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Training solutionsCatalogue

TECHNICAL TRAINING

ENGLISH

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FCA Italy - Training & Consulting is an organization of Professional Trainers fully dedicated to support Operations training initiatives at World Wide level

World Class Approach

Vision

Create a “world class” learning organization able to transfer Wold Class best practices and know-how and contemporarily develop people and continuous improvement culture

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problemsopportunities

best practicesstudy sessions

training in classroom solutions

training on the job solutions

!

improvementculture

People development and continuous improvement

From reactive to preventive and

proactiveSystematic elimination of loss and waste

Internal Trainers certification

Accelerated expansion

Support to plants in skills certification and standardization

Mission

Develop and Deliver World Class Training & Consulting

Industry 4.0Digitalization

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EXERCISES

ON THE JOB TRAINING

SIMULATION CLASSROOM

ON FIELD COACHING

LAB TRAINING

TR

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Training & Consulting (T&C) team has developed solutions of Technical Training based on three levels, as shown in figure.

The programs for “Technical Education” aim at supporting the plants through the formation of specific figures having a high practical/manual content (Craft schools).

The ”Basic Courses” for the roles of the factory aim to create a basic technical culture in the workers of the factories. They cover all the major issues of industrial technology, in order to increase the specific skills of the trade.

The “Advanced Courses” are designed to consolidate expertise of role using specialistic know-how. The educational activities are based on real evidence and allow to achieve tangible results.

The solutions pyramid of the Technical Training

Technical Education Courses targeted to the crafts creation

Basic Courses Basic courses for the roles at the factory

Advanced Courses

Specialistic Contents

CREATE CrAfTs

DEVELOpKNOW HOW

CREATE DOmiNiON

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sPECifiC

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fULL

TrAiNiNG sOLUTiONs CATALOGUE

TrAiNiNG PrOGrAm CUSTOMIZATION

starting from the individual solutions in the catalog you can build custom paths routes, in order to meet the specific requirements as rationally and efficiently as possible

Training & Consulting methods

CLASSROOM WITH SIMULATIONS

CASE STUDIES

LEARNING GAMES

WORLD CLASS pROGRAM & SUppORT KICK-OFF

KAIZEN WEEK

WORKSHOp MAJOR KAIZEN

WORKSHOp ADVANCED KAIZEN

ON THE JOB SUppORT

TRAIN THE TRAINER pROGRAM

ASSESSMENTTOOLS

MOBILE TRAINING

GAMIFICATION

WEB ACADEMY

WEBINAR

BU

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BASIC COURSES

mechanical drafting basic 6

mechanics basic 7

Electromechanics basic 8

Electro-fluidics basic 9

Pneumatics basic 10

Oleohydraulics basic 11

Lubrication 12

ADVANCED COURSES

Mechanicsmaintenance of bearings 13

mechanical drafting following the AsmE Y14.5m standard 14

FluidicsPneumatics logic 15

Oleohydraulics advanced 16

Electrical SystemsElectrical industrial systems advanced 17

PLCAllen&Bradley sLC 500 PLC 18

Allen&Bradley ControlLogix PLC 19

Allen&Bradley DeviceNet Automation Network 20

simATiC s5 PLC 21

simATiC s7 PLC basic 22

simATiC s7 PLC advanced 23

simATiC s7 PLC maintenance 24

simATiC Hmi WinCC flex 25

simATiC Net: Profibus for s7 26

simATiC Net: ProfiNet for s7 27

Computerized Numerical ControlsCNC siNUmEriK 840D use, management and programming 28

CNC fanuc use, management and programming 29

CNC siNUmEriK 840C maintenance 30

CNC siNUmEriK 840D maintenance 31

CNC siNUmEriK 840D sL maintenance 32

Industrial Roboticsrobot Comau C3G+ maintenance 33

robot Comau C4G use and management 34

robot Comau C4G programming 35

robot Comau C4G maintenance 36

TECHNICAL EDUCATION (CRAFT SCHOOLS) machine tools operator (turning) 37

machine tools operator (milling) 38

GmAW welder 39

Paint shop revisionist 40

GAMIFICATION

WEB ACADEMY

WEBINAR

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Training

mechanical drafting basicObjectivesUpon course completion the learner will be able to:

• Deepen the knowledge base on standards, reading and interpretation of the mechanical drawing

• Interpret drawings related to equipment and mechanical components of installations affected by maintenance operations

• Obtain information about the components from the overall

• Obtain information about the components from the manuals of suppliers

5 days

Course Timeline

Content• Rules for the graphical representation of the

mechanical details

• Dimensioning systems, dimensional and geometric tolerances

• Exercises in reading and interpretation of mechanical drawings

• Analysis and interpretation of specific drawings of the plant with particular attention to sections and dimensioning

