

• Problem Solving Tools

• Control Charts

• X-bar and R Charts

• Other Variable Charts

• Attribute Control Charts

• Measurement Systems Analysis (MSA) Concepts

• Gage Repeatability and Reproducibility Studies (Gage R&R)

• Capability Analysis


TOLERANCE STACK-UP ANALYSISTwo- or Three-Day Course

DescriptionLearn a simple procedure for determining the clearance/interference relationships between pairs of components that

have been geometrically dimensioned and toleranced. The method is easily interpreted. Results can be quickly and easily

checked, and revisions can be made with ease. If the work is interrupted, the analysis can be continued later without

confusion. The mathematics involved in extracting and specifying assimilability tolerances for the mating features of

conventionally-toleranced workpieces will also be reviewed.

AudienceThis course is intended for personnel who are currently generally familiar with the principles, concepts, and practices

contained within ANSI Y14.5; who are engaged in the work-a-day preparation or other use of engineering drawings; and

now need to gain a further knowledge regarding an efficient method of performing tolerance stack-up analysis on the

components of assemblies where conventional tolerance methods have been specified, or where a mix of both of the

preceding two methods has been specified, or it is intended to take advantage of statistical probability theory and to

apply it to either or both methods of dimensioning and tolerancing.

Learning Objectives• Reduce tolerance stack-up in products

• Perform and develop a tolerance stack-up analysis

• Understand the role of the ANSI Y14.5M-1994 in stack-up analysis

• Decrease excess tolerance reqwuirements and increase part fit and function

Course Outline • Quick review of ANSI Y14.5M-1994, as it may relate to extracting and assigning tolerances

to mating components

• Quick review of Fixed and Floating Fastener concepts

• Quick review of Virtual Condition and Resultant Condition concepts

• Introduction to Tolerance Stack-up Analysis Procedure for assemblies where conventional tolerancing has been specified (one00 percent interchangeability)

• Tolerance Stack-up Analysis of True Position Tolerancing

• The stack-up sizes of internal/external features

• Tolerance stack-up analysis for a floating fastener condition, where Geometric Tolerances of location have been specified

• Statistical Probability Theory

• The Frequency Distribution Curve

• The Arithmatic Mean

• Normal Distribution of Tolerance and the Standard Deviation

• Statistical Probability as it may be applied to Tolerance Stack-up Analysis

97ToolingU.com | 866.706.8665



TOTAL PRODUCTIVE MAINTENANCETwo-Day Course

DescriptionThe development of total productive maintenance (TPM) tools means little without a master plan for their implementation

and strategic use. This course will focus on building a master plan, creating visual references, and securing management

buy-in. This is accomplished through a group plant tour and group exercises that examine plant support systems, task

development, equipment enhancements and more. When the plan is complete, the facility is able to make a smooth

transition into each phase of development (guidelines provided). In order to implement the complex features of TPM

internally, five types of action teams are created involving representation from all skill levels and departments. This step

results in increased staff ownership and buy-in of TPM ensuring the ongoing success of the system, and, ultimately,

increased plant capacity.

AudienceBecause of TPM’s plant-wide involvement, it is recommended that plant managers, maintenance managers, TPM

champions and production supervisors attend this course.

