Bodywork Training Program 2017 March 2017 KTD GmbH Seite 1
Foreword In order to accomplish bodywork repairs qualitatively at reasonable prices, fundamental technical skills as well as a comprehensive knowledge of modern repair technologies are required. What has been learned within "basic education" is often no longer sufficient to meet the rapid technological progress. If bodywork and paint repairs are not professionally handled, the calculated profit simply remains on the line. The losses to be recorded are not due to the fact that the calculations are too low, but rather to the inefficiency of the operating business. The car body and paint specialists of the KTD GmbH have developed a modular training concept, which leads step by step to the individual qualification of interested or generally technically savvy personnel due to the many years experience for workshop personnel. At the same time, the "professionals" can further qualify in the new current repair techniques and test available tools and materials. Due to the modular training structure, "interested newcomers" in the body shop are not overwhelmed and professionals are only confronted with topics which serve their further qualification. Note: Before you select employees for a training, please check their suitability or prerequisite. This means that you can already make sure that the costs for the respective training are sensibly placed and that the Return off investment is then made for the investment. Training description The developed trainings are specifically geared to the current requirements in the repair business. Thus, the finding of water leakage and disturbing noise is trained as well as the craft aspect in the repair of high-strength steel plates. The reliable recognition of the total scope of damage and the exact determination of the repair costs can be learned as well as the precise capture of measuring points using modern measuring technology. The spectrum of the body training is rounded off by qualification measures in the painting preparation and the paint repairs. In all trainings, we attach great importance to "practical proximity", as it occurs in the real repair business. During the trainings the participants can work with up-to-date equipment and try new tools and materials. Depending on the requirements and the intensity, the trainings are carried out in smaller groups, so that the intensive supervision by the respective trainer is ensured. This approach guarantees the greatest possible training success and certainly leads to the desired training goal. March 2017 KTD GmbH Seite 2
Ford Bodywork and assembly techniques new Ford models Model specific information about manufacturing and assembly features as well as repair tips for the latest vehicle models. Models and dates upon request! Technical shop personnel with experience in bodywork. Description Benefit In the training course for auto body and assembly techniques on new Ford models, only current topics from the auto body repair manual and construction and manufacturing characteristics will be taught. Further elements are assembly techniques of attachments and individual repair tips for an expert and economical repair. Current auto body repair techniques Information on manufacturing and assembly characteristic Mounting and dismounting of auto body attachments Adjustment and calibration work Repair materials and the latest tools Model specific repair tips Influence of modern assistance systems on body- and assembly work Applications and work with the IDS diagnostic tool in bodywork Handling of vehicle-specific repair instructions Ford Etis 200.00 / day plus tax March 2017 KTD GmbH Seite 3
Ford Basic diagnostics for bodywork and paint specialists Diagnosis of electrical vehicle systems This course is designed for auto body and paint specialists who have little or no previous knowledge in automotive electrical systems. This course gives you an overview of the fundamentals of automotive electric and electronic technology in order to be able to perform simple electronic work yourself and be able to assess problems. The content is also suitable for employees whose training took place some time ago. Description and benefit of the training course Electrical Assistant and Comfort Systems is an integral part of modern vehicle construction. For timely accident repairs, it is therefore important to master the fundamentals of automotive electrical diagnostics. Together with Ford we have developed a two-day training course. Basics of automotive electrical systems Measuring with the multimeter Determining simple electrical errors with the multimeter Important terminal designations Circuit symbols and their functions Reading and using circuit plans when Troubleshooting Repair of electrical cable damage Reading and deleting errors with the diagnostic device Adjustment work (headlight systems, rain sensor, ) with the help of the diagnostic tester Networked systems and their advantages and disadvantages Diagnostic strategies and case studies 280.00 / day plus tax March 2017 KTD GmbH Seite 4
Ford Professional vehicle preparation Practical training for professional vehicle preparation Personnel for vehicle preparation / vehicle assessment Description Benefit Optimally prepared used vehicles, in addition to new vehicles, represent the quality standards of your dealership. Thus, you can already show your customers from your used vehicle lot what they can expect once inside. The goal of the training course is to increase the sales and value of your used Ford vehicles through effective and targeted preparation methods. In the training course, methods and products to be presented for vehicle preparation are available. These can of course be extensively tested by the participants. The training course also includes the limits of preparation and the source of possible errors. Paint treatments (polishing and sealing) Interior cleaning (upholstery, floor coverings) Repair of upholstery and leather damage Plastic Treatments Removal of small scratches Possible spot repairs 240.00 / day plus tax March 2017 KTD GmbH Seite 5