• Analysis of the criticality for disassembly of the components from the overall

Expected Benefits• Acquired critical reading of mechanical drawings of the plant

Target Audience• Maintenance leaders

• Technologists

• Electrical and mechanical maintainers

prerequisites• Basic knowledge of technical drawing

Classroom

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mechanics basic

Training

5 days

Course Timeline

Expected Benefits• Acquired basic operating ability to perform replacements of mechanical devices

Target Audience• Newly hired maintainers

prerequisites• No prerequisites required

5 days

50%hands-

on

Examples & Exercises

ObjectivesUpon course completion the learner will be able to:

• Identify the mechanical components of the machines for connection, transmission, positioning and motion transformation

• Detect the functional characteristics of the mechanical linkage, positioning and motion conversion systems

• Use drills, grinders and manual tools respecting the safety rules

• Increase the base knowledge about the rules of reading and interpretation of mechanical design

• Interpret drawings related to equipment and mechanical components of installations

• Obtain information about the components from the overall design

• Get information about the components from the manuals of their suppliers

Content• Mechanical parts for the transmission of motion

• Transmissions, kinematic mechanisms and restoring of mechanical parts

• Technical representation of machine parts

• Assembly and machining cycles

• Specific safety regulations for the role

• Specific equipment for mechanical maintenance

• Methodologies of construction for simple mechanical elements, related machining, and processing techniques at the bench

• Dimensional and geometric tolerances

• Exercises about reading and interpretation of mechanical drawings

• Reading and interpretation of specific drawings of plant, focusing on sections and dimensioning

• Critical issues about dismounting the components from the overall assembly

Classroom / maintenance box


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Training

2.5 days

Course Timeline

Classroom / laboratory

2.5 days

50%hands-

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Electromechanics basicObjectivesUpon course completion the learner will be able to:

• Know the fundamentals of electrical engineering, understand the wiring diagrams for power and control circuits and the main components used in electromechanical circuits

• Know the electric motors, with particular reference to the three-phase asynchronous motors

• Execute electrical measurements by means of the multimeter

• Replace electromechanical components and motors that present failures

Content• Ohm’s law

• Series/parallel and network connections

• Power

• Electromagnetism

• Electrical measuring instruments

• Relays and timers

• Electric motors: three phase asynchronous motors, operation, command mode, typical circuits

• Reading and interpretation of simple electrical diagrams

• Contactors and starting of electric motors

• Soft starters

Expected Benefits• Acquired basic operating skills to execute maintenance interventions on traditional systems




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Electro-fluidics basic

Training

2.5 days

Course Timeline

Expected Benefits• Acquired basic operating skills to execute maintenance interventions of electro-fluidic systems using

traditional type control


prerequisites• Basci knowledge about electrotechnics

and fluidics


2.5 days

50%hands-

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• Locate the internal electro-pneumatic and electro-hydraulic (limit switches, proximity switches, solenoid valves, etc.)

• Understand the symbols used in the electro-fluidic wiring diagrams

• Carry out the reading of wiring diagrams relative to electro-fluidic systems

Content• Electro-fluidic components: generalities,

symbology, functionality, and types of devices and their characteristics (transducers, actuators)

• Operation of the fluidic system: relationship between command / control and actuation

• Reading and interpretation of wiring diagrams related to electro-fluidic systems

• Approach to troubleshooting

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2.5 days

Course Timeline


2.5 days

50%hands-

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Pneumatics basicObjectivesUpon course completion the learner will be able to:

• Know the potentialities and features of pneumatic components

• Know the function and symbolism of pneumatic components

• Make adjustments on pneumatic components

• Perform the replacement of the components

• Read and understand diagrams of conventional pneumatic systems

• Recognize conditions of anomaly and interpret the weak signals

• Carry out the assessment of the failure causes

Content• General information about pneumatics: concept of

pressure and flow rate, the si system

• Characteristics and capabilities of pneumatic components

• Operation principle and symbolism of pneumatic components

• How to adjust the physical parameters of pneumatic systems

• Methodology for reading and interpreting diagrams of pneumatic systems

• Analysis of the potential anomalies of fluidic components

• Research and evaluation of the causes that led to the anomaly

• Elements of specific accident prevention; residual stored energy in pneumatic systems and related safety measures

• Methodology of interpreting information, diagnosis and troubleshooting on pneumatic systems

Expected Benefits• Acquired operating skills to execute maintenance interventions on conventional pneumatic systems


• Mechanical maintainers


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Oleohydraulics basic

Training

2.5 days

Course Timeline

Expected Benefits• Acquired operating skills to execute maintenance interventions of the hydraulic installations

equipped with traditional devices





2.5 days

50%hands-

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• Know symbolic representation and working principle of the hydraulic components

• Know the main applications of hydraulic components

• Replace the components of hydraulic systems

• Know the potentialities and features of oleodynamic components

• Make adjustments on the hydraulic components

• Read and understand diagrams related to hydraulic systems with a view to troubleshooting and maintenance purposes

