training and consulting - festo · pdf filewith training and consulting. 7 courses, ......

Training and Consulting

Range of courses for 2010

www.festo-tac.com

Technology, Organisation,

People.

The perfect interplay of these

main factors is essential in order

to successfully put knowledge

into practice at a company.

These factors lay the founda-

tions for top performance and

financial success.

The Festo Competence Model

combines social, logistical and

technical skills to form a suc-

cess-oriented model for initial

and further training.

3

Course Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Organisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

People . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Table of contents

4

“Ideas are only as good as

their practical and successful

implementation.”

(Dr. Kurt Stoll)

In the case of training activities,

this means that training must be

tailored closely to your require-

ments in order to ensure suc-

cessful implementation.

The basis for this is professional

consultancy and precise deter-

mination of your requirements.

This has been the principle be-

hind the development of our

new range of training and con-

sultancy services, which com-

prise everything from an analy-

sis of training needs through

to public seminars and in-house

training programmes, offering

the right solution for every

need.

In view of the ever-increasing

competitive pressure faced by

companies today, lean produc-

tion systems, reduced downtime

and increased machine availa-

bility are vital prerequisites for

long-term success. This success

can be achieved only if improve-

ments in production and admin-

istration are codified into stan-

dards at regular intervals and

further improved. For this pur-

pose, companies need staff who

are able to recognise potential

for optimisation in a timely

fashion, no matter whether this

relates to communication, orga-

nisation or technology.

As an experienced and strong

partner, we can help you to pre-

pare your staff and your compa-

ny to meet these challenges of

the future.

This catalogue describes our

complete range of training and

consulting services. A new in-

clusion is the area of process

automation, for which we have

developed a comprehensive

range of services. You will also

find an overview on page 10 – 13

which shows the target groups

to which our services relate.

This will help you to select the

right courses for your staff.

We would be delighted to be

allowed to offer you support in

dealing with the challenges fac-

ing your business and hope that

this catalogue will be the first

step towards successful train-

ing.

5

Sustainable commitment to

people and technology

Festo AG

Global player in

Automation and Didactic

13,500 people worldwide are

working towards innovative

advances in the production of

capital and consumer goods.

This reflects Festo’s philosophy

of full partnership and close

proximity to more than 300,000

customers in over 200 indus-

tries, realised via 250 Festo

locations and 57 national Festo

companies.

The focus of all activities is on

people and technology. From its

foundation, Festo has seen itself

as a strong partner and an inte-

gral component of societies and

business worldwide.

6

Training Courses

Industrial Consulting

Experienced instructors and

consultants provide customised

solutions to make your employ-

ees and your company success-

ful. Furthermore the results are

clear and sustainable

Methods and formats

Training Courses

Approx. 42,000 course parti-

cipants per year attend more

than 2,900 courses. Modular

and quality-assured training

content in over 39 languages.

Industrial Consulting

Projects in the areas of:

– Procurement and logistics

– Product development

– Lean production

– Competence Management

Innovation and productivity begins

with training and consulting

7

Courses, workshops,

best-practice events and

corporate strategy games

Public or in-house – the focus is

always on hands-on experience

using actual products in learn-

ing factories.

Rapid implementation in daily

practice is a key quality crit-

erion, since individual learning

success can be measured.

Training content

Technology

– Pneumatics, hydraulics

– Manufacturing automation

– Control engineering

– PLC technology

– Robotics

– Sensors

Organisation

– Process optimisation

– Pull production

– Equipment efficiency and

setup optimisation

– Value-stream analysis

– Target engineering

– Customer centricity

People

– Problem-solution processes

– Moderating teams

– Efficient communication

– Intercultural competence

– Management skills

A hands-on approach to learning

Trainings

8

TPM

Total Productive Maintenance

Making the best possible use of

production plants: we jointly

track the progression of a prod-

uct through your company, with

the ongoing goal of keeping the

procedure efficient and avoiding

wastefulness. For this process,

experienced consultants employ

methods and tools that are the

best of their kind worldwide and

used by Festo.

TPM methodology drastically

improves the overall effective-

ness of existing systems by

means of integral approaches

and the involvement of all

employees.

Principles

– Usage of sturdy, tried-and-

tested processes

– Complete elimination of errors

and malfunctions

– Identification and resolution

of the true causes of problems

– Optimisation of all process

factors

– Close communication with

machine operators

– Cleanliness, order, discipline

and standardisation as the

basis for quality

Benefits and results

– Improvement in the

qualification of all employees

– Increase in machine efficiency

by up to 40%

– Reduction in errors and rejects

by up to 90%

– Reduction in unexpected

machine downtime

by up to 90%

– Practically no accidents

Format: workshop and project

in the company.

