Mechatronics - a new name for learning advanced manufacuring

Mechatronics is the latest term for training multi-skilled technicians, using Time and motion study, Total Quality Management, kaizen, or other programs that cross-train operators and maintenance workers in electrical, mechanical, pneumatic and hydraulic processes as well as trouble shooting, predictive maintenance, and PLC programming. The word was invented by a Japanese man in 1969 to describe the integration of electronically controlled programming into existing manufacturing processes.

Randy Clark, a consultant from Kentucky Community and Technical Colleges (KCTC) , presented the Siemens Mechatronics training model at the SCC-BMW Center on Tuesday and Wednesday. Representatives from Greenville Technical College, Piedmont Technical College, and Spartanburg Community College learned about how KCTC has built its programs using this model, and the instructor training that they offer in the US.  Other states investigating this model are Ohio, Florida, Texas and Missouri.

Siemens is the largest manufacturing company in the world, after General Electric. In fact, the Siemens company is larger than the manufacturing division of GE. Standardizing the training assures that students will have the well-rounded knowledge, skills and mindset necessary to be effective operators, maintenance technicians and managers.

Siemens has a word for the qualities that a good technician should have: hanslungkompetenz, which means that a peson can adapt to a new work environment quickly and appropriately.

The skills learned in this platform are transferable to any manufacturing process with any brand of equipment. The curriculum is designed to teach students to consider the whole system and how indvidual components work together, rather than teaching each piece in isolation.

Festo’ educational platform has several requirments:

• Program must be taught in English, regardless of the national language where the training will be done.
  Currently programs are being taught in China, Denmark, and France as well as Germany. The Stuttgart training facility chooses 50 trainees from 2000 applicants each semester.
• Training facility must have Mechatronics trainers installed for hands on work in class.
• Instructors must be certified with Paradigm training in Berlin for one week, with one more week of specific
  training in systems-oriented lesson design. The tuition includes housing and travel within Germany, but not food or airfare.
• Schools must be accredited through an appropriate organization such as SACS (Southern Association of Colleges and
  Schools).
• The school must have a local Siemens plant, or in the US, the school will be a partner with Siemens Atlanta
  or the home office of Siemens in Germany.

Three levels of training have been designed. Level One, for operator-technicians, has been taught in high school as an vocational specialization program and as a one-semester certificate program in two-year colleges either for credit or as continuing education. After completing the class, the student takes a standarized, written test online through a third party provider. On passing the test, the student receives international certification to operate mechatronics equipment.

Level One operators should be able to

• Be responsible for efficient operation of machinery/ workstation
• Do routine preventive maintenance and predictive maintenance
• Use system documentation intelligently
• Work as an effective member of a manufacturing team
• Observe all local and company safety regulations

Level Two maintenance technicians would also be able to investigate, troubleshoot and repair complex manufacturing systems. An associate degree might include both Level One and Two, along with general education courses. This test requires both written and hand-on demonstrations.

Level Three is for maintenance management, and would be taught as part of a bachelor’s program. The Siemens platform assures that credits for the first two Mechatronics classes would transfer.

SCC instructors Tim Coggins and Mark Spencer have already attended the Festo Mechatronics training in Stuttgart in preparation for instructing students in the Union County Robotics Training Facility.