Content• Hydraulic components: general features and

operating principles

• Hydraulic pumps, actuators and pressure controls

• Characteristics and capabilities of hydraulic components

• Reading and interpretation of diagrams of industrial installations

• Methodology of troubleshooting on hydraulic systems

• Specific safety in oleodynamics field; residual stored energy in hydraulic systems and related safety measures


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Training

1 day

Course Timeline


1 day

50%hands-

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LubricationObjectivesUpon course completion the learner will be able to:

• Know the techniques and the devices used at the installations for the lubrication of the mechanical parts

• Interpret the directions of the diagnostic system from the perspective of troubleshooting

Content• Lubrication systems:

– typical configurations

– devices

– fluids

– components

Expected Benefits• Acquired basic operating skills to execute adjustments and maintenance interventions on lubrication

systems



• Equipment leaders

prerequisites• Basics of mechanics, technical drawing

and fluidics


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maintenance of bearings

Training

2.5 days

Course Timeline

Expected Benefits• Acquired operational capability to carry out any replacement of mechanical devices

Target Audience• Experienced mechanical maintainers

prerequisites• Knowledge of mechanics, materials

technology and technical drawing

2.5 days

50%hands-

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• Know the basic characteristics of rolling bearings

• Know the typologies, designation, application fields and combinations, housings, spacers, preload, spring packs, labyrinth seals

• Know the methods of assembly / disassembly, tools preparation and specific equipment

• Know the typologies of bearings failures: diagnosis of the causes and possible remedies

• Know the problems of lubrication: types of lubricants, equipment and systems

Content• Features of the rolling elements: friction,

loads, surfaces and lubricant

• Rolling bearing types, sizes and applications

• Typologies, designation, application fields and combinations, housings, spacers, preload, spring packs, labyrinth seals

• Mounting methods; tools preparation and specific equipment

• Bearings failure: diagnosis of the causes and possible remedies

• Lubrication: types of lubricants, equipment and systems

• Tools and methods for the analysis of operating conditions


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3 days

ClassroomTraining

Course Timeline

mechanical drafting following the AsmE Y14.5m standardObjectivesUpon course completion the learner will be able to:

• Know, understand and use the geometrical tolerances indication system of mechanical drafting in advanced industrial according to the AsmE Y14.5m international standard

Content• Representation of mechanical parts using

the AsmE Y14.5m standard

• Reading and interpretation of mechanical drawings

• Measurement procedure of mechanical fittings in accordance with AsmE Y14.5m

Expected Benefits• Acquired operational capability to perform, read and interpret technical drawings according to the

AsmE Y14.5m standard



• Technologists

prerequisites• Basics of ISO mechanical drawing


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Pneumatics logic

Training

2.5 days

Course Timeline

Expected Benefits• Acquired operating skills to execute maintenance interventions on installations equipped with

pneumatic logic component



prerequisites• Basics of pneumatics

2.5 days

50%hands-

on



• Know the potentialities and features of pneumatic logic components

• Know the function and symbolism of pneumatic logic components

• Make adjustments on pneumatic logic components


• Read and understand diagrams of pneumatic logic systems

• Interpret the indications from diagnostics and weak signals

• Carry out the assessment of failure causes

Content• Characteristics and capabilities of pneumatic

logic components

• Operation principle and symbolism of pneumatic logic components

• Procedures of adjusting the physical parameters of pneumatic systems

• Methodology for reading and interpreting diagrams of installations having pneumatic logic components

• Analysis of potential anomalies of fluidic components

• Research and evaluation of the causes that led to the anomaly

• Elements of specific accident prevention and related safety measures

• Methodology of troubleshooting on fluidic systems



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Training

2.5 days

Course Timeline


2.5 days

50%hands-

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Oleohydraulics advancedObjectivesUpon course completion the learner will be able to:

• Know the potentialities and characteristics of hydraulics components with electric proportional control

• Know the operational and symbology of hydraulics components with electric proportional control

• Make adjustments of the reference electrical parameters onto the electronic boards


• Read and understand diagrams

• Interpret the directions of the diagnostic system and the weak signals

• Carry out maintenance on hydraulics components with electric proportional control

Content• Accident prevention

• Specific safety in oleodynamics field

• Characteristics and capabilities of the hydraulic components

• Operation principle and symbolism of the hydraulic components

• Characteristics of systems having components with electric proportional control

• Reading and interpreting diagrams relating to industrial hydraulic installations

• Maintenance of hydraulic components having electric proportional control

Expected Benefits• Acquired operating skills to execute maintenance interventions on systems with hydraulics

components with electric proportional control



• Electrical maintainers

• Technologists

prerequisites• Basics of oleodynamics

• Basics of electromechanics

• Basics of electro-fluidics


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Electrical industrial systems advanced