Adding value

Consulting

9

Training Course Overview

10

Training Courses

Technology, Organisation, People

Valves in Process Automation – Introduction

Valves in Process Automation – Specialist

Explosive Safety – Introduction

Explosive Safety – Specialist

Safety integrity level (SiL) to IEC 61508 – Fundamentals

Safety integrity level (SiL) to IEC 61508 – Specialist

Symbols in PA ISA-based (P&ID; PFD; BFD) – Introduction

Symbols in PA ISA-based (P&ID; PFD; BFD) – Advanced

Closed Loop Control – Optimising settings

Practical Mastery of Closed Loop Control

Principals of industrial Measurement & Instrumentation - Introduction

Principals of industrial Measurement & Instrumentation

Modern Process Automation – Executive Summary

Modern industrial pneumatics – Fundamentals

Troubleshooting and maintenance of pneumatic systems

Effective maintenance of pneumatic systems

Effective problem solving techniques

Use of vacuum in handling systems

Valve terminal CPX – Commissioning, modification and fault elimination

Valve terminal CPV – Commissioning, modification and fault elimination

Energy-efficient design of pneumatic systems

Safety in Pneumatics

Modern industrial hydraulics

Troubleshooting industrial hydraulics

Proportional hydraulics

GRAFCET – The new process description

FEC1 – FEC mini control systems – Basic principles

FEC2 – Networked FEC mini control systems and visualisation

Simatic S7 – Basic principles

Simatic S7 – Intermediate

Simatic S7 – Bus technology

Effective maintenance of Simatic S7 PLC

CoDeSys – A hardware-independent introduction for programmers

CoDeSys for Industry

Training Courses

PA111

PA121

PA131

PA141

PA151

PA161

PA171

PA181

PA191

PA201

PA211

PA221

PA311

PN111

PN121

PN132

PN142

PN152

PN163

PN173

PN183

PN193

HY511

HY521

HY132

AUT111

PLC111

PLC122

PLC211

PLC222

PLC232

PLC243

PLC281

PLC271

Technology

565674

565673

565676

565675

565678

565677

565680

565679

565681

565682

565683

565684

565685

559395

559396

559390

559417

559405

559389

559388

559391

559392

559448

559449

559451

559452

559457

559458

559381

559383

559382

559378

570614

570612

Course Code

VALVE PA 1

VALVE PA 2

EX PA 1

EX PA 2

SIL PA 1

SIL PA 2

ISA PA 1

ISA PA 2

CONTROL PA 1

CONTROL PA 2

INST PA 1

INST PA 2

PA-COMPACT

P111

P121

EM-PEP

EM-PST

VUU

CPX

CPV

DESIGN1

DESIGN2

H511

H521

PH711

GRAFCET

FEC1

FEC2

S7-BASIC

S7-INTERMEDIATE

S7-BUS

EM-S7

Former

Course Code

Order Number

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

Page

11

Target Groups

Target Groups

Operators Maintenance Design/

Engineering

Trainer Management Operators

Fields – Process –

Laboratory

Maintenance

Process –

Engineering

Trainer/

Consultant

Design/

Engineering

Management

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Factory Automation

End User/OEM

Process Automation

End User/EPC, OEM, System Integrator

Technology

PA111

PA121

PA131

PA141

PA151

PA161

PA171

PA181

PA191

PA201

PA211

PA221

PA231

PN111

PN121

PN132

PA142

PA152

PA163

PA173

PA183

PA193

HY511

HY521

HY132

AUT111

PLC111

PLC122

PLC211

PLC222

PLC232

PLC243

PLC281

PLC271

Course Code

12

Training Courses

Technology, Organisation, People

Basic principles of sensor technology

Introduction to Mechatronics

Fundamentals of Electric Drives

Fast, confident electric drive configuration

Safety circuits for maintenance crew and designers

Understanding the new machine directive – one day orientation event

Understanding the new machine directive – 2 day training event

SYNCHRO – Introduction to Lean Production and VSM

KANBAN – Pull production control

SMED – Reducing set-up time with SMED

TPM – Maintenance strategies and TPM

FLOW – Efficient production processes and layout

Leadership Training Module 1

Train-the-Trainer – Mastering key trainer skills

Service Ambassador – Communication skills for service engineers

Team based problem solving and process – FMEA

Training Courses

AUT121

AUT211

ED111

AUT201

AUT431

SN121

SN131

LP111

LP121

LP131

LP141

LP151

LS111

TTT111

CO111

IM111

Technology

565669

565671

562553

570024

570881

567355

571083

Organisation

561209

559423

559425

559428

559413

People

565668

559442

560278

559418

Course Code

SENSOR

AUT 211

P141

SYNCHRO2

KANBAN

SMED

TPM

FLOW

LEADERSHIP 1

TTT

SA1

TEAM-PST

Former

Course Code

Order Number

50

51

52

53

54

55

56

58

59

60

61

62

64

65

66

67

Page

13

Target Groups

Target Groups

Operators Maintenance Design/

Engineering

Trainer Management Operators

Fields – Process –

Laboratory

Maintenance

Process –

Engineering

Trainer/

Consultant

Design/

Engineering

Management

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Factory Automation

End User/OEM

Process Automation

End User/EPC, OEM, System Integrator

Technology

AUT121

AUT211

ED111

AUT201

AUT431

SN121

SN131

Organisation

LP111

LP121

LP131

LP141

LP151

People

LS111

TTT111

CO111

IM111

Course Code

Triple skills

Experience

For over 40 years, we have been

providing support for all devel-

opment stages of automation

technology. Our seminars use

the latest technology.

Close collaboration with our

parent company ensures access

to the latest machines and sys-

tems, while our trainers have

first-hand expertise.

Innovation

We place tough demands on

our training. At our seminars,

you will notice the difference

compared to other training pro-

viders. We provide new answers

to long-standing questions that

help you to make decisive steps

in your company plans.

Vision

Our trainers are active in their

trade, and know the areas of

work of your participants.

This knowledge extends beyond

purely technical requirements

to questions concerning topics

such as Just in time, TPM and

Kanban.

Technology

15

Technology

16 Online booking: www.festo-tac.com

Process Automation

Valves in process automation –

Introduction

PA111

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Comments

This course gives you an overview of process valve technology and of selecting the right valve for the

right application with the economical drive system. It also provides an overview of international standards

and an introduction to the basic streamline principles.

FA: N/A

PA: Field-Process-Laboratory Operators

• Overview of design and function of process valves

• Material selection for media, process and process valve

• Testing and certification requirements of process valves (such as works test certificate)

• Basic principles of process valve actuating systems (manual, hydraulic, electric and pneumatic)

• Reading and interpreting basic process valve symbols

• Influence of international regulations on the process valve selection (AWWA; API etc.)

The participant:

• can select, assemble, and test basic process valve installations

• can maintain and troubleshoot basic process valve installations

• can identify and describe the construction, design features, and operation of the

standard process valve types

• can read technical specifications and identify graphical symbols for process valves

• knows the role of process valve actuation – manual, hydraulic, electric and pneumatic

• is aware of innovative developments and current trends in process valve automation products and

their application

Basic technical understanding

1 day

565674

We are happy to adapt this course to your industry-specific needs.

Technology

Online booking: www.festo-tac.com 17

PA121

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Comments

This course provides you with insight into process valve technology, including valve/drive selection

based on materials and standards, and taking cavitation into account. It also gives you an understanding

of entire valve control systems.

FA: N/A

PA: Field-Process-Laboratory Operators, Process-Engineering Maintenance, Design/Engineering,

Trainer/Consultant

• Overview of design and function of process valves, taking international standardisation into account

• Physical principles and material selection related to media and process valves

• Testing and certification requirements of process valves (such as works test certificate)

• Cavitation – what is cavitation, how to avoid cavitation damage with specially designed

valve types

• Principles and selection of process valve actuation (manual, hydraulic, electric and pneumatic)

• Reading and interpreting process valve symbols

• Influence of international regulations on the process valve selection (AWWA; API etc.)

• SIL regulation (Safety Integrity Level), explosive safety and the influence on the process valves

The participant:

• can select, assemble, and test complex process valve installations

• can maintain and troubleshoot complex process valve installations

• can identify and describe the construction, design features, and operation of process valves

• can interpret technical specifications and data relating to process valves and systems

• can identify and explain graphical symbols for process valves

• can perform simple calculations of pressure, flow and force

and

• knows the role of process valve actuation – manual, hydraulic, electric and pneumatic

• knows how to prevent cavitation damage

• knows innovative development and current trends in process valve automation products and

their application


4 days

565673


Valves in process automation –

Specialist

Process Automation

Technology


Process Automation

Explosive safety –

Introduction

PA131

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Comments

This course gives you an overview of standards-based explosive safety with risk analysis and the

operation/maintenance of electrical & mechanical installations. It also covers conformity with CE mark,

explosive safety documentation and explosive safety in other countries.

FA: N/A

PA: Field-Process-Laboratory Operators, Process-Engineering Maintenance, Design/Engineering

• Explosive safety fundamentals EN 60079, EN-1127, EN-13463, IEC61241 + appropriate guidelines,

function and duties, selection and qualification, ATEX Directive 94/9/EC

• Process safety management

• Process hazards analysis with risk management

• Documentation and approvals

The participant:

• can understand and use EU guideline 94/9EG + dedicated guidelines

• knows explosive safety – function and duties, selection and qualification

• knows fundamentals of technical explosive safety – electrical & mechanical

• knows appropriate legal regulations and responsibilities of the operator / owner

• knows relevant standards (ISO/DIN/AWWA/ANSI ….)

• know accreditation and relevant guidelines (German Lloyd, FDA ….)

• can assist with operational explosive safety

• can assist with the implementation of an operational explosive safety concept

• can read, understand and verify EX documentation

• can communicate with internal and external bodies


1 day

565676


Technology


PA141

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Comments

This course gives you an insight into standards-based explosive safety & explosion protection with

risk analysis and operation/maintenance of electrical & mechanical installations. It also covers the

development of explosive safety rules for machines, equipment and switchgear, conformity with the

CE mark, explosive safety documentation as well as explosive safety in other countries.

FA: N/A

PA: Trainer/Consultant

• Explosive safety fundamentals EN 60079, EN-1127, EN-13463, IEC61241- plus appropriate guidelines,

function and duties, selection and qualification

• ATEX Directive 94/9/EC, IECEex, UL-Aex ...

• Process safety management, risk management

• Process hazards analysis

• Implementation of a explosive safety management

• Documentation and approvals

The participant:

• understands and can use EU guideline 94/9EG + dedicated guidelines

• knows explosive safety – function and duties, selection and qualification

• knows fundamentals of technical explosive safety – electrical & mechanical

• knows appropriate legal regulations and responsibilities of the operator / owner

• understands the reaction and properties of materials, chemicals and mixtures in gas and dust areas

• knows / understands relevant standards (ISO/DIN/AWWA/ANSI ….)

• can perform accreditation and relevant guidelines (German Lloyd, FDA ….)

• can organise and develop operational explosive safety measures and implement them in operational

concepts

• can develop / form EX documentation and initiate approvals

• can communicate with internal and external bodies

• is familiar with the framework, definitions, systems, hardware and software requirements


4 days

565675


Explosive safety –

Specialist

Process Automation

Technology


Safety Integrity Level (SIL) to IEC 61508 –

Fundamentals

PA151

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Comments

This course enables you to understand what SIL is and learn about several different methods to

determine Safety Integrity Levels and the selection of appropriate technologies for safety applications

based on Safety Integrity Level procedures (SIL IEC-61508).

FA: N/A

PA: Field-Process-Laboratory Operators, Process-Engineering Maintenance, Design/Engineering

• IEC 61508 guideline + dedicated guidelines, function and duties, with the fundamentals of SIL

• Impact of manual testing, automatic diagnostics and redundancy on overall system performance

• Overview of accreditation under relevant guidelines and standards

• Overview of operational organisation of the appropriate Safety Integrity Level

• Documentation under Safety Integrity Level aspects

The participant:

• understands the IEC-61508 guideline and dedicated guidelines

• can assist with a risk management in accordance with IEC-61508 regulations and standards

• understands the safe electrical control chain

• knows the classification of safety levels such as limitation of damage, protective devices

• understands safety lifetime cycles and the individual Safety Integrity Levels (SIL) of safety related

systems

• has an overview of the framework, definitions, systems, hardware and software requirements


1 day

565678


Process Automation

Technology


PA161

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Comments

This course enables you to develop and understand to utilize several different methods to determine

Safety Integrity Levels and to select appropriate technologies for safety applications based on a required

performance. It also covers the impact of manual testing, automatic diagnostics and redundancy of field

devices on overall safety system performance.