Ford Tips and tricks for paint refinishing and repairs Professional and economical painting methods, timely and efficient repairs. Experienced painting personnel, service advisors body and paintwork. The participants receive the latest Ford information relating to the area of painting. In this hands-on training course, problems with technical applications are discussed. The participants then have the possibility to apply and expand on what they have learned with hands-on exercises. The impact of the current structure of factory paint on warranty repairs and tips for efficient paint refinishing are part of the training course. Through the use of current industry examples, participants are able to see how economic efficiency can increased without reducing refinishing quality. Effective implementation of Ford Repair Directives Tips and tricks in working with special effect colours Measures for colour matching Working with colour matching devices Touch-ups and Smart-Repair Working with matt coatings Instructions for foiling techniques 300.00 / day plus tax March 2017 KTD GmbH Seite 6
Ford MIG soldering in auto body repair Introduction to the material- and corrosion-resistant joining technology Experienced bodywork professionals Due to the increased use of high-strength heat-treated or galvanized steel sheet metal, classic welding methods with process-related high heat input function only partially. MIG soldering offers the advantage of being able to work with much lower temperatures. The negative effects on the material strength from structural changes are thus reduced. Similarly, anti-corrosion coatings (aluminium coating, galvanizing) show significantly less damage. Despite all the advantages, it should be remembered that the solder used has generally a lower strength than the material to be joined. It is therefore particularly important to ensure a quality connection of the solder joint with MIG soldering. The course teaches all methods necessary to produce a professional solder joint. The predominantly practically-oriented course offers each participant the opportunity to practice and improve his soldering skills. Practical welding exercises for all solder types used in auto body repair Use of various MIG soldering devices Error detection and avoidance Material science Theoretical fundamentals 260.00 / day plus tax March 2017 KTD GmbH Seite 7
Ford Dent repair without paint damage Removal of parking and hail damage Experienced painting or body work personnel The participants are taught through intensive training the various repair techniques for dent repair without paint damage. In addition to teaching theoretical fundamentals and commonly available tools, our focus is on the acquisition of technical skills gained by ongoing practice on auto body parts. Dent repair without paint damage serves as a supplement to the existing portfolio of services offered by every Ford body specialist operation. Comprehensive customer service and improved customer loyalty are the main advantages of this repair method in addition to the additional business that it generates. Assessment of the damage pattern and determination of the optimal repair path Use of various dowel-press Tool Use of gluing technology for dent repair Repair work on original vehicle parts Repair work on complete vehicles 300.00 / day plus tax March 2017 KTD GmbH Seite 8
Ford Glazing removal / re-glazing Primarily practical training on the safe removal of automotive glazing Experienced body work personnel with customer contact experience, service advisors body and paintwork The re-glazing of motor vehicles offers growth opportunities for your body shop. Tie your customers to your dealership by demonstrating your competence in this Business area as well. For commercial repairs, for example the removal and replacement of vehicle glazing, it is always important to work with the correct tools. In the training course, you will receive an overview of current repair techniques and have the opportunity to thoroughly test them. In addition to the standard front disc replacement, special cases such as side or rear window replacement are also handled. Theoretical fundamentals Tasks and function of a slices gluing Comparison of current removal tools and their advantages and disadvantages Removing several slices with the tools recommended by Ford Installation of the slices with the adhesives approved by Ford Avoiding processing and user Errors Safety information and accident prevention 1 day 260.00 / day plus tax March 2017 KTD GmbH Seite 9
Ford Exterior dent repair Practical training for current repair techniques Experienced auto body personnel, service advisors body and paintwork Just as auto body techniques have changed in recent years, repair technology for auto body exteriors has radically evolved. Through constantly updated joining techniques in vehicle production, it is becoming increasingly important in auto body repair to preserve the original bond of the chassis. The trend in auto body repair is thus to regenerate rather than replace body parts. Decisive advantages of regenerating rather than renewing are: No or reduced assembly work Preserving the original chassis bond from the manufacturer Preserving the original corrosion protection of the manufacturer Reducing loss of value on the sale of the vehicle Reduced repair time when using the correct technology Shock-free removal of the damaged area, thus less tension on the material Theoretical fundamentals of materials science and dent repair techniques Assess and remove dents and bumps Additions to vehicle and problem analysis Practical exercises with different technologies Removing dents - grazing damage Reshaping work on wheel arches, sills Manufacture of edges and contours Removal of wide-area damage Usage and combination of various tools Assessment of paint damage and its repair and care 300.00 / day plus tax March 2017 KTD GmbH Seite 10