Training

2.5 days

Course Timeline

Expected Benefits• Knowledge of safety issues related to the implementation of networks and automatic control

sequences in production facilities, and the necessary circuital precautions

• Acquired operational capabilities for the safe execution of the interventions of electrical maintenance on electrical equipment of industrial machines and plants

Target Audience• Electrical and electronic maintainers

• Maintenance leaders

• Electronic laboratory technicians

prerequisites• Basic knowledge of electrical engineering

and hazards related to electricity

2.5 days

50%hands-

on



• Correctly interpret the functioning of electrical networks, both combinational and sequential, in industrial electrical circuits by means of reading the sequence diagrams and electrical schematics

• Develop and / or integrate new functions into existing circuits in order to obtain their modification and / or their restoration of functioning in the event of changes in the plant

Content• Analysis of methodologies of utilization

of electromechanical and electro-fluidic components

• Design and implementation of automatic controlling sequences for actuators (automated systems)

• reading and interpreting electrical schematics and sequence diagrams

• Precautions against starts and sudden movements in automatic sequences

• methodology of electrical troubleshooting in sequential circuits

• synthesis of static and dynamic diagnostic networks


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Training

2.5 days

Course Timeline


2.5 days

50%hands-

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Allen&Bradley sLC 500 PLCObjectivesUpon course completion the learner will be able to:

• Know the main parts that compose the A/B sLC 500 system: modules and connections

• Know the address modes for the i/O modules

• make the PC-PLC connection using rsLogix 500 software

• Use the programming terminal for programs management and editing

• Know the software online functions in order to make a correct diagnosis and troubleshooting

Content• Architecture of the A/B SCL 500 PLC system

• Typical hardware configurations for the PLC

• Type of modules and relative functions/features

• I/O interfacing to the field

• Utilization of the software package RSLogix 500 for system configuration change, program documentation, print functions and upload/download of programs

• PLC operation and programming: ladder diagram

• Instructions for relays, timers and counters

• Comparison, logical and arithmetic instructions

• Instructions program control instructions

• Status file, search and forcing

Expected Benefits• Acquired operating skills to execute maintenance interventions on systems managed by

programmable logic

• Use of tools and software programming for optimization and configuration of the programs in the plant


• Technologists


prerequisites• Attendance at courses in basics

of electromechanics, or equivalent knowledge


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Allen&Bradley ControlLogix PLC

Training

2.5 days

Course Timeline


programmable logic



• Technologists




2.5 days

50%hands-

on



• Know the main parts that compose the A/B ControlLogix system: modules and connections

• Know the address modes for the I/O modules

• Make the PC-PLC connection using RSLogix 5000 software



Content• Components and hardware-software

configuration of A/B ControlLogix 5000 PLC systems with reference to the factory installations

• Network connections and communications to remote i/O

• Utilization of the programming terminal equipped with software:

1. rs Linx for network connection to A/B ControlLogix 5000 system

2. rs Logix 5000 for the applicative program reading, interpreting and editing

• Procedures for programs upload/download using the programming terminal

• Search and troubleshhoting functions; restoring of the machines operations



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Training

1.5 days

Course Timeline


1.5 days

50%hands-

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Allen&Bradley DeviceNet Automation Network ObjectivesUpon course completion the learner will be able to:

• Acquire knowledge on the A/B DeviceNet network related to its architecture, features, operating modes and configurations

• Know the software A/B rsNetWorx for DeviceNet, the i/O data communication management to PLC and ControlLogix system

• interpret diagnostics for proper and quick troubleshooting

Content• Configurations of the components of the A/B

DeviceNet industrial network in reference to the ControlLogix systems present on industrial plants, links and communication to remote i / O

• Utilization of the programming terminal equipped with software:

1. rs Linx and rs Logix 5000 for connection to A/B ControlLogix 5000 system and data monitoring

2. rs NetWorx for DeviceNet network and i/O management

• Procedures for programs saving/loading using the programming terminal

• Techniques for troubleshooting and the restoring of the plant operating conditions

Expected Benefits• Acquired knowledge about the procedures to be followed for the maintenance on machinery

equipped with industrial field networks

• Acquired ability to recognize of the anomalous state and to interpret the indications of diagnostics


• Technologists


prerequisites• Attendance at courses on PLC A/B basics,

or equivalent knowledge


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simATiC s5 PLC

Training

2.5 days

Course Timeline


programmable logic



• Technologists




2.5 days

50%hands-

on



• Know the fundamental parts that make up the simATiC s5 system: modules and connections

• Know the address modes for the I/O modules

• Make the PC-PLC connection using the software sTEP5



Content• SIMATIC S5 architecture: system components,

hardware and software configuration related to the plant facilities

• i/O connections and addressing

• Utilization of the programming terminal using the sTEP5 software for the connection to the s5115U/s5155U PLC

