The project deals with statistical process control in series production. Every day, hundreds or thou-sands of identical parts are produced in a modern production based on the division of labour in au-tomated manufacturing. To guarantee the function of the complete system after installation the unit and to avoid large costs of product liability, these parts must be nearly error-free. As a constant monitoring is highly uneconomic, random tests are run on, for example, one in twenty parts. The results of these random checks are used to compile statistics that can be used to reflect on the quality of all parts produced. Hence the production process is monitored and regulated by means of statistical process control (SPC). The majority of apprentices work in companies either with their own locations abroad or companies that collaborate with other international businesses. Here, the German-Polish business collabora-tion is of major importance. Both countries have a large share in the Inter-European market of sup-ply products. A lot of clients choose to certify their suppliers in order to ensure a high standard of quality in the products delivered, which forces a very low error tolerance on all parts produced. In order to be able to guarantee a high product quality, SPC is used to coordinate and regulate the production process. There is more than one objective to be aimed at in this project. One major goal is to increase the apprentices’ professional expertise in monitoring product quality and process quality. This will be achieved by an action-oriented learning environment focussing on statistical process control. In addition to that, the participants will be informed on the German-Polish history, the culture of their partner country and an improvement of their linguistic competence. By means of working in groups, an enhancement of social skill and personal competence will be accomplished. Besides, the participants’ ability in using modern media for communication, presentation and evaluation of measurement results will improve. Last but not least the partnership of the two schools will be in-tensified with this project. Each school will participate with 12 apprentices and 3 teachers. The participants from TGS BBZ Neunkirchen are apprentices in the fields of industrial and tool me-chanics. The pupils of ZMS No.1 in Cracow are apprentices with the goal of becoming mechatronic technicians. Among other things, their field of activities includes monitoring of product quality and process quality. They conduct surveys of machine capability and process capability, they collect pro-cess data and calculate characteristic values that are assessed with the help of graphics. The as-sessments are based on statistical methods of quality assurance in series production by means of a software application. They record the results of their inspection according to their clients’ specifica-tions. The teachers involved are familiar with the topic and can assist by bringing in their own pro-fessional experience to the project. In addition to that, there is a close cooperation with SPC-businesses that support the project with their software and training courses. Both partner schools choose a workpiece and set inspection characteristics. In the next step, both schools build a measuring station that is tested on its capability during the first school exchange. After that the measuring stations are put into operation and each school produces 50 identical workpieces on a single CNC-machine. The testing of these 50 workpieces enables an examination of machine capability. In addition to that, the data will be examined on their standard distribution. In a next step the pupils will conduct measurement exercises with their respective measuring sta-tion and the SPC-software in use. In parallel, a workbook is created that includes an introduction to SPC-technology with practical exercises in SPC-technology and theoretical background-knowledge. As a long-term benefit, following generations of apprentices can use the workbook, the measuring station and the measuring computer. The project results will be presented at both schools to an audience consisting of guests from the area of politics, representatives of school boards, Chambers of Crafts and of the training companies. The measuring station can be used as a presentation object and demonstrator in educational fairs and similar information events. During each school exchange, there will also be a cultural programme for the participants. The German-Polish history will be discussed and the pupils will be informed about cultural background, history and politics. They will also get an insight into the everyday life in the hosting country. In addition to the two school exchanges, there will be video conferences via Skype on a regular basis and an exchange of ideas and results via an eTwinning-platform or the school’s homepage.
Every day, thousands of identical parts are produced in a modern mass production based on the division of labor in automated manufacturing. Since constant monitoring is highly uneconomical, only a random sampling test is performed, the scope of which is fixed. The results of these random tests are used to generate statistics that reflect the quality of all parts produced. The production process is monitored and controlled by statistical process control (SPC). An essential goal of the project was to increase the professional competence of the trainees. In addition to the development and manufacture of the required measuring device, the understanding and necessity of statistical process control in the area of product quality and process quality monitoring has been achieved. In addition, the participants were informed about the German-Polish history, the culture of their partner country. Working in groups has increased the social and personal skills of the participants. In addition, the ability of participants to use modern media for the communication, presentation and interpretation of measurement results has been improved. Last but not least, the partnership between the two schools was intensified with this project. Each school was involved in the project with 12 apprentices and 3 teachers. The participants of the TGS BBZ Neunkirchen were apprentices from the fields of industrial and tool mechanics. The students of ZMS No.1 in Krakow were apprentices with the aim to become mechatronics technicians. The content specified in the curriculum of the trainees for monitoring product quality and process quality was sustainably implemented with the help of the project. The participants carried out measurements to determine the machine and process capability, collected process data and calculated characteristic values, which were evaluated with the aid of graphics. The evaluations were based on statistical methods of quality assurance in series production by means of a software application. In several joint training sessions in English, the project participants were introduced to the theory of statistical process control in more detail. SPC companies trained all participants, both German and Polish participants, in dealing with the required measuring software. Both partner schools chose a gear shaft as the workpiece and set test characteristics; Concentricity and diameter of the shaft at defined points. As a result, a measuring station was developed and technically implemented by both schools. In addition to the shaft mounting, the measuring stations consist of four inductive measuring probes and a linear drive required for concentricity testing. In order to be able to implement an automated measurement process, the trainees configured the necessary electropneumatic components. The handling of the waves to be measured was carried out by a school-owned industrial robot. The shaft storage was a 5x5 pallet equipped with a recapturing unit. This was designed by the trainees and manufactured with the help of a 3-D print. The overall process was structured using a Grafcetplan. Thus, the participants of the vocational training centers developed a technically sophisticated mechatronic system that meets the requirements of Industry 4.0. After the successful trial run, the trainees of both schools produced 25 more waves each. The test of these 50 waves made it possible to check the machine capability. In addition, the data obtained were analyzed for their standard distribution. Quality control chart could be generated. As a long-term advantage, subsequent generations of apprentices can use the measuring station consisting of measuring station, measuring computer and shaft storage. The results of the project were presented to a wide audience of politicians, representatives of school boards, chambers of trade and training companies at both schools. For the presentation in Krakow, both measuring stations were linked together. In addition to their use in class, the measuring stations can be used in the future as a presentation object and demonstrator at educational fairs and similar information events. During the mutual 10-day visit to the European twin city, the focus was not only on developing technical solutions but also on cultural exchange. An intense exchange and varied supporting programs in the respective country made initial restraint between the international student groups disappear and friendships emerge. The German-Polish history was discussed and the students were informed about cultural backgrounds, history and politics. Thus, the trainees also got a deeper insight into everyday life in each host country.