FA: N/A

PA: Consultant/Trainer

• IEC 61508 guideline + dedicated guidelines, function and duties, selection and qualification with the

fundamentals of SIL taking into account the impact of manual testing, automatic diagnostics and

redundancy on system performance

• Accreditation under the relevant guidelines and standards

• Operational organisation of the appropriate Safety Integrity Level

• Implementation of a Safety Integrity Level concept

• Documentation under Safety Integrity Level aspects

The participant:

• understands and can use the IEC-61508 guideline and dedicated guidelines

• can develop SIL analysis with various methods based on failure mode and redundancy

• can assess risk management in accordance with IEC-61508 regulations and standards

• can systematically allocate probabilities of failure in accordance with SIL

• can calculate and evaluate the safe electrical control chain

• can classify safety levels such as limitation of damage, protective devices

• can consider the safety lifetime cycles and individual Safety Integrity Levels (SIL) of systems

• is familiar with the framework, definitions, systems, hardware and software requirements


3 days

565677


Safety Integrity Level (SIL) to IEC 61508 –

Specialist

Process Automation

Technology


ISA-based symbols in PA (P&ID, PFD, BFD) –

Introduction

PA171

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Comments

This course gives you an overview ISA-based symbols used in process automation. It also provides an

overview of basic streamline principles, enabling you to understand the entire process control system in

your company. (ISA = The Instrumentation, Systems and Automation Society)

FA: N/A


• Symbols and standards for the relevant industry segments

• Schematics of functional relationship of piping, instrumentation and system equipment

components

• Schematics of the processing system

• Schematics of the main process

• Reading process component symbols

• Influence of international regulations

The participant:

• knows the symbols used in process automation such as valves, instruments etc.

• can read Piping & Instrumentation Diagrams (P&ID)

• can read Process Flow Diagrams (PFD)

• can read Block Flow Diagrams (BFD)

• can identify and explain graphical symbols for process valves, instruments, piping etc.


1 day

565680


Process Automation

Technology


PA181

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Comments

This course provides you with an insight into the ISA-based symbols used in the process automation.

It also familiarises you with the basic streamline principles enabling you to understand the entire process

control system in your company. (ISA = The Instrumentation, Systems and Automation Society)

FA: N/A

PA: Process-Engineering Maintenance, Design/Engineering, Trainer/Consultant

• Symbols and standards for the relevant industry segments

• Schematics of functional relationship of piping, instrumentation and system equipment components

• Schematics of the processing system and diagrammatic representation of main processes

• Reading and interpreting process component symbols

• Influence of international regulations

The participant:

• understands and knows all the symbols used within the process automation such as valves,

instruments etc. Plus guidelines + dedicated guidelines

• can use and develop Piping & Instrumentation Diagrams (P&ID)

• can use and develop Process Flow Diagrams (PFD)

• can use and develop Block Flow Diagrams (BFD)

• can identify and explain graphical symbols for process valves, Instruments, piping etc.


2 days

565679


ISA-based symbols in PA (P&ID, PFD, BFD) –

Advanced

Process Automation

Technology


Closed Loop control –

Optimising settings

PA191

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Comments

In this course you will master the principles of automatic process control and the operation of the

feedback loop to include proportional, integral and derivative control modes. It also covers concepts

of cascade, ratio, and feed forward control as well as controller tuning methods.

FA: N/A


• Operation of the components in a closed-loop control system including static and dynamic functions

• Requirements for open-loop and closed-loop stability

• Three control system tuning methods to achieve specified quality control

• Functionality of cascade control loops

• Principles and design features of feed forward control

• Advantages of feed forward control over feedback control

• Operation and function of ratio control systems

• Safety concerns and procedures when operating control systems

The participant:

• can commission a basic closed-loop control system

• can initiate basic closed-loop control systems

• can identify components

• can read a circuit diagram or wiring schematic

• can connect components according to a circuit diagram or wiring schematic.

• knows the fundamentals of closed-loop controls


1 day

565681


Process Automation

Technology


PA201

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Comments

In this course you will master the principles of automatic process control and the operation of the

feedback loop to include proportional, integral and derivative control modes as well as advanced

concepts of cascade, ratio, and feed forward control. You will also learn and practice controller tuning

methods and get an overview of drawings used in industry.

FA: N/A

PA: Process Engineering Maintenance, Design/Engineering, Trainer/Consultant

• Operation of the components in a closed-loop control system including static & dynamic functions

• Requirements for open loop and closed-loop stability and control system tuning methods

• Functionality of cascade control loops and the advantages of cascade control over single-element

feedback control, and tuning a cascade control loop for optimum control

• Principles and design features of feed forward control and tuning a feed forward control system for

optimum control

• The operation and function of ratio control systems and tuning of ratio control systems


The participant:

• can commission a basic closed-loop control system

• can initiate and modify basic closed-loop control systems

• can identify components

• can read a circuit diagram or wiring schematic

• can connect components according to a circuit diagram or wiring schematic

• can operate, describe, identify and analyze a control

• knows the fundamentals of closed-loop controls


4 days

565682


Practical Mastery of Closed Loop Control

Process Automation

Technology


Process Automation

Principles of industrial Measurement and Instrumentation –

Introduction

PA211

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Comments

In this course you will cover the equipment used in process automation to measure and control a process.

You will learn how process equipment is used to form an open- and closed-loop system and gain an

understanding of drawings used in industry.

FA: N/A


• Basic electric principles and electrical safety

• Transducers & sensors

• Principles of measurement (flow, level, temperature & pressure)

• Control valves, their components and functions

• Control theory

• Fundamentals of control loops

• Instrumentation symbols and drawings


The participant:

• can measure and describe the difference between basic electrical principles

• can identify analog and digital signals and describe the difference between them

• can identify and understands the principles of sensors used to measure process variables

• knows principles of various installations used to measure process variables

• can identify and describe the different components of a control valve

• can explain the main parts of open- and closed-loop systems, their function and signal

flows

• can identify the symbols and components used in instrumentation drawings


1 day

565683


Technology


Process Automation

PA221

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Comments

In this course you will cover the equipment used in process automation to measure and control a process.

Using practical exercises and training, you will learn how process equipment is used to form an open- and

closed-loop system, and will gain an understanding of drawings used in industry.

FA: N/A


• Basic electric principles and electrical safety

• Transducers & sensors

• Principles of measurement (flow, level, temperature & pressure)

• Control valves, their components and functions

• Control theory

• Fundamentals of control loops

• Instrumentation symbols and drawings

• Practical training on software and hardware with loop tuning & adjustment


The participant:

• can measure and describe the difference between basic electrical principles

• can identify, describe and measure the difference between analog and digital signals

• can identify and measure and understands the principles of sensors used to measure process

variables

• knows principles of various installations used to measure process variables

• can identify and describe the components of a control valve

• can explain the main parts of open- and closed-loop systems, their function and signal

flows

• can identify the symbols and components used in instrumentation drawings


4 days

565684


Principles of industrial Measurement and Instrumentation

Technology


Modern Process Automation –

Executive Summary

PA311

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Comments

This course gives you a general overview of the latest technologies, regulations and standards used in

the process automation, including process valve technology, explosive safety in process automation

installations with Safety Integrity Level aspects, and the importance of process control & measurement.

FA: N/A

PA: Management

• Design and function of different process valve types

• Basic principles of process valve actuating systems (manual, hydraulic, electric and pneumatic)

• Reading and interpreting basic process valve symbols

• Explosive safety fundamentals EN 60079, EN-1127, EN-13463, IEC61241 plus appropriate guidelines,

function and duties, selection and qualification

• IEC 61508 guideline + dedicated guidelines, function and duties, with the fundamentals of SIL

• Symbols and standards

• Schematics of the main process

• Overview of types of instruments

• Open- and closed-loop control


The participant:

• can verify process valve selections and control systems

• can discuss and understand explosive safety topics and the influence of their operation

• can identify Safety Integrity Level targets

• understands the process control theory as an overview

• understands the main symbols used in the process automation and the importance of proper

documentation


1 day

565685


Process Automation

Technology


Pneumatics

PN111

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

In this course you will cover in detail the most up-to-date products, current tools and methods used in

industry. Our principle is learning from the real world for the real world!

