Ford's plant in Saarlouis is undergoing a change in its business profile, from a vehicle manufacturer to a parts supplier for the central European spare parts center in Cologne. In this process, one of the key areas is the production of plastic components. To systematically build the necessary expertise in this field, Ford is cooperating with the SKZ plastics center. The training takes the form of practical in-house courses conducted directly on the company's own injection molding machines and using the tools employed at the plant. This approach is intended to enable the rapid transfer of acquired knowledge into daily production. As early as 2025, two training courses were completed, each for eight participants. Their program was based on the SKZ certification scheme for certified setup technicians, which was adapted to Ford's requirements. The scope covered the most important topics in plastics technology and injection molding, including the safe setting of mold clamping force, securing the injection phase, and the correct determination of the holding pressure phase.
Particular emphasis was placed on the practical part. Participants worked exclusively with original Ford tools, producing components such as fuel caps and tow hook covers. This meant that the training was directly linked to the plant's actual production environment. As Ulrich Schätzlein, senior injection molding trainer at SKZ, emphasizes, "We are pleased that in 2026, in cooperation with Ford in Saarlouis, we will once again be able to conduct two in-house training sessions in small groups of eight participants each." He also adds that "the high practical component and the work with real components ensure lasting learning success."
Defect analysis and process optimization for bumpers
The four-day training sessions planned for 2026 are to focus in particular on the analysis and systematic correction of typical injection molding defects. The main focus is on bumpers, the molds for which were returned to Saarlouis by various suppliers and are currently being used on other machines.
At the outset, a filling study is carried out. As part of this, the hot runner nozzle cascade is optimized to prevent streaks, achieve uniform flow lines, and eliminate surface defects. Of crucial importance here are the precise adjustment of injection speed and the optimal setting of the holding pressure phase.
With regard to part quality, compliance with tight tolerances and flawless paintability are particularly important. Therefore, after the work is completed, 18 bumpers are painted and assessed by Ford quality experts, including for paint adhesion.
Training conducted directly at the plant
SKZ offers companies the possibility of training several employees simultaneously in an in-house format, according to their needs, either directly on site or at a selected location. The scope of the courses is tailored each time to the company's specific production processes and requirements.
An important advantage of this solution is that the training is carried out on the company's own machinery and using available tools. This provides a direct link to practice, facilitates the implementation of knowledge in daily work, and can increase efficiency.
Upon request, the training sessions can also be conducted in English or with the support of an interpreter, which is particularly relevant for internationally active companies and multilingual teams.
SKZ in-house training at the Ford plant in Saarlouis.