• Online functions for the visualization, the interpretation and the editing of applicative programs

• Program save and restore procedures using the programming terminal

• functions for troubleshooting and the machine functionality restoring



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Training

2.5 days

Course Timeline


2.5 days

50%hands-

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simATiC s7 PLC basicObjectivesUpon course completion the learner will be able to:

• Know the main parts that compose the simATiC s7-300 system: modules and connections

• Know the address modes for the i/O modules

• make the PC-PLC connection using sTEP7 software



Content• Overview of the control system simATiC s7

• The “sTEP7 basic package” environment

• Digital operations: timer, counter

• Design and installation of simATiC s7

• Commissioning HW and sW of an automation system

• Hardware configuration and parameters of a PLC s7-300

• Documentation and storage of programs

• Hardware troubleshooting

• Use of the functional blocks

• Using of the sTEP7 package for the software troubleshooting

• search for software bugs


programmable logic



• Technologists


prerequisites• Attendance at basic courses of

electromechanics, or equivalent knowledge


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simATiC s7 PLC advanced

Training

2.5 days

Course Timeline

Expected Benefits• Increase in knowledge and skills of maintenance personnel of manufacturing plants managed with

advanced technology systems

• Acquired knowledge on the use of machinery/equipment and on the procedures to be followed for the specific maintenance operations

• Acquired ability to recognize of the anomalous state and interpretation of the indications of diagnostics


• Technologists


prerequisites• Attendance at SIMATIC basic courses, or

equivalent knowledge

2.5 days

50%hands-

on



• Know and manage data block, either inserting initial data or editing current data

• Set parameters for functions and functional blocks (fC and fB)

• Know the main system functions as an example

• Know the STEP7 advanced instruction set, and analyze the software on the installations at the factory

Content• Compound data and indirect addressing of

data and variables

• Parameter assignment for FB and FC

• Overview of system blocks and usage of some of them as an example

• Usage of the status bits for the management of blocks for calculation and conversion

• Features of the MPI network and PLC connection via the Global Data Configuration

• Characteristics of the analog I/O modules and their use by the user program



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Training

2.5 days

Course Timeline


2.5 days

50%hands-

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simatic s7 PLC maintenanceObjectivesUpon course completion the learner will be able to:

• Know the capabilities and characteristics of the family simATiC s7

• Know the architecture of simATiC s7 300

• Know the main instructions of sTEP7

• Use the programming terminal to verify the functionality of the installations using the online functions provided by sTEP7 software

• Know the procedures for the uploading and the saving of the programs

Content• s7 hardware: configurations of the station,

specific modules and installation modes

• Use of the package sTEP7 for the archiving functions of user program

• Program on-line functions

• forcing functions and conditioning program functions

• Cross references functions (cross reference, memory occupation, program structure, etc.)

• Operating procedures for the fault finding by using the programming terminal and the typical instrumentation of the electrical maintainer

Expected Benefits• Acquired knowledge about the use of the software and the procedures to be followed for the

specific maintenance

• Use of the programming software for the fault finding



• Technologists


prerequisites• Attendance at basic courses of

electromechanics, or equivalent knowledge


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simATiC Hmi: WinCC flex

Training

1.5 days

Course Timeline

Expected Benefits• Development of knowledge and skills of maintenance personnel of manufacturing plants managed

using advanced technological systems

• Acquired knowledge about the use of the machine/plant and about the procedures to be followed for the specific maintenance operations



• Technologists




1.5 days

50%hands-

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• Know the state of the art of SIMATIC HMI operator panels (line, graphical, and under Windows environment)

• Use the WinCC Flex software package for the design and modification of operator interfaces (string and graphics)

• Know the connection modes to the controller and the upload/download procedures when replacing the system

Content• SIMATIC STEP7

• WinCC Flex development package for the creation of man-machine pages

• Features management of the SIMATIC HMI operator panels

• Modes of integrating and connecting with alarms

• Functions of input and output to the process



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Training

1.5 days

Course Timeline


1.5 days

50%hands-

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simATiC Net: Profibus for s7ObjectivesUpon course completion the learner will be able to:

• Know the characteristics, the possible configurations and potentiality of Profibus and Profibus DP networks

• Analyze the features and available choices relating to the s7 stations at the installations in the plant

• Build a Profibus DP network by using educational simulators

• Use the diagnostic organizative blocks for the identification of anomalies caused by “falls” of slaves and participants to the network

Content• Network Connections into MPI and Profibus DP

• Program transfer operations

• Characteristics of field and cell networks

• Components of the Profibus DP network

• implementation of Profibus DP networks

• system Diagnostics



• Use of the programming software for the fault finding



• Technologists





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simATiC Net: ProfiNet for s7

Training

1.5 days

Course Timeline



• Acquired knowledge about the use of the machine/plant and about the procedures to be followed for the specific maintenance operations