FA: Operators, Maintenance, Design/Engineering, Trainer

PA: N/A

• Drives : Cylinders for different drive purposes

• Valves: Various valve types (pneumatic/electric controlled, structures, different mid

positions etc)

• Controls: Pneumatic and electric controls of valves

– Position control: Limit switches and sensors

– Speed control: Uses of throttle valves

– Logic control: And/or valves

– Pressure control: Uses of adjustable pressure sensors

– Time-dependent control

• Basic principles of industrial electric controls: Buttons, contacts, relays

• Basic principles of compressed air supply: Production, preparation, distribution

• Symbolic representation of devices, standards

• Identifying and eliminating faults, including safety aspects

• Cutting installation costs – from single valve to valve terminal

The participant:

• can design, assemble and test basic pneumatic circuits

• can maintain and troubleshoot pneumatic components and basic control systems

• can identify and describe the design, features, and operation of pneumatic components

• can identify and explain symbols for pneumatic components

• can interpret technical specifications and data relating to pneumatic components

• knows the fundamentals of compressed air generation

Technical understanding

3 days

559395

Modern industrial pneumatics –

Fundamentals

Technology


Troubleshooting and maintenance of pneumatic systems

PN121

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

This course allows you to extend your specialist knowledge of complex pneumatic systems and

improve your methodological skills. Practical exercises on training equipment for setup, commissioning,

troubleshooting and fault elimination facilitate the transfer of knowledge to your day-to-day work.

FA: Maintenance, Design/Engineering, Trainer

PA: N/A

• Setup and commissioning of pneumatic and electropneumatic systems

• Analysis of control tasks using GRAFCET in accordance with DIN EN 60848

• Design and function of pneumatic and electropneumatic circuits

• Special pneumatic components (valve terminals)

• Different types of valve terminal actuation

• Operating modes (AUT/MAN/EMERGENCY STOP)

• Electropneumatic and electronic control systems

• Latest standards and regulations

• Practical exercises and systematic troubleshooting

The participant:

• can set up and commission complex pneumatic systems

• can systematically troubleshoot pneumatic systems

• knows the role of PLC in automation and can integrate the PLC into the control section

• can work with valve terminals

• can interpret latest standards and regulations

Modern industrial pneumatics – Fundamentals training

3 days

559396

Pneumatics

Technology


Pneumatics

PN132

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

This course allows you to extend your technical and methodological knowledge and to identify and

eliminate faults without delay using a systematic procedure and the ability to understand the functional

relationships of complex machinery.

FA: Maintenance, Trainer

PA: N/A

• Functional relationships between mechanical elements, pneumatics, electronics and PLC

• Design and function of pneumatic and electropneumatic components

• Basic principles of sensor technology

• Reviewing, completing and using machine documentation

• Developing and applying troubleshooting strategies in a team

• Optimising systems using fault documentation

• Learning and applying safety regulations and valid standards

• Process FMEA (Failure Mode and Effect Analysis) as a method of preventive maintenance

• Optimisation of a production-related system with TPM (Total Productive Maintenance) components

• Practical exercises on systematic troubleshooting

The participant:

• can describe the functional relationship between mechanical, pneumatic, electronic and PLC

components

• masters troubleshooting techniques and strategies

• is familiar with safety aspects of pneumatic systems

• can explain the function and operation of selected MPS stations

• can apply FMEA (Failure Mode and Effect Analysis) to a machine

• can describe the structure of GRAPHCET and identify applications that use its strengths

• is aware of products and services that support TPM


4 days

559390

Effective maintenance of pneumatic systems

Technology


Pneumatics

Effective problem solving techniques

PN142

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Modern industrial plants have a high level of complexity, making it increasingly difficult for maintenance

staff to detect the cause of faults with technical competence and experience alone.

A methodical approach is required. This includes analysis of the environment, communication with

specialist departments and systematic use of appropriate problem-solving techniques.


PA: N/A

• Function plans of complex industrial equipment

• Introduction to GRAFCET

• Troubleshooting using problem solving techniques

• Causes of downtime and how to prepare a fault list

• Methods/tools for analysing weak spots

(Pareto, cause-effect diagram, brainwriting, FMEA, measure list, measure plan)

The participant:

• becomes familiar with the technical structure of a complex machine

• understands the causes of downtime and failures

• can prepare and evaluate failure lists

• can solve technical problems using a structured approach


2 day

559417

Technology


Pneumatics

PN152

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

In this course you will learn the special features of using a vacuum as opposed to conventional

compressed air. You will also learn about generation and measurement of vacuum, as well as selection

and dimensioning of reservoirs and suction cups, and the use of appropriate valves and sensors.


PA: N/A

• Generation and provision of vacuum

• Differences from conventional handling technology with grippers in terms of drawing in,

conveying and depositing

• Vacuum sensing for process control

• Dimensioning vacuum suction cups

• Air requirements of vacuum systems

• Influence of material properties on vacuum handling

• Practical exercises in small groups on special training units and individual components using

different materials

The participant:

• can describe the fundamentals of vacuum

• knows about vacuum generation and applications

• can select vacuum generation components

• can select suction cups for different industrial applications

• can troubleshoot vacuum applications


2 day

559405

Use of vacuum in handling systems

Technology


Valve terminal CPX –

Commissioning, modification and fault elimination

PN163

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Preconfigured complex systems with valve terminals and mechanical, pneumatic and electrical compo-

nents bring numerous advantages but create new tasks for maintenance staff. This courses enables you

to understand how pneumatic and electrical components work together. You will also learn identification

and elimination of faults, and troubleshooting aids.

FA: Maintenance, Design/Engineering


• Design and function of three different CPX valve terminal series

– MPA

– Midi

– VTSA

• Valve functions

• Creating pressure zones

• Drawing and reading pneumatic circuit diagrams

• Functional relationships between pneumatics and electrical engineering

• Terminal configuration and spare parts ordering

• Modification and replacement of parts

• Versatile electrical connection technology

• Adjustable failsafe behaviour

• Detection and elimination of pneumatic and electric controls

• Diagnosis via fault LEDs at the Profibus node

• Creating a Profibus configuration using STEP7

• Testing and diagnosis via Profibus using a programming unit

• Programmed diagnosis

The participant:

• is familiar with the CPX valve terminals and operation principles

• can interact with the CPX interface

• can diagnose failures of CPX valve terminals

• can undertake diagnosis via Profibus


2 days

559389

Pneumatics

Technology


Pneumatics

PN173

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Preconfigured complex systems with valve terminals and mechanical, pneumatic and electrical compo-

nents bring numerous advantages but create new tasks for maintenance staff. This course enables you

to understand how pneumatic and electrical components work together. You will also learn identification

and elimination of faults, and troubleshooting aids.



• Functional relationships between pneumatics and electrical engineering

• Creating pressure zones

• Production and reading of pneumatic circuit diagrams

• Terminal configuration and spare parts ordering

• Modification and replacement of parts

• Detection and elimination of pneumatic and electric controls

• Diagnosis via fault LEDs at the Profibus node

• Creating a Profibus configuration using STEP7

• Testing and diagnosis via Profibus using a programming unit

• Programmed diagnosis

The participant:

• becomes familiar with the CPV valve islands and operation principals

• can interact with the CPV interface

• can diagnose failures of CPV valve islands

• can undertake diagnosis via Profibus


2 days

559388

Valve terminal CPV –

Commissioning, modification and fault elimination

Technology


Energy-efficient design of pneumatic systems

PN183

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Incorrect dimensioning leads to higher costs, a reduction in quality and other problems. Covering the

basic solutions for correct dimensioning using real examples, this course enable you to plan and design

safe optimized pneumatic systems. Working with Festo ProPneu software you will learn relationships

between pressure, load and speed.

FA: Design/Engineering

PA: N/A

• Costs of compressed air production with calculation examples

• Compressed air drying and costs

• Costs of leaks

• Optimum dimensioning and material selection for compressed air networks

• Compressed air quality for different applications

• Function and design of the service unit, slow restart pressurisation

• Speed measurement of a cylinder with different fittings and tubing

• Dimensioning of a pneumatic system from the service unit through to the drive, including the hoses

and fittings

• Determining the air requirement for a plant, including procedure and calculation examples

• Use of ProPneu calculation software

• Different pressures for advance and return strokes

• Reducing installation costs – from a single valve to valve terminal

• Various valve terminals, selection criteria

The participant:

• knows key efficient design features from compressed air generation to drive section

• can use software tools to improve design quality and optimise system dimensioning

• can apply key aspects of proactive maintenance

• can detect and avoid energy waste in pneumatic systems


2 days

559391

Pneumatics

Technology


PN193

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Health and safety are key design criteria for pneumatic systems. Safe systems require clear structuring

of processes, correct choice of components and circuits with the necessary safety features. In this course

you learn how to clearly define processes with Grafcet, how pneumatic components behave in different

operating modes, and which safety standards have to be taken into account when designing circuits.