Learning Objectives• Create TPM equipment visual references

• Recognize the value of daily/weekly check sheets

• Apply process flow diagrams

• Use lubricant color-coding

• Apply equipment care diagnostics

• Determine TPM support requirements

• Create satellite lube centers

• Complete work requests

• Learn from deficiency tagging

• Examine OEE tracking

• Explore the benefits of story boarding

• Efficiently monitoring TPM

• Develop the team

• Determine PM routes

• Create implementation teams

• Consider equipment enhancements

QUALITY AND TESTING



Course Outline • Benchmark Questionnaire

• NEADS Analysis

> What’s in Place Now

> Enjoyment − what’s working

> What would you Alter/change

> TPM Decision process

> Solution development

• Master Plan Phase One

• Transition of PM to TPM

• TPM Requirement Overview

• Video Review and Evaluation

• Plant Tour

• Review of Plant’s Support Systems

• Visual Reference Development

• Daily/Weekly Task Development

• Equipment Enhancement Action Plan

• Satellite Lube Center Requirements

• Consolidating Daily/Weekly Tasks

• Create Master Prints

• Building A TPM Process Flow

• Defect Tagging/Work Requests

• Master Plan - Phase two

• Tracking OEE Overview

• PM Development Requirements

• PM Requirements Identified

• Tracking of OEE

• Review of Team – Developed PM’s

• Consolidation of PM’s

• Create Maintenance Routes

• Master Plan – Phase Three

• Action Plan Development

99ToolingU.com | 866.706.8665



VALUE ANALYSIS AND VALUE ENGINEERINGTwo-Day Course

DescriptionValue analysis/value engineering is increased in a part or offered service by effecting either required function or inherent

cost according to predefined formulae. Its success is widespread across the automotive, architecture, medical, government

and defense industries. Participants of the course will gain information that could be vital to their company’s continued

growth and competitiveness.This course uses participant’s knowledge and expertise in a cross-functional team setting to

increase customer value in current product or future products. Participants will learn how to meet client requirements for

comprehensive VA/VE analysis. The course will also address applying the concepts internally for continuous improvement.

AudienceThis course is designed for anyone who is interested in learning more about VA/VE and applying the knowledge gained.

This workshop is especially appropriate for cost estimators, design engineers, manufacturing engineers, quality, sales

and marketing personnel.

Learning Objectives• Enhance part or office service function

• Improve team interaction by working on different projects in a team format

• Develop internal VA/VE action plan that can be implemented immediately

• Comply with client requirements or supersede their requirements

• Interaction provides great brainstorming sessions and future approaches to projects

Course Outline System Overview

• The Job Plan

• Function

• Habits and Attitudes

> Change – Risk – Stress

• Teams and organization

• Value

• Creativity

• Case history Example

• Case Study Problem

Phase I − Information

• Cost

> Effect on Products

> Elements of cost

> Program cost and creep

• Target – Goal for achievement (GFA)

> Setting target goal

> Competition and contracts

• Function and function definition

> Why functions?

> Products and systems

• Value

> Basis for decision

> Function Cost

• Target for Opportunity (TFO)

> Function cost – value

QUALITY AND TESTING



Phase II − Creativity

• Creativity and function

• Creativity and the Job Plan

• Creativity methods

> The process

> The people

• Blocks to creativity

• Brainstorming

Phase III − Evaluation

• Select the best idea

• Screening and evaluation techniques

> B&W index, Pareto voting

> Paired comparisons

• Identify concepts for development

Phase IV − Planning

• Develop concepts

> Identify roadblocks

> Actions required

> Minimize problems

> Develop recommendations

Phase V − Report Recommendations

• Summarize results

• Show benefit

• Cite action plan

• Request approval

Phase VI − Implementation

• Champions − Implement action

• Value Council − Oversee operations

• Follow-up − Justify effort

• Program goals

101ToolingU.com | 866.706.8665

102ToolingU.com | 866.706.8665102 Instructor-Led Training

VIRTUAL INSTRUCTOR-LED TRAINING

Tooling U-SME developed virtual instructor-led training (VILT) with one goal in mind: to give you a training method that can

be implemented consistently across your organization, around the world. Our On-Demand Library comprises the recordings

of live public sessions we recently hosted. The recordings are available for integration into your organization’s training

program. The list of sessions also represents many of the sessions we can deliver live in a custom session to your team or

entire workforce.

ON-DEMAND LIBRARY

Design & Engineering

• Advanced GD&T: Composite Position

• Advanced GD&T: Datums

• Advanced GD&T: Profile of a Surface

• Blueprint Reading Auxiliary Print Information

• Blueprint Reading: Introduction and Orthographic Projection

• Design for Manufacturability and Assembly (DFM/A): Design for Assembly I

• Design for Manufacturability and Assembly (DFM/A): Design for Assembly II

• Design for Manufacturability and Assembly (DFM/A): Design for Manufacturability I

• Design for Manufacturability and Assembly (DFM/A): Design for Manufacturability II

• GD&T for Management

• GD&T Standard Update

• Introduction to GD&T: Rules & Concepts of GD&T

• Introduction to GD&T: The Need for GD&T

• Introduction to GD&T: Tolerances Applied to a Feature of Size

• Introduction to GD&T: Tolerances Applied to a Surface

• Fundamentals of Metrology: Metrology Concepts, Variation, and Calibration

• Fundamentals of Metrology: Measurement Systems Analysis (MSA)