• Technologists




1.5 days

50%hands-

on



• Know the characteristics, the possible configurations and potentiality of ProfiNet networks

• Analyze the features and available choices relating to the s7 stations at the installations in the plant

• Build a ProfiNet network using educational simulators

• Use the diagnostic organizative blocks for the identification of anomalies caused by “falls” of slaves and participants to the network

Content• Characteristics of ProfiNet networks

• Network components: addressing and connecting modes

• ProfiNet network configuration in a STEP7 environment

• Practical implementation of a Profinet network with simulated network diagnosis



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Training

4 days

Course Timeline


6 days

60%hands-

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CNC siNUmEriK 840Duse, management and programmingObjectivesUpon course completion the learner will be able to:

• identify and understand the factors and signals relevant for the proper management of the process and intervene in case of drifts

• Operate on numeric controls used on specific installations

• manage programs on board of the siEmENs control system, also by performing simple program changes and / or inserting tool data

Content• Introduction to CNC machines: structures,

typical configurations

• Structure of the CNC: memories, programs, dynamic behaviors

• Description and use of the operation panel

• Type of operation: automatic, manual, MDA

• Organization of the program files

• Using the tool offsets

Expected Benefits• Development of knowledge and skills of the staff entered in conducting production plants / working

areas managed by CNC systems

• Acquired knowledge about the use of machinery/equipment and the procedures to follow for the specific operations of use and management

Target Audience• Equipment leaders of mechanical

processing systems

• CNC operators

prerequisites• Knowledge of machining, drawing

and tooling


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CNC fanucuse, management and programming

Training

2.5 days

Course Timeline

Expected Benefits• Development of knowledge and skills of the staff entered in conducting production plants / working

areas managed by CNC systems

• Acquired knowledge about the use of machinery/equipment and the procedures to follow for the specific operations of use and management

Target Audience• Equipment leaders of mechanical

processing systems

• CNC operators

prerequisites• Knowledge of machining, drawing

and tooling

2.5 days

50%hands-

on



• Identify and understand the factors and signals relevant for the proper management of the process and intervene in case of drifts

• Operate on numeric controls used on specific installations

• Manage programs on board of the GE fanuc Control system, also by performing simple program changes and / or inserting tool data

Content• Introduction to CNC machines: structures,

typical configurations

• Structure of the CNC: memories, programs, dynamic behaviors

• Description and use of the operation panel

• Type of operation: automatic, manual, MDA

• Organization of the program files

• Using the tool offsets



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Training

2.5 days

Course Timeline


2.5 days

50%hands-

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CNC siNUmEriK 840C maintenanceObjectivesUpon course completion the learner will be able to:

• Perform basic operations regarding the use and programming of numerical control of the series 840C

• Carry out maintenance on the control of machine tools with CNC 840C

• Perform the commissioning of machine tools with CNC 840C

Content• Hardware configuration of the CNC; connections

• Concept and description of the space and speed loops

• Alarms and I/O diagnostic messages

• Setting data and data backup

• Structure of interface PLC / CNC with regard to blocking signals for moving program

• Analysis of the modes of utilization and configuration of motor drives

• Optimisation of the digital drives settings

• PLC’s I/O status visualization; protection levels; data backup creation

• Specific PLC-CNC interface signals

• Overall memory reset and CNC restart

• CNC machine data

• Drives configuration

Expected Benefits• Increase in knowledge and skills of maintenance personnel in manufacturing plants managed with

advanced technology systems

• Acquired knowledge about the use of machinery/equipment and the procedures to follow for the specific operations of maintenance



• Technologists





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CNC siNUmEriK 840D maintenance

Training

2.5 days

Course Timeline


advanced technology systemsti




• Technologists




2.5 days

50%hands-

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• Perform basic operations regarding the use and programming of numerical control of the series 840D

• Carry out maintenance on the control of machine tools with CNC 840D

• Perform the commissioning of machine tools with CNC 840D

Content• Hardware configuration of the CNC; connections

• Concept and description of the space and speed loops

• Alarms and I/O diagnostic messages

• Setting data and data backup

• Structure of interface PLC / CNC with regard to blocking signals for moving program

• Analysis of the modes of utilization and configuration of motor drives

• Optimisation of the digital drives settings

• PLC’s I/O status visualization; protection levels; data backup creation

• Specific PLC-CNC interface signals

• Overall memory reset and CNC restart

• CNC machine data

• Drives configuration



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CNC siNUmEriK 840D sL maintenanceObjectivesUpon course completion the learner will be able to:

• Perform basic operations regarding the use and programming of numerical control of the series 840D solution Line