FA: Design/Engineering

PA: N/A

• Representation of control sequences (Grafcet)

• Practical flow control for pneumatic drives depending on the relevant load

• Influence of mass moment of inertia in semirotary drives

• Intermediate positions in pneumatic drives

• Introduction to proportional technology, use, function and soft stop

• Safety in the event of power failure: clamps, 5/3-way valves, piloted non-return valves

• Behaviour of pneumatic drives when power is restored

• Pneumatics for safety applications

• Equipment symbols as per DIN/ISO 1219-1

• Designation of equipment in circuit diagrams as per DIN/ISO 1219-2

• Pneumatic diagrams in FluidDRAW®

• Simulation of pneumatic circuits in FluidSIM®

The participant:

• recognises the importance of the Grafcet planning method and understands its symbols

• knows the effect of one-way flow control valves, the meaning of push, pull and alternating loads and

can select and use one-way flow control valves accordingly

• knows the effect of moments of inertia on semirotary drives and can use the Festo “Moment

of Inertia Calculation Tool” to calculate the moment of inertia and select the correct semirotary drive

using the data sheets

• knows ways of stopping pneumatic drives in intermediate positions

• has an insight into the safety technology standards, knows basic terms, understands the function of

pneumatic actuators in relation to various pneumatic and electropneumatic valves and is familiar

with circuits for various safety categories


2 days

559392

Safety in Pneumatics

Pneumatics

Technology


HY511

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

This course provides you with an insight into hydraulic components and their function. You will create

and read circuit diagrams and set the pressure, pressure and position of hydraulic drives. As in all Festo

Didactic seminars, there is an emphasis on practical exercises.

FA: Operators, Maintenance, Engineering, Trainer

PA: Operators Field-Process-Laboratory, Maintenance Process-Engineering, Design/Engineering,

Trainer/Consultant

• Equipment and circuit diagram symbols, reading and interpreting basic hydraulic circuit diagrams

• Physical principles

• Structure and mode of operation of basic components

• Measuring volumetric flow and pressure

• Technology and characteristic data of valves and drive elements

• Intensive training for industrial practice: setting up systems in accordance with circuit diagrams,

commissioning

• Fundamentals of proportional hydraulics

• Structure of simple relay controls

The participant:

• design, assemble and test basic hydraulic circuits

• maintain and troubleshoot basic hydraulic control systems

• identify and describe the construction, design features and operation of hydraulic components

• interpret technical specifications and data relating to hydraulic components and systems

• identify and explain graphical symbols for hydraulic components

• describe fundamentals of oil flow


4 days

559448

Modern industrial hydraulics

Hydraulics

Technology


Troubleshooting industrial hydraulics

HY521

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Careful maintenance can almost double the operating times of hydraulic components.

This course provides you with the relevant knowledge and necessary strategies and methods to tap

into these potential savings.

FA: Maintenance


• Special cylinders, hydraulic motors, piloted valves, synchronisation controls, valve fittings,

power supply systems with hydraulic reservoir and variable displacement pumps

• Technical knowledge, communication and teamwork

• Maintenance: Increasing operational reliability of production plants

• Inspection: Identification, measurement and evaluation of wear on systems

The participant:

• knows the features of piloted vales, special cylinders, hydraulic motors, valve fittings and

power supply systems with hydraulic reservoir and variable displacement pumps

• understands how availability of production equipment can be improved

• can recognise and assess the degree of machine wear and carry out the relevant measurements

• can apply the principles of systematic troubleshooting to real applications

• can identify and analyse the weak points of a machine and initiate measures to eliminate them

• can safely recommission the system

Modern industrial hydraulics training

5 days

559449

Hydraulics

Technology


HY132

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

In this course you will learn the function and control of proportional valves and the structure of basic

circuits in practical industrial applications. An extensive practical part gives you the opportunity to set up

circuits, set parameters and gain experience in commissioning and troubleshooting proportional hydraulic

controls.


PA: N/A

• Structure, function and characteristic data of proportional, way, pressure and flow control valves

• Generation of setpoints (analog and digital)

• Adapting amplifier electronics to required conditions

• Development and interpretation of proportional hydraulics circuit diagrams

• Intensive practical training through setup of circuits according to circuit diagrams and

setting parameters for optimal commissioning

• Tips for maintenance, troubleshooting and commissioning

• Proportional valves in the open-loop controls and control valves in closed-loop control

• Introduction to servo valve technology and control

• Current standards and safety regulations for industrial practice

The participant:

• understands the principles of proportional hydraulics

• can explain the structure and mode of operation of proportional, way, pressure and flow control valves

• can interpret the characteristic data of proportional valves

• can adapt amplifier electronics to the required conditions

• can develop, read, understand and interpret proportional hydraulics circuit diagrams

• can explain the principles of servo valve technology and control

• can explain the difference between open- and closed-loop controls

• can name current standards and safety regulations for industrial practice

Modern industrial hydraulics training

3 days

559451

Proportional hydraulics

Hydraulics

Technology


GRAFCET –

the new process description language

AUT111

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Used in automation and process engineering, GRAFCET is a specification language for sequences in

accordance with DIN/EN 60848. It replaces DIN 40719-6 Function Chart. If you are involved in design

and engineering, the course provides you with an invaluable planning tool. GRAFCET provides a primary

working document for plant engineers and line builders – and maintenance personnel with the key to

fast and effective troubleshooting for maintenance.


PA: Process-Engineering Maintenance, Design/Engineering, Trainer

• Explanation of the key elements of the standard

• What can GRAFCET do that Function Chart cannot?

• Modes of operation

• Hierarchies

• Macro- and microstructures

• Decentralized intelligence and sequences

• Creating example GRAFCETs

The participant:

• knows the advantages, benefits and application fields of GRAFCET

• knows the characteristics and structure of GRAFCET plans

• can read and understand a GRAFCET plan

• can visualize automation technology problems step by step with GRAFCET

• can draw own GRAFCET plans of varying degrees of difficulty

Basic knowledge of control technology

1 day

559452

Automation

Technology


PLC111

Target groups

Contents

Outcomes

Duration

Order number

Not every industrial application requires a complex PLC. Often a few inputs and outputs are sufficient

to automate a small application quickly and safely. This course gives you the knowledge to program

clearly structured and effective programs using a simple PLC – that is, the FEC – with FST, an equally

uncomplicated and easy to learn programming language.

FA: Maintenance, Engineering, Trainer

PA: N/A

• Basic structure of various FECs

• Properties of inputs and outputs

• The two FST programming languages: Instruction List (IL) and Ladder Diagram (LD)

• Basic FEC and FST commands

• Latching

• Timing with the FEC

• Counting with the FEC

• Archiving and restoring of FEC programs

The participant:

• can read out and create hardware configurations

• can create logic associations and sequences as PLC programs and commission these

• can implement modes such as Automatic, Manual and EMERGENCY STOP

• can combine various program modules to structured programs

• can identify and eliminate faults using the status display

• can identify reasons for machine stoppages with the aid of the PLC program

3 days

559457

FEC mini control systems –

Basic principles

PLC

Technology


Networked FEC mini control systems and visualisation

PLC

PLC122

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

This course acquaints you with the diagnostic messages that are visualized by a diagnostic devices for

minicontrollers networked via Ethernet. You learn to connect FECs via Ethernet, load programs, evaluate

diagnoses, and eliminate faults. The course builds on T-PL-11-1, which is a prerequisite.

FA: Maintenance , Engineering, Trainer

PA: N/A

• Establishing the IP address of the FEC

• Establishing communication with the FEC via Ethernet

• Integrating several FECs

• Programming communication between FECs

• Creating FED applications and loading them into the FED

• Connecting FEDs to the FECs and programming communication

The participant:

• can plan and create simple operating and diagnostic interfaces

• can program complex systems with the aid of networked minicontrollers

• can assign and transmit own IP addresses to FECs and FEDs

• can network various FECs and FEDs via Ethernet

• can plan data exchange between several FECs and commission

• can create FED applications and incorporate these into FEC programs

• can visualise FEC data in MS-Excel and Internet browsers

FEC mini control systems – Basic principles training

2 days

559458

Technology


PLC211

Target groups

Contents

Outcomes

Duration

Order number

You will learn the structure and mode of operation of the Simatic S7 as well as how to create simple

logic association and sequence programs. A key element of the course is application and handling,

using the programming terminology and taking into account the various interfaces between the individual

technologies (mechanical, pneumatic, hydraulic, electrical and PLC).



• Basic structure of the Simatic S7 controller

• Roles of the input and output modules

• The 3 programming languages: FUC, LD and IL

• The basic instruction set of Simatic S7

• Latching

• PLC timers

• Archiving and restoring PLC programs

The participant:

• can configure and commission a Simatic S7 controller

• can create, read out and change hardware configurations

• can create and commission PLC programs with logic associations and sequences

• can combine various program modules into structured programs

• can delimit and eliminate faults and errors using the diagnostic buffer and status display

4 days

559381

Simatic S7 –

Basic principles

PLC

Technology


Simatic S7 –

Intermediate

PLC

PLC222

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

This course focuses on the process to be automated. The material covered in this advanced seminar will

allow you to implement your automation solutions with the Simatic S7.



