Academy,
Leadership and Organizational Development
As a leading supplier to the food, beverage and pharmaceutical industries, GEA relies on perfect welds. To counter the looming shortage of qualified welders worldwide – by 2026, t he USA alone will be short of around 300,000 skilled workers, and Europe is facing similar problems – GEA has set up an international competence center for welding technology. The machine and plant manufacturer is leaving nothing to chance when it comes to the training and further education of its welders.
“Welding simply plays a central role for us,” says Robert Ströbel, Head of Production at GEA’s Kitzingen site, Germany. “Despite all the automation and support from cobots, manual welding is still an important step in our production.” But recruiting staff is becoming an increasing challenge for GEA. Global demographic developments and the image of the welder
profession are leading to a decline in the number of applicants. In addition, many interested parties do not meet the requirements of relevant guidelines and standards, says Ole Bang, Vice President Production LPT.
Despite all the automation and support from cobots, manual welding is still an important work step in our production.
Robert Ströbel Head of Production, GEA Brewery Systems GmbH
Initial and recertifications can now be carried out internally
“GEA’s welding competence center in Kitzingen is designed to close precisely these gaps. It is designed to improve the quality of training and further education and to provide the welders hired with the qualifications required by GEA. Staufen supported GEA in developing the concept for setting up the center,” says Peter Merhof, Head of Welding Technology & Standards at GEA. “We were able to draw on the experience of our own Staufen Academy,” explains Martin Becker, partner at Staufen.
A team of trainers ensures comprehensive and practical training. It is modular in structure and begins with basic training, in which basic techniques, specific requirements of the stainless steels used, occupational safety requirements and know-how are taught. In a certification course, participants are intensively prepared for the initial certification. The use of a welding simulator makes it easier to get started without wasting resources. Extensive safety precautions are not required.
In addition, the competence center will now take on a task that was previously performed externally: regular recertification with refresher courses on theoretical and practical knowledge. Every three years, skilled welders must officially prove that they meet all requirements and work safely. This guarantees that only sufficiently qualified people weld
Close cooperation with developers and designers
Another task of the competence center is to introduce innovative welding processes. Employees learn new techniques and optimize their processes, which increases overall productivity. Special courses such as repair welding, welding for service technicians, and flame straightening will complete the training offering in the future.
In addition, there is intensive exchange between the various departments. There will be special theoretical courses for buyers. Here, they will acquire the necessary know-how for procurement so that purchased components also meet all GEA requirements for welding.
A particularly important task of the competence center will be the collaboration with developers and designers. Michael Wagenhäuser, Head of Quality, Health, Safety and Environment in Kitzingen, describes the plans: “We want to offer courses for product developers so that they can then develop designs suitable for welding. The feedback from our welders also helps to plan new designs in a practical way for production.” The increasing automation in welding technology poses new challenges for product development. For example, the position of the weld seams often has to be adjusted in the first prototypes in order to avoid problems with the range of motion of the robots.
left: ROBERT STRÖBEL, Director Leadership Production – BU Liquid Technologies, GEA Brewery Systems GmbH right: MICHEAL WAGENHÄUSER, Head of Quality, Health, Safety and Environment, GEA Brewery Systems GmbH
About GEA
GEA is one of the world’s largest system providers for the food, beverage and pharmaceutical industries. The portfolio includes machines and systems as well as sophisticated process technology, components and comprehensive services. GEA solutions help to make production processes more sustainable and efficient in a wide range of industries.
Further competence centres are being planned
In the future, the tasks of the competence center will also include series of tests and trials with new welding equipment, digitalization applications and welding robots as well as the latest welding technologies. All of this is aimed at improving productivity and sustainability.
“This means that production is much better prepared for the new possibilities and delays caused by errors are avoided,” emphasizes quality expert Wagenhäuser. “These possibilities and experiences are not limited to Kitzingen, but apply to all GEA plants worldwide.” The welding competence center is intended to serve as a model for the development of further competence centers, for example for machining processes such as milling or turning. “The Kitzingen site is way ahead when it comes to welding,” says production manager Ströbel, “but there are other GEA sites that are better at machining, for example.” The company is therefore planning to set up further competence centers in which the knowledge and skills within GEA will be expanded and shared.
“The GEA welding competence center is a logical step to improve the quality and efficiency of welding work throughout the company worldwide and at the same time counteract the shortage of skilled workers,” explains Staufen partner Becker. “Through continuous training and the use of the latest technologies, employees are optimally prepared for the challenges of the future.”
Staufen, your reference for Operational Excellence. As the leading top management consultancy for operational excellence, we enable our clients to improve results in all areas along the value chain.
Siamo convinti che la Lean Transformation può essere implementata con successo solo quando manager e dipendenti hanno qualifiche di primo livello. Questo è il motivo per cui l’Accademia Staufen è una parte importante del nostro approccio.
Digital learning formats are revolutionizing lifelong learning at BSH, Europe’s leading home appliance manufacturer. Together we set up a virtual learning island on value stream organization and a virtual factory tour around value stream analysis in order to improve the further training of its managers and production teams distributed around the world.
A new, mandatory qualification program is intended to strengthen the production team leaders in the German Schaeffler plants in their leadership role on the shop floor. The program conveys the Group’s leadership essentials and is very practice-oriented.