• Carry out maintenance on the control of machine tools with CNC 840D sL

• Perform the commissioning of machine tools with CNC 840D sL


• Technologists


prerequisites• Attendance completed at SIMATIC basic

courses, or equivalent knowledge

Content• Hardware configuration, panels and accessories

• Connections

• Required and optional software

• System Initialization

• ToolBox installation

• STEP7 Project / Profibus network configuration

• SINAMICS Drives

• Major machine data details

• Using commissioning tools

• Major CNC/PLC interconnection signals

• Main FB/FC (FB1, FC10, FC19)

• Option management and activation (via the Internet)

• Data backup/restore

• Alarms and warnings (FC10)

Examples & ExercisesTraining

2.5 days

Course Timeline

2.5 days


50%hands-

on


advanced technology systemsti




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robot Comau C3G+ maintenance

Training

2 days

Course Timeline

Expected Benefits• Acquired operational capabilities to carry out electrical / electronic maintenance interventions on the

C3G+ Control system for Comau robot

Target Audience• Electrical-electronic maintainers

• Robotics maintenance technicians



prerequisites• Knowledge about the use and

programming of the C3G family of Comau robot

3 days

60%hands-

on

Practice in the maintenance box


• Know the hardware organization of the C3G+ control unit and the available technical documentation

• Analyze malfunctions and alarms from the Control Unit

• Carry out with method the troubleshooting on the C3G+ control unit and on the interconnections to the line and to the robot

• Perform module replacement, and make any necessary software loading operations: configuration and machine data

Content• Hardware organization of the C3G+Control and of

the relative controlled arm

• Organization of the positioning control system. Transducers

• Axes calibration procedure, calibration data visualization and saving

• Turn set operation

• Interpretation and use of wiring diagrams of the control system, the individual blocks making up the system and the controlled arm

• Faults viewing, alarm types, codes and relative interpretation

• Description of electromechanical safety chains

• Simulation and analysis of the behaviour and typical faults for various modules that make up the servo Amplifier Unit 2 and the Control Unit

• Simulation analysis of the most recurrent faults: directions for substitutions



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Training

2.5 days

Course Timeline


2.5 days

50%hands-

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robot Comau C4G use and managementObjectivesUpon course completion the learner will be able to:

• Know the general characteristics of the robot Comau having the C4G Control Unit and its hardware architecture (both electrical and mechanical)

• manage both local and remote activities of the C4G system (programs activation and run, cycle stop and reset)

• move the robot by using the appropriate techniques

• Perform the calibration procedures prearranged for the machine

Content• General organization of the system and its

interconnections with C4G robot, line and equipment

• General organization of the software, SW system, command environment, editors, applications

• Programming terminal: commands, multi-function menu, etc.

• Basic usage procedures (system startup, choice of the operating mode, fault signaling, use of menus)

• Movement of the robot while programming (manual movement techniques, tool dimensions, external axes handling)

• Management of programs into memory (file types, file loading and saving, programs execution) and management of communication with the outside world (networks, ports, etc.)

Expected Benefits• Acquired operational capabilities to perform simple programming changes and handling to restore

the work cycle

Target Audience• Equipment leaders of automated

systems





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robot Comau C4G programming

Training

2 days

Course Timeline

Expected Benefits• Acquired operational capabilities to carry out corrective actions and implementation of programs

with use of language PDL2

Target Audience• Equipment leaders of automated

systems



prerequisites• Knowledge about the use and

programming of the C3G family of Comau robot or attendance at Comau robot courses

3 days

60%hands-

on



• Have a general knowledge of PDL2 programming language and the EAsY PDL standard

• Intervene in the work programs through a special programming environment, for their modification and optimization

• Interpret specific programs at the plant through knowledge of the instructions and the most important software structures

Content• Structure of the program and its types

(holdable, nohold), key elements of the PDL2 programming language (constants, system and user variables, types of variables)

• Fundamental statements of the language, most frequently used routines (instructions for i/O management, control instructions, point of rest management, tool coordinates management)

• Organization and usage of the program editor, step-to-step verification procedures, identification of the step to change and execution of the modification

• Analysis and interpretation of specific programs at the plant



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2.5 days

Course Timeline


2.5 days

50%hands-

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robot Comau C4G maintenanceObjectivesUpon course completion the learner will be able to:

• Know the hardware organization of the C4G Control Unit and the available technical documentation

• Analyze system malfunctions and alarms from the Control Unit

• Carry out with method the troubleshooting on the C4G CU and on its interconnections to the line and to the robot

• Perform module replacement, and make any necessary operations of software loading: configuration and machine data

Content• Hardware organization of the C4G Control Unit

and of the controlled arm

• Organization of the positioning control system. Transducers

• Axes calibration procedure, calibration data visualization and saving

• Turn set operation

• Interpretation and use of wiring diagrams of the control system, the individual blocks making up the system and the controlled arm

• Faults viewing, alarm types, codes and relative interpretation

• Description of electromechanical safety chains

• Simulation and analysis of the typical faults and the modules and motor drives functions