• Deeper exploration of STEP 7

• Structured programming

• Sequence programming in FUC

• GRAFCET planning aid as per DIN EN 60848

• Reading and normalizing analog values

• Application of various organizational modules

• Generation of and working with data modules

• Declaration of variables in function modules and functions

• Application of standard and system function modules

• Application of IEC modules from the library

The participant can:

• understand and create complex program structures

• find errors in complex programs quickly and efficiently

• establish the reasons for machine stoppages with the aid of the PLC program

• make changes and additions to programs developed by others

Simatic S7 – Basic principles training

4 days

559383

Technology


PLC232

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

It is hard to imaging industrial automation without communication via bus systems. This course gives you

an introduction to various technologies: Profibus, Interbus, AS-i bus, and fieldbus and enables you to use

and commission them and identify and eliminate faults.



• Function of the AS interface

• Addressing AS-I user modules and commissioning of an AS interface with the Simatic S7-300

• System information and structure of the MPI network

• Configuration and commissioning of an MPI network with a Simatic S7-300

• Technical system information on the Profibus DP

• Mode of operation of the Profibus DP

• Commissioning of various Profibus components with the Simatic S7-300

The participant:

• can parameterise and diagnose Profibus DP slaves

• can plan and systematically commission AS-i system

• can identify and eliminate faults in an AS-i network

• can plan and systematically commission a Profibus network

• can identify and eliminate faults in a Profibus network


Simatic S7 – Bus intermediate training

3 days

559382

Simatic S7 –

Bus technology

PLC

Technology


Effective maintenance of Simatic S7 PLC

PLC

PLC243

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

These days, numerous machines and systems use the structure of pneumatic power part, electro-

pneumatic drives and PLC-controlled signal processing. Such systems make great demands on you as a

service technician. This course gives you a thorough understanding of the PLC, electrical systems and the

controlling pneumatic or mechanical systems. Only this knowledge will allow you to find and eliminate

the cause of unscheduled downtime as quickly as possible.



• Commissioning of a complex, automated system

• Structure and mode of operation of a PLC

• The PC as a troubleshooting aid

• Troubleshooting in and as a team

• Using existing documentation

• Knowing and using safety regulations and applicable standards

• Process FMEA (Failure Mode and Effect Analysis) as a method for preventive maintenance

• Practical exercises and systematic troubleshooting

• Communication of system modules via Profibus DP

• Optimization of complex automated systems using TPM (Total Productive Maintenance)

– Elements

– Identifying sources of loss

– Collecting optimization methods

– Execution of optimization

– Assessment of results achieved

The participant:

• can use documentation and PLC programs to quickly identify faults

• can identify weak points and develop suggestions for improvement

• can identify optimisation potential and implement optimisation

• can ensure stable uninterrupted production as a result of all these measures


Simatic S7 – Intermediate training

Simatic S7 – Bus technology training

5 days

559378

Technology


PLC

PLC281

Target groups

Contents

Outcomes

Duration

Order number

Flexibility despite a high degree of automation’s one of the most important challenges in manufacturing

companies. It demands the integration and networking of different controls in a complex automation sys-

tem. This is complicated by the huge variety of programming software available. Differences in user-inter-

face, functionality and commands sets cause confusion and make mistakes more likely. CoDeSys – a tried

and tested, globally-introduced hardware-independent software from 3S offers a Controller Development

System according to the IEC 61131-3 with all defined programming languages independent of the hard-

ware manufacturer. This training demystifies CoDeSys and gives participants confidence in using it.


PA: Operator Field-Process-Laboratory, Maintenance Process-Engineering, Design/Engineering,

Trainer/Consultant

• Overview of the standard IEC 61131-3

• Introduction to the CoDeSys programming environment

• Use of the 6 programming languages IL, ST, LD, FBD, SFC, CFC

• Use of visualisation

• Working with simulation

• Functions, function blocks and libraries

• Conversion of PLC programs

• Use of variable and symbolic operands

• Using the Help function

• Aids to trouble-shooting

The participant:

• can explain the scope and potential of CoDeSys

• can explain the positioning of CoDeSys to other programming environments

• can select the best programming language for a given task

• can identify which products can be programmed with CoDeSys

• select appropriate language for a specific task and combine them to a complete project

• can create a basic simulation based on the internal SoftPLC from CoDeSys and test programs

• can create a basic visualisation (e.g. belt or distribution station)

2 days

570614

CoDeSys –

A hardware independent introduction for programmers

Technology


PLC

PLC271

Target groups

Contents

Outcomes

Duration

Order number

In order to master the fast-changing requirements of embedded and PC-controlled industrial applications,

it is increasingly important to master and apply different programming languages. This is complicated by

the huge variety of programming software available. Differences in user-interface, functionality and com-

mands sets cause confusion and make mistakes more likely. CoDeSys – a tried and tested, globally-intro-

duced hardware-independent software from 3S offers a Controller Development System according to the

IEC 61131-3 with all defined programming languages independent of the hardware manufacturer.

This training demystifies CoDeSys and gives participants confidence in using it.

FA: Maintenance

PA: Maintenance Process-Engineering, Design/Engineering, Service technicians, electricians,

programmers and others

• Construction and function of a PLC

• Overview of the standard IEC 61131-3

• Overview of automation structures and bus systems

• Functionality of the CoDeSys programming environment

• Use of the 6 programming languages IL, ST, LD, FBD, SFC, CFC

• Offline simulation

• Visualisation

• Configuration and commissioning on Festo automation systems – and much more...

The participant:

• can use and combine IEC 61131-3 languages (CoDeSys v2.3) to program an professional solution

for an industrial application quickly and efficiently

• can program IEC 61131-2 compatible industrial controllers

• can describe the sequence of the MPS Distribution Station using Grafcet

• can program the sequence of the MPS Distribution Station using a language or combination

of languages

• can use debugging tools to simulate, test and trace

• can use CoDeSys features to troubleshoot

• masters the fundamentals of visualisation

• can create and use different kinds of variables (local, global)

• knows how to find help within the software

3 days

570612

CoDeSys for Industry

Technology


AUT121

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Sensors are used for a wide range of functions in automated systems, such as to measure pressure, force

and distance, detect the presence and/or position of workpieces and the completion of process steps.

This course gives you an overview of sensor technology including the design and function of different

types of sensors, their applications and limitations.


PA: N/A

• Basic physical principles and characteristic features in use

• Sensor selection based on materials and ambient conditions

• Terms and definitions in sensor technology

• Design, function and applications of different sensors for detecting presence, distance, travel, force

and pressure, material quality etc.

• Industrial applications and realisation

• Technical data and limits on use of sensors

• Connection technology and signal processing

• Practical exercises and fault analysis

The participant:

• knows the functions of various sensors such as indicating, distance, pressure, force etc.

• can select and install sensors for various applications

• can adjust and calibrate sensors

• can interpret sensor technical data

• can troubleshoot sensor faults

Technical understanding

3 days

565669

Basic principles of sensor technology

Automation

Technology


Introduction to mechatronics

AUT211

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Today we are surrounded by automation systems that are a combination of mechanical engineering,

electronics and software. This seminar provides you an understanding and lays the foundation for

mastery of industrial automation, enabling you to commission, operate, adjust and maintain these

machines.


PA: N/A

• Basic physical principles

• Fundamentals of mechanics, pneumatics or hydraulics

• Motion control by electrical engineering

• Motion control by PLC

• Various sensor types and limit switches

• Basics of servo technology

• Factory automation simulation using MPS stations

• Practical exercises and troubleshooting

The participant:

• can troubleshoot basic mechatronic control systems

• can assemble and test basic mechatronic circuits (pneumatic, electrical, and software)

• can install or replace, and commission pneumatic, electropneumatic, electrical and PLC hardware

components

• can use diagnostic software to assist troubleshooting

• recognises and can differentiate between the different types of programming used in industry

• can download a program and commission a simple PLC control system

• can identify and describe the operation of pneumatic, electropneumatic, electrical and PLC components

and sensors

• can interpret technical specifications and data relating to pneumatic, electropneumatic, sensor,

electrical and PLC components and systems

General technical understanding, background in automation

5 days

565671

Automation

Technology


ED111

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

The increasing use of these servo drives in industry has led to a skills gap that can have a negative impact

on productivity. If you are a user of conventional pneumatic drive technology, this course provides you

with the knowledge and skills to master the basics of electrical servo drives.