• Fundamentals of Metrology: Inspections and Sources of Error

• Precision Machine Design for Mechatronic Automation: Mechanical Design Fundamentals

• Precision Machine Design for Mechatronic Automation: Power Transmission Fundamentals

• Precision Machine Design for Mechatronic Automation: Servo System Design

• Precision Machine Design for Mechatronic Automation: System Integration

• Tolerance Stacks: Advanced Tolerance Stacks

• Tolerance Stacks: Stacks with GD&T

• Tolerance Stacks: Tolerance Stacks Fundamentals

Lean

• Cell Planning: Cell Layout

• Cell Planning: Six Steps to Cell Plans

• Lean Management Systems: Leader Standard Work and Visual Controls

• Lean Management Systems: Putting the Lean Management System Together

• Lean Management Systems: Tiered Performance Metrics

• Lean that Lasts: Lean Foundations

• Lean that Lasts: Lean Practices and Techniques for Continuous Improvement, Part 1

• Lean that Lasts: Lean Practices and Techniques for Continuous Improvement, Part 2

• Lean that Lasts: Introduction to Value Streams and Value Stream Mapping

• Lean that Lasts: Lean for Supervisors and Managers

• Lean that Lasts: Lean Measurement Systems and Business Results

103ToolingU.com | 866.706.8665

• Lean that Lasts: Creating a Lean Culture

• Lean Layout Planning: How to Evaluate and Select the Best Layout Plan

• Lean Layout Planning: How to Plan Lean Layouts with Systematic Layout Planning (SLP)

• Lean Layout Planning s: Material Flow Analysis for Lean Layout Planning

• Lean Layout Planning s: Relationship Charting and Diagramming for Lean Layout Planning

• The ABCs of A3s - A3 Problem Solving: A3 Overview

• The ABCs of A3s - A3 Problem Solving: Coaching Follow-up

• Total Productive Maintenance: From Autonomous Maintenance to Maintenance Prevention

• Total Productive Maintenance: Kaizen Events and Daily Kaizen

• Total Productive Maintenance: The Value of Total Productive Maintenance

• Total Productive Maintenance: Total Productive Maintenance Fundamentals

Maintenance

• Analyzing Modern Hydraulic Systems: Energy Efficient Hydraulic

• Analyzing Modern Hydraulic Systems: Hydraulic Automation Components

• Analyzing Modern Hydraulic Systems: Hydraulic Clamping and Presses

• Analyzing Modern Hydraulic Systems: System Sizing Considerations

• Hydraulics: Hydraulic Component Details

• Hydraulics: Hydraulic Connectors and Conductors

• Hydraulics: Hydraulic Fundamentals

• Hydraulics: Hydraulic Schematics and Troubleshooting

Management

• Leading Sustained Performance in Manufacturing: Conducting a Project FMEA

• Leading Sustained Performance in Manufacturing: Calculating a Breakeven Analysis

• Leading Sustained Performance in Manufacturing: Using Leadership Styles Effectively

• Leading Sustained Performance in Manufacturing: Communicating Effectively

• Leading Sustained Performance in Manufacturing: Building Coalitions

• Leading Sustained Performance in Manufacturing: Creating Metrics that Drive Performance

• Safety: Globally Harmonized System (GHS) and Hazard Communication (HCS)

• Safety: Introduction to OSHA Standards, Part 1

• Safety: Introduction to OSHA Standards, Part 2

• The Economics of Burrs and Deburring: Concepts and Data

• The Economics of Burrs and Deburring: Deburring Department Costs

• The Economics of Burrs and Deburring: Plantwide Costs - More than the Deburring Department Costs

• The Economics of Burrs and Deburring: Simple Cost Calculations Per Part

Materials

• Advanced Composites Manufacturing: Fiber Reinforced Polymer Materials

• Advanced Composites Manufacturing: Manufacturing Processes

• Advanced Composites Manufacturing: Tooling


is your workforce ready? - tooling u-sme · 3 instructor-led training toolingu.com | 866.706.8665 3...

Documents