• Description, simulation and analysis of the most recurrent faults: directions for substitutions

Expected Benefits• Acquired operational capabilities to carry out electrical and electronic maintenance interventions

on the COmAU robot C4G control unit


• Electrical/electronic maintainers



prerequisites• Knowledge about the usage and the

programmation of C4G family Comau robots


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machine tools operator (turning)

Training

2.5 days

Course Timeline

Expected Benefits• Availability of qualified personnel able to operate on traditional machining machines (lathes)

Target Audience• Mechanical maintenance operators

• Operators on traditional machines

prerequisites• Knowledge about mechanical drawing

2.5 days

50%hands-

on

Field Practice


• Know the turning machines

• Equip the machines

• Carry out lathe work on cylindrical surfaces, conical internal and external, single and coupled (iT7 – iT8, ra 2 -3.2)

• Perform the measurement of worked particular using adequate test and measuring instruments

Content• Health and safety regulations specific to lathing

• Machine tools for turning

• Materials used in the construction of tools

• Typical angles for turning tools

• The chip formation in lathe

• Codes identification for turning inserts

• Tools finish and wear

• Cutting data

• Machining cycles

• Cylindrical and conical turning, internal and external

• Measurement, check and testing of machined parts

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Training

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Course Timeline

2.5 days

50%hands-

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Field Practice

machine tools operator (milling)ObjectivesUpon course completion the learner will be able to:

• Know the milling machines

• Equip the milling machines

• Carry out mill work on flat and grooved surfaces, single and coupled (iT7 – iT8, ra 2 -3.2)

• Perform the measurement of worked particular using adequate test and measuring instruments

Content• Health and safety regulations specific to milling

• Machine tools for milling

• Materials used in the construction of tools

• Typical angles for milling tools

• The chip formation in mill

• Codes identification for milling inserts

• Tools finish and wear

• Cutting data

• Machining cycles

• Flat and grooved milling

• Measurement, check and testing of machined parts

Expected Benefits• Availability of qualified personnel able to operate on traditional machining machines (mills)


• Operators on traditional machines


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GmAW welder

Training

1 days

Course Timeline

Expected Benefits• Availability of qualified personnel able to operate on arc welding systems to execute welds on parts

with different thickness in any position

Note: also available courses about Electrode Welding, TiG and Oxygen-Acetylene Welding with the same duration


• General maintenance operators

• Production operators


and materials technology

4 days

80%hands-

on

Field Practice


• Make adjustments of process parameters on continuous wire welding

• Weld on plates of small and medium thickness at various positions

• Perform checks on welds

Content• Specific professional safety regulations

• Understanding of metallurgy: steel, welding and protective gases

• Technology of electric arc welding GMAW (mAG)

• Adjustment of welding parameters

• Welding execution techniques

• GMAW welds in various positions

• Quality control in electric arc welding

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Training

0.5 days

Course Timeline

9.5 days

95%hands-

on

Field Practice

Paint shop revisionistObjectivesUpon course completion the learner will be able to:

• Know the painting technique and patching technique on finished vehicles ready for shipment

• Know the techniques of masking vehicle

• Know the paints and their main characteristics

• Perform simple patches

Content• Safety regulations specific to the craft

• Utilization of the airbrush

• The paints used in the process: primer and enamel (of various types: pastel, metallized, micalised, triple layer, transparent, etc.)

• The masking and the preparation of the materials

• Patching techniques for the finishing and the polishing

Expected Benefits• Availability of qualified personnel able to perform coachwork patching at the end of the line or in

the forecourt

Target Audience• Paint shop personnel involved into the

repair vehicles area

prerequisites• Ability to paint simple parts

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For more information please contact:

Gobetto Marco

T&C manager mobile +39.335.1248697 [email protected]

Castronovo Carmelo

Technical Training, mTs & roles/Jobs schoolmobile +39.335.7490699 [email protected]

Carra Maurizio

T&C External market supportmobile +39.335.7375026 [email protected]

FCA Italy - Training & ConsultingRegistered Office:

FCA Italy S.p.A.

Corso Agnelli 20010135 Turin - italy Operating Office:

Training & Consulting

Corso settembrini 53 – Gate 1610135 Turin - italy secretary Office: +39.011.0047591 e-mail: wcmtraining&[email protected] site: www.wcm.fcagroup.com

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TR

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We join together

to help our Customers be World Class.

Come join us!

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This catalogue is part of the following training solutions offer:

training solutions for World Class Manufacturing implementation classified into three different levels of application: Basic, Intermediate and Advanced

WORLD CLASSTRAINING

TECHNICAL AND ROLES TRAINING

WCM ACADEMY

training solutions for technical training on main process technologies used in operations and paths for main professional roles of the factory

training solutions with an hands-on approach in a friendly learning environment

WORLD CLASS WEBACADEMY

training solutions online for World Class methods and tools

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