PA: Maintenance Process-Engineering, Design/Engineering, Trainer/Consultant

• Fundamentals of electrical drives

• Encoders (absolute, incremental, resolver)

• Motors (asynchronous, synchronous, AC servo, DC, stepper)

• Controllers, motion profiles, positioning drives

The participant:

• can describe the function of stepper, servo and positioning drive

• can describe the interplay of mechanical and electrical components

• knows the criteria for selecting a drive

• can commission an electric drive system

• can localise and eliminate simple faults

• can use the Festo Configuration Tool software

• can assemble, power up and configure a system

• can select the most appropriate drive for a given application

• can identify and eliminate faults and can interpret error messages

• can work safely with an electric drive

• has completed practical exercises with spindle and toothed-belt axes, cantilever axes, stepper and

servo motors.

Basic electrical and sensor understanding

2 days

562553

Fundamentals of Electric Drives

Electric drives

Technology


Fast, confident electric drive configuration

AUT201

Target groups

Contents

Outcomes

Prerequisites

Requirements

Duration

Order number

For many years it seemed that pneumatics was superior to electrical drives in linear and rotary motion.

Electric drives have developed to an energy-efficient, versatile technology. The increasing use of these

drives in industry – demanding the mastery of mechanical and electrical components and software has

led to a skills gap that can negatively impact productivity. If you are a user of conventional pneumatic

drive technology, this course provides you with the knowledge and skills to master the basics of electrical

servo drives.

FA: Design/Engineering, Trainer

PA: Design/Engineering, Trainer/Consultant

• Influence of application data on the required system

• Dimensioning and selection of the right system

• Significance of the mass moment of inertia

• Understanding the control behaviour

• Factors influencing positioning accuracy and repeatability

• Designing and dimensioning systems using the “Positioning Drives” software

• Tips for safe mechanical and electrical design

• Tips on user guide, system documentation, maintenance and repair

• Safety in the electrical control

• Emergency stop

• Types of Stop

• Safety categories according to EN ISO 13 849-1 and EN 62 061

• Safe stop using the controller

• Practical exercises with the following components, spindle axis, toothed belt axis, cantilever axis, han-

dling device, stepper and servo motors

The participant:

• can describe the function and design of new electric drives

• can select, configure, dimension and integrate optimal electrical drive systems for applications

• knows relevant technical data, formulas, parameters

• can use configuration and dimensioning software to select according to their needs

• can select, configure, dimension and integrate optimal electrical drive systems for application

• Is familiar with appropriate safety legislation and standards and can adapt to the needs of their own

operational needs within production

Basic electrical and sensor understanding

Hardware similar to TP800 plus components

2 days

570024

Electric drives

Technology


AUT431

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

An important part of the role of maintenance crew is to quickly and confidently troubleshoot faults in

safety circuits and for designers to foresee the safety aspects of machines during designing stage and

select the right components and circuits. A sound understanding of the components and their interplay is

essential for this. All maintenance crew should be competent in safety technology and the standard EN

ISO 13 848-1. In this course the participant learns key locate faults, replace parts and recommission

machines safely in P and EP circuits up to control category 4 safely and responsibly.

FA: Maintenance, Design/Engineer

PA: Maintenance Process Engineering, Design/Engineering

Introduction to EN ISO 13 849-1

• Fundamental and proven safety principles in pneumatics

• Control and stop categories and their effects

• Safe handling of potential dangers in pneumatic circuits

• Selected measures for safe pneumatics

– unexpected movement, blocking, braking and reversing movement, two hand safety control, ...

• Troubleshooting safety circuits

• Select the right spares based on fault prediction

• Safe pressurising and depressurising of drives and installations

• Affect of overrun in pneumatic drives in the protected area of light barriers

• Safe use of brakes and clamps

• Recognising and eliminating tampering

• Tips on operation and maintenance

• Practical exercises

The participant:

• knows about the relevant technical data, formulas, parameters for

– cylinders, valves, valve islands and service units

– mechanical actuators (belt, spindle)

– motors (servo, stepper)

– various safety relays

– controllers

– movement profiles

• can

– take safety measures for pneumatic circuits of the machines

– estimate the potential unsafe conditions relating to various applications

– design, troubleshoot and improve the machines with safety aspects

– can safely test the circuits

• can select, configure, dimension and integrate optimal electrical drive systems for application

– He knows where to find CAD drawings and integrate / download into his CAD environment

Modern industrial pneumatics – fundamentals PN111

2 days

570881

Safety circuits for maintenance crew and designers

Safety

Technology


Understanding the new machine directive –

one day orientation event

SN121

Target groups

Contents

Outcomes

Duration

Order number

Do you use or build machines or installations? Then the new machine directive is valid for you. It comes

into force on 29 December 2009 without any transition period. The standard DIN EN 954-1 has been

replaced by the new ISO 13 849-1. This means that in future you must define a Performance Level and

Diagnostic Coverage for your machine. This one day training gives an overview of the key aspects and

implications of the Machine Directive. There is an extended 2 day version on the following page in which

additional competencies are transferred.


PA: N/A

• New machine directive 2006/42/EG

• Changes compared to old machine directive 98/37/EG

• Risk assessment according to EN ISO 13 849-1

• Differences to DIN EN 954-1

• Terms and definitions of EN ISO 13 849-1:

– Performance Level PL

– Diagnostic coverage DC

– Common Cause Failure CCF

– Mean time to failure MTTF

– Establishing values based on selected pneumatic and electropneumatics circuits

This event can be run as a presentation to many – in which case the outcome is:

The participant

• has seen an overview important aspects and implications of the machine directive

• has been provided with documentation and software tools (in some cases)

• has seen how key values can be calculated

1 day

567355

Safety

Technology


SN131

Target groups

Contents

Outcomes

Duration

Order number

Do you use or build machines or installations? Then the new machine directive is valid for you. It comes

into force on 29 December 2009 without any transition period. The standard DIN EN 954-1 has been

replaced by the new ISO 13 849-1. This means that in future you must define a Performance Level and

Diagnostic Coverage for your machine. This 2 day training gives an overview of the key aspects and impli-

cations of the Machine Directive and provides fundamental skills.


PA: N/A

• Changes in Machine Directive

• The II-B declaration

• The relationship between guidelines and standards (relationship)

• Design and risk

• Concept , standards (A, B, C, )

• Safety circuits and safety components

• Common component faults

• Life expectancy

• Faults and fault tolerances

• Calculation of MTTFd

• Background of functional safety

• Design of functional architecture

• Step-by step methodical procedure for calculating key values

In this 2 day event for a smaller group (up to 12 participants) the following outcomes are achieved in the-

oretical exercises:

The participant

• understands responsibilities related to machine safety

• understands the integration of standards and the machine directive in own installations

• can conduct a risk analysis

• can select, integrate and test a testing a technical selection for appropriate safety

• can minimise cost while conforming to the standard

2 days

571083

Understanding the new machine directive –

2 day training event

Safety

An excellent company

We know what makes an

excellent company:

a focus on customer satisfac-

tion, corporate and quality

strategy, employee satisfaction,

efficient processes, responsible

and target-oriented employee

management, job-oriented

qualification, positive business

results and a positive impact

on society.

We will prepare your entire

organisation for the new tasks

you will face.

Our consultants will advise your

employees on the development

of an independent and auto-

nomous working style. The aim

of their work is to enable com-

panies to efficiently structure

work, organisation and qualifi-

cation processes.

Organisation

57

Organisation


LP111

Target groups

Contents

Outcomes

Duration

Order number

Introduction to Lean Production and Value Stream Mapping

Taking the form of a strategy game, this training gives you a holistic view of material and information

flows within a company and sensitises you to different types of waste in processes. You learn to analyse

the causes of delivery problems and low productivity and to develop and implement ideas for meeting

customer needs and improving processes. The main goal is to instil lean thinking in your company.

The strategy game provides practical experience for all employees involved in lean production projects.

FA: Maintenance, Design/Engineering, Trainer, Managers

PA: Process-Engineering Maintenance, Design/Engineering, Trainer/Consultant, Managers

• Inventory minimisation as an important basis for increased productivity

• The principle of pull production control

• Advantages compared to conventional production control methods

• Types and function of different pull production control methods

• Application of methods

• Kanban – the classic pull principle

• SMED – Optimisation of setup processes with Single Minute Exchange of Die

• CIP processes as part of the business game

• Introduction to Value Stream Mapping (VSM)

The participant:

• can analyse the causes of delivery problems and low productivity

• can develop and implement ideas for meeting customer requirements and process improvements

2 days

561209

Lean Production

Organisation


Kanban –

Pull production control

LP121

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

This course uses an example of kanban to teach you the tools and methods for better planning and

implementation of pull processes. You learn to use these methods to optimise processes and inventories

automatically, freeing up resources and capital. You quickly learn to use the practical knowledge to

implement simple pull processes in your own company.