Ford Aluminium repairs Practical training for the repair of aluminum vehicle parts Experienced auto body personnel The use of aluminium as an auto body work material has been steadily on the rise for years. The main advantage of weight reduction is offset by the disadvantage of a higher price. This means that the repair of a damaged auto body part is often preferable to exchanging it. Aluminium repair is much different from classic steel repair. Significant differences already exist in the design of the workplace and also in the selection of appropriate tools and machines. Basic technical skills and capabilities must be learned. There are limits on repair work which must be observed if one wants to avoid high costs. Fundamentals and materials science Repair and machining of aluminium body panels Introduction to dent repair techniques Exterior dent removal for small dents Exterior bodywork for major damage Thermal retraction Fundamentals of aluminium welding techniques Assessment of the damage image and determining the appropriate repair method 300.00 / day plus tax. March 2017 KTD GmbH Seite 11
Ford Bonding and riveting in auto body repair Practical training of the current repair techniques Experienced body work personnel Cold joining method, commonly called bonding and riveting, is increasing used in auto body repair. The advantages of cold joining are obvious: No heat distortion of the components thereby reducing rework No temperature-related damage to the factory applied corrosion protection No structural changes and resulting alteration in strength properties of high and highest strength steel components Reduction in work times This course is designed by the manufacturer, but focuses on Ford's already released adhesive repair solutions, for example the roof repair of the current Ford Mondeo. In addition, the training prepares the participants for the future challenges in the body repairs. Through a very practically oriented course, participants will learn all the requirements and skills necessary for professional auto body repairs in the area of bonding. Fundamentals of cold joining techniques Materials and tools for professional repairs Necessary preparatory work Various joining techniques (bonding and riveting) Recognizing and avoiding errors in cold joining Development of metal spatulas and spongy-material substitutes Installation of glued outer skin The course is based on the manufacturer s repair requirements. The participants have the ability to perform all of the work steps themselves thus acquiring the knowledge and skills to perform the various repair methods. Realistic bodywork repairs carried out on the basis of the manufacturer s specifications. 220.00 / day plus tax March 2017 KTD GmbH Seite 12
Ford Advanced bodywork training Mechanical sheet metal work, bodywork and measuring technology, using common joining techniques Technical shop personnel with entry level body work experience This training is intended to provide an introduction to body repair. Smaller car body damage can often be repaired without the use of expensive straightening systems. It is important to master the necessary techniques and to use the appropriate tools. The training gives you an overview, but cannot replace our themenity-specific courses. Instruction in working and safety precautions Professionalism cutting of welded components Application of mechanical and thermal sheet processing techniques Use of different welding techniques Production of continuous surfaces Introduction to electronic body measurement techniques Replace a welded body part 260.00 / day plus tax March 2017 KTD GmbH Seite 13
Ford In-depth bodywork training Replacement part repair, repair in auto body structure area, high and higher-strength materials, specific joining techniques Technical shop personnel with experience in bodywork This training is a continuation of the advanced training course and gives the participants knowledge for further repair work. The Intervention in the vehicle bodywork or the structure area of a vehicle does not mean everyday work and therefore requires extensive knowledge and skills. These include: partial replacement of structural and load-bearing body parts, return deformation to original dimensional accuracy with straightening and measuring systems, handling and treatment of highstrength car body materials and light metal constructions as well as the safe mastery of the differentspecific joining techniques. The training serves as a continuation for graduates of the construction training or as a refresher for the trained bodybuilder who carries out rare structural repairs. Instruction in working and safety precautions Partial replacement in bodywork composite and structural area Re-forming using classic and electronic straightening and measuring systems Handling and treatment of sensitive auto body materials, for example highly resistant steels 320.00 / day plus tax March 2017 KTD GmbH Seite 14
ZKF 1 Aluminium repair on outer skin parts Together with ZKF, we offer a two-day course "Aluminum repairs on outer skin parts". The course is designed for experienced body personnel with experience in steel / sheet metal processing. Repair and machining of aluminium outer skin parts Introduction to dent repair techniques Exterior dent repair to minor dents Exterior repairs for major damage Exterior repairs for major damage with the use of heat Thermal retraction Damage image and repair procedure Perform repair with use of bonding and riveting techniques 590.00 plus tax per participant (for ZKF member companies) 649.00 plus tax per participant March 2017 KTD GmbH Seite 15
