Course Title:

    Industrial Production Engineering for Flexible Packaging Industry

    Course Duration:
    • Total Duration: 5 Days
    • Daily Duration: 6 hours per day
    • Format: Combination of lectures, practical sessions, case studies, and assessments
    Course Objectives:
    • Understand the fundamentals of production engineering in the context of flexible packaging.
    • Learn the principles of process design, optimization, and automation in packaging manufacturing.
    • Gain insights into production flow, machinery, material handling, and facility layout.
    • Develop problem-solving skills related to production efficiency, quality control, and machine maintenance.
    • Explore the latest technologies and trends in industrial engineering for flexible packaging.
    Target Audience:
    • Production engineers and managers.
    • Process engineers and technologists.
    • Maintenance engineers and machinery operators.
    • New hires and experienced professionals aiming to enhance their production engineering skills.
    Day 1: Introduction to Industrial Production Engineering

    1. Overview of Industrial Engineering in Flexible Packaging:

      • Introduction to the role of production engineering in the packaging industry.
      • Key components of flexible packaging manufacturing: materials, processes, and machinery.

    2. Principles of Production Engineering:

      • Basic concepts in production flow, process efficiency, and industrial engineering.
      • Key metrics for evaluating production performance (KPIs, OEE, etc.).

    3. Packaging Materials and Their Impact on Production:

      • Types of packaging materials (plastics, laminates, films, foils).
      • How material properties affect production processes and machine settings.

    4. Practical Session:

      • Introduction to basic production machinery and equipment used in flexible packaging.
    Day 2: Process Design and Facility Layout

    1. Process Flow and Optimization:

      • Mapping the production process: input, transformation, and output.
      • Techniques for optimizing production flow to reduce cycle time and bottlenecks.

    2. Facility Layout Planning:

      • Principles of effective facility design for flexible packaging plants.
      • Layout considerations: production lines, material flow, machine placement, and space utilization.

    3. Material Handling Systems:

      • Understanding different material handling systems (conveyors, automated systems, etc.).
      • Optimizing material flow for increased efficiency.

    4. Hands-On Workshop:

      • Designing an optimized facility layout for a flexible packaging operation.
    Day 3: Machinery, Automation, and Maintenance

    1. Machinery and Equipment in Flexible Packaging:

      • Overview of key machinery: extruders, printers, laminators, slitters, bag-making machines.
      • Understanding machine functions, settings, and maintenance requirements.

    2. Automation in Production:

      • The role of automation in improving efficiency, precision, and consistency.
      • Introduction to Industry 4.0 technologies (robotics, AI, IoT) in flexible packaging.

    3. Preventive and Predictive Maintenance:

      • Importance of maintenance in minimizing downtime and extending machine life.
      • Techniques for implementing preventive and predictive maintenance programs.

    4. Practical Session:

      • Demonstration of machine operation and maintenance procedures.
    Day 4: Quality Control and Process Improvement

    1. Quality Control Systems:

      • Integrating quality control into production engineering.
      • Techniques for monitoring and controlling product quality during production.

    2. Statistical Process Control (SPC) and Process Improvement:

      • Basics of SPC and its application in flexible packaging.
      • Identifying and eliminating sources of variation in production processes.

    3. Lean Manufacturing and Six Sigma:

      • Introduction to lean manufacturing principles in reducing waste and improving efficiency.
      • Using Six Sigma tools for process improvement and defect reduction.

    4. Group Activity:

      • Analyzing production data to identify improvement opportunities using SPC and lean principles.
    Day 5: Sustainability, Innovation, and Future Trends

    1. Sustainable Production Practices:

      • Overview of eco-friendly materials and processes in flexible packaging.
      • Designing for sustainability: reducing waste, energy consumption, and environmental impact.

    2. Emerging Technologies in Production Engineering:

      • Impact of new technologies on flexible packaging production: 3D printing, nanotechnology, smart packaging.
      • Future trends in automation and digitalization in production engineering.

    3. Final Project and Presentations:

      • Group project on designing an optimized production process or facility layout.
      • Presentation of project findings and recommendations.

    4. Review and Certification:

      • Recap of key concepts from the course.
      • Written and practical assessments.
      • Course feedback and certification ceremony for successful participants.
    Course Materials:
    • Detailed course manual covering production engineering topics.
    • Process design templates and facility layout guides.
    • Machine operation and maintenance checklists.
    • Case studies on process improvement and automation.
    • Assessment and feedback forms.
    Evaluation and Feedback:
    • Daily quizzes and hands-on evaluations.
    • Final written and practical assessment.
    • Participant feedback forms for course improvement.

    This course provides participants with a solid foundation in industrial production engineering, equipping them with the tools and knowledge to enhance production efficiency, quality, and sustainability in the flexible packaging industry.