FA: Maintenance, Design/Engineering, Trainer, Management

PA: Process- Engineering Maintenance, Design/Engineering, Trainer/Consultant, Management

The various kanban methods

• Kanban – manual or electronic?

• How do we produce in the customer’s takt time? How do we calculate this?

• Calculating the order point

• Determining batch size

• How do we dimension a supermarket?

• How do I design a kanban board or kanban card

• Audit systems, key characteristic values

The participant:

• can design kanban circuit

• can calculate buffer inventories, kanban quantities, customer takt time, order point and lead times

• can determine batch sizes

• can design supermarkets

• can design kanban boards and cards

• can use audit systems

• can calculate key characteristic data

• can put approaches into practice

Some experience in production control

1 day

559423

Lean Production

Organisation


LP131

Target groups

Contents

Outcomes

Duration

Order number

Optimum batch size is often determined based on minimum inventory and job changeover costs.

But this approach has one critical flaw: It views changeover costs as unchangeable. This often results in

overproduction, excessive inventories, adjusted transport routes and scrapping, high cycle times and

delivery problems. This course enables you to radically reduce machine and plant downtime caused by

setup.

FA: Operators, Maintenance, Engineering, Trainer

PA: N/A

• Relationship between batch size and setup time

• Reducing setup times as the only way to reduce batch sizes and inventories in production

• The SMED (Single Minute Exchange of Die) method and its phases

• The OTED (One Touch Exchange of Die) method

• Constructive solutions for fast setup processes

• Work organisation options for fast setup processes

• Influence on production control

• Practical implementation of methods in a model plant

The participant:

• is able to recognise waste

• knows the importance of short setup times for fast and economical order processing,

flexible production and low inventories

• can apply and teach the SMED method

1 day

559425

Reducing set-up time with SMED

Lean Production

Organisation


TPM –

Maintenance strategies and Total Productive Maintenance

LP141

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

This course provides service technicians with an overview of commonly used maintenance strategies,

compares these based on different requirements and thus provides you with a basis for making

maintenance decisions to maximize availability in your own company.


PA: N/A

• Production systems and their influence on maintenance

• Six typical types machine and system loss

• Roles and self-image in maintenance

• Organizational structures for maintenance

• Comparison of maintenance strategies:

– Event-oriented maintenance

– Routine maintenance

– Total Productive Maintenance (TPM)

– Reliability-Centered Maintenance (RCM)

– Risk-Based Maintenance (RBM)

• Data for recording maintenance performance

• Examples and practical exercises

The participant:

• can establish sources of loss on machines and systems

• sees maintenance as a service provider for production

• can evaluate various maintenance strategies and select the appropriate one for the company

or various machines

• can implement the company’s maintenance strategies

• can select and collect data for recording maintenance performance

Experience in maintenance

2 days

559428

Lean Production

Organisation


LP151

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

As one of the most important principles for the implementation of lean manufacturing, flow production

allows drastic reduction of throughput time and inventories while increasing flexibility. But this approach

presents conventional series production with difficult challenges. In this course you will learn how to

analyse the flow potential of production processes, what can be implemented, and how hurdles can be

overcome.


PA: N/A

• Analysis of workplaces with the Standard Operation Sheet

• Adjusting the cycle times of individual workplaces

• Flow and takt time production

• Avoidance of material transport with linear and U layouts

• Structure and development of open-plan production

• Line Back system

• Integration of logistic processes with kanban and milk run systems

• Flexible employee systems: relay and caravan systems

• Multimachine operation

• Examples and practical exercises

The participant:

• can analyse and evaluate workplaces

• can develop suitable optimization concepts

• can take the interaction between employees, organization and technology into account

• can integrate micrologistics

• can plan multimachine operation

• can implement concepts in practice

Experience with production planning and layout

2 days

559413

Flow –

efficient production processes and layout

Lean Production

Bringing out your best side

Social skills and effective net-

works are the key to a success-

ful organisation.

In the future, both managers

and specialists will be required

to continue developing not only

their technical but also their

social skills.

Knowing how to overcome

difficult situations and support

teams throughout processes of

change is becoming more and

more important. Festo will teach

you how to positively design all

levels of a process in order to

achieve a successful overall

solution.

People

63

People


LS111

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Comments

This module on the Principles of Leadership is the first of 3 that includes team leadership and personal

mastery. With a minimum theory and maximum activities, you experience key leadership principles and

skills and gain an understanding of what makes a good leader (role model). Group activities give you a

shared view of leadership and allow you to start identifying the changes you need to make.

FA: Junior management

PA: Junior management

• Definition of leadership

• Principles of leadership

• Role of a manager

• Management and motivation of employees

The participant:

• understands what constitutes a good leader

• identifies the changes necessary to become a good leader

• understands the principles of management

• knows the key tasks of a manager

• knows different styles of leadership and how and when to apply them

• knows how and when to delegate

The course is designed for First Line Leaders, that is, junior management.

3 days

565668

The 3 modules are given over a roughly 6-month period. An interim project which is defined by the end of

the first module. The program is preceded and closed by a review meeting (you and your superior). The

modules are best run with around 12 participants. The concept was developed in cooperation with our

key customer EADS.

Leadership Training Module 1

Leadership

People

65Online booking: www.festo-tac.com

Train-the-trainer –

Mastering key trainer skills

TTT111

Target groups

Contents

Outcomes

Duration

Order number

If you want to impart knowledge or train competencies, you not only need the specialist knowledge but

didactic know-how. This course will teach you to present content in a clear and engaging way, thus

increasing effectiveness. This Train the Trainer course gives you methods and important tips that will

allow you to meeting your training goals in a professional and qualified manner.


PA: Maintenance Process-Engineering, Design/Engineering, Trainer/Consultant, Management

• Didactics and methods for training

• Competency-based training, training aims and seminar design

• Physiology of learning

• Didactic reduction

• Teaching and learning methods

• Progress checks

• Active listening and asking questions

• Giving and receiving feedback

The participant:

• knows the classical learning mechanisms and can adapt training content to participants’ needs

• knows creative techniques to make technical training engaging

• knows the most important media and knows how they can be used for a specific training aim or

target group

• can communicate effectively with participants

• knows feedback rules and can give and receive feedback

• can structure training content in a clear and appropriate way

• can present complex topics clearly through didactic reduction

3 days

559442

Train-the-Trainer

People


CO111

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

This course presents a compelling new approach to customer communication. Proven tools guide the

service professional and develop the core skills needed for effective communication. The training course

is part of the four-part Service Ambassador program providing you, as a service engineer, with the skills

to build relationships, enhance loyalty, discover opportunities and differentiate their business from the

competition.

FA: Maintenance

PA: Process-Engineering Maintenance

• Identifying the ‘environmental factors’

• The core competencies of a professional and successful service engineer

• Comparing ‘modern consultative’ and ‘adversarial’ communication

• The communication cycle

• Key skills for ‘setting the stage’

• Strategic questioning skills

• Listening skills and the barriers to effective listening

• Identifying customer needs and expectations

• ‘Delivering the result’ – customer focus

• Achieving customer satisfaction and future commitment

The participant:

• has developed an increased awareness of customer perceptions

• is able to apply the customer ‘communication cycle’

• has enhanced customer-focused communication skills

• has developed skills to help identify customer needs and expectations

• can identify ways to enhance the customer’s opinion of themselves and their company

• can develop a personal action plan to help implement benefits gained in daily working

Practical understanding of the machines for which customer support is required as well as experience in

visiting customers in an after-sales technical support role

2 days

560278

Service Ambassador –

Communication skills for service engineers

Communication

People

67Online booking: www.festo-tac.com

Team-based problem solving and process –

FMEA

IM111

Target groups

Contents

Outcomes

Prerequisites

Duration

Order number

Growing complexity makes it increasingly difficult for maintenance staff to identify faults using technical

competence and experience alone. This course teaches you a systematic approach with analysis of the

environment, communication with specialist departments, and targeted use of appropriate techniques.


PA: Process-Engineering Maintenance, Design/Engineering, Trainer/Consultant, Management

• Part 1: Understanding and practicing team-based problem solving techniques:

Is/Is Not Analysis, Pareto chart, cause-and-effect diagram, brainstorming, filtering and scoring,

trend charts, box-and-whisker plot

• Part 2: More about similar techniques:

Deming, 8D report, DMAIC, RADAR logic

• Part 3: Understanding and practicing process FMEA

The participant:

• knows how team-based problem solving techniques can improve team effectiveness as part of

continuous improvement process (CIP)

• has started to undergo a change in self-image. Participants start to see themselves as knowledge

bearers who are proactive and deliberate to help reduce waste and risk in production.

Experience with team work , basic knowledge of quality control instruments as users

2 days

559418

Improvement Management

www.festo-tac.com

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