ZKF 2 Cold-joining technique in auto body repair Together with ZKF, a 2-day course in cold-joining methods in auto body repair is conducted on current BMW vehicles. Cold joining processes have decisive advantages No temperature application, no change in material structure and strength No heat distortion in the connection area No destruction of surface corrosion protection (sheet metal coatings) Connection of different materials possible (for example steel with aluminum or plastic) Higher strength, stability and durability than conventional welded joints Through a very practically oriented course, participants will learn all the requirements and skills necessary for professional auto body repairs in the area of bonding. Basics of cold joining Technology Materials and tools for professional repairs Necessary preparation work Various adhesive techniques Various riveting techniques (punch riveting, full riveting) Recognizing and avoiding errors in cold joining Removal of glued body parts in case of repetitive repairs Appropriate loosening of rivet connections and new riveting Working and special features in high-strength rivet Joints Processing metal spatula instead of tin The course is based on the manufacturer s repair requirements. The participants have the ability to perform all of the work steps themselves thus acquiring the knowledge and skills to perform the various repair methods. Realistic bodywork repairs carried out on the basis of the manufacturer s specifications. 490.00 plus tax per participant (for ZKF member companies) 539.00 plus tax per participant March 2017 KTD GmbH Seite 16
ZKF 3 Electrical system diagnostics in auto body repair - basics Electrical assistance and comfort systems have maintained an ever-increasing role in modern vehicle construction. For timely accident repairs, it is therefore important to understand these systems and master the fundamentals of automotive electrical diagnostics. Together with ZKF, we have developed a twoday training course. This course give you insight into networked vehicle systems. It teaches you the skills and fundamentals that you need to to bring a vehicle after body repair back into operating condition electronically. The objective of the course is to increase your shop capacity and keep a lucrative diagnostics business in house. The course has a 70% practical content and offers the opportunity to become familiar with various diagnostic units and be able to compare them directly with one another. Devices from Bosch, Gutmann and AVL Fundamentals of vehicle electrical / electronics Measurement methods using a multimeter Networked systems in motor vehicles and the impact on the diagnosis Reading circuit diagrams, recognizing connections and performing practical applications Structured approach in error diagnosis (test plan) Practical work with various diagnostic devices on modern European vehicles Read error codes, evaluate and remedy Re-program vehicle 590.00 plus tax per participant (for ZKF member companies) 649.00 plus tax per participant March 2017 KTD GmbH Seite 17
ZKF 4 Electrical system diagnostics in auto body repair advanced training For participants with good fundamental electronic knowledge, for example, participants who have already attended the basic course, we developed a new advanced course. Use of the oscilloscope in diagnostic devices Signal types of sensors and actuators Differences between various data bus Systems Use of electric circuit diagrams Modern lighting Systems Modern driver assistance Systems Modern on-board power Systems Measuring exercises on the vehicle of the mentioned Systems Performing programming, basic settings and adjustments with diagnostic Equipment Possibilities of re-programming the control Units Developing diagnostic strategies 590.00 plus tax per participant (for ZKF member companies) 649.00 plus tax per participant March 2017 KTD GmbH Seite 18
ZKF 5 Specialist for work on HV intrinsically safe vehicles ZKF arranged 2-day courses Specialist for work on HV intrinsically safe vehicles exclusively for ZKF member companies. Due to the expected future increase in hybrid vehicles, the professional association has called for a specialist for working on HV intrinsically safe vehicles such as hybrid vehicles. Course requirements The course Specialist for work on HV intrinsically safe vehicles is open to bodywork and chassis builder Masters as well as Master automotive technicians. Further participants could be vehicle electricians, vehicle mechanics and vehicle mechatronics with training completed after 1973. Auto body and vehicle mechanics with training qualifications after 2002 are also eligible for the course. Fundamental electro-technical knowledge Alternative fuels and Propulsion Structure, function and operation of HV vehicles Protective measures against electrical shock and electrical arcs Electrical hazards and first aid Definition "HV intrinsically safe vehicles Professional responsibility General safety rules and safety instructions Practical procedures when working with HV vehicles and Systems Practical exercises and demonstrations Course execution Level 1: The course participants must complete a written entry test prior to the start of the course. Should a participant lack technical knowledge, the theory portion must be learned through self-study. Level 2: 2 day course Specialist for work on HV intrinsically safe vehicles at KTD in Calw. Level 3: Examination at the end of the course 420.00 plus tax per participant (for ZKF member companies) 462.00 plus tax per participant March 2017 KTD GmbH Seite 19