Free Automation Specialist Course (6Months)

Automation Specialist:

Brief Job Description

Individuals at this job are responsible for providing support to production operations through maintenance of process control systems installed at shop floor for various Manufacturing processes.

Personal Attributes

This job requires the individual to work independently and take decisions pertaining to ones area of work. The individual should be result oriented. The individual should also be able to demonstrate skills for information ordering, mathematical and logical reasoning, manual dexterity and oral expression skills along with comprehension. The individual must be physically fit as he has to maintain unusual working hours.

Work effectively in a team:

Elements and Performance Criteria

Effective communication

To be competent, the user/individual on the job must be able to:

PC1.    maintain clear communication with colleagues

PC2.    work with colleagues

PC3.    pass on information to colleagues in line with organisational requirements

PC4.. work in ways that show respect for colleagues

PC5.    carry out commitments made to colleagues

PC6.    let colleagues know in good time if cannot carry out commitments, explaining the reasons

PC7.            identify problems in working with colleagues and take the initiative to solve these problems

PC8.    follow the organisations policies and procedures for working with colleagues

PC9.    ability to share resources with other members as per priority of tasks

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1. the organisations policies and procedures for working withcolleagues, role and responsibilities in relation to this

KU2. the importance of effective communication and establishing goodworking relationships with colleagues

KU3. different methods of communication and the circumstances inwhich it is appropriate to use these

KU4. benefits of developing productive working relationships withcolleagues

KU5. the importance of creating an environment of trust and mutualrespect

KU6. whether not meeting commitments, will have implications onindividuals and the organisation

KU7. different types of information that colleagues might need and theimportance of providing this information when it is required

KU8. the importance of problems, from colleagues perspective andhow to provide support, where necessary, to resolve these

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1.     complete well written work with attention to detail

GS2.     read instructions, guidelines/procedures

GS3.     listen effectively and orally communicate information

GS4.             make decisions on a suitable course of action or response

GS5.             plan and organise work to achieve targets and deadlines

GS6.             check that the work meets customer requirements

GS7.     deliver consistent and reliable service to customers

GS8.             apply problem solving approaches in different situations

GS9.             apply balanced judgements to different situations

GS10. apply good attention to detail

GS11. check that the work is complete and free from errors

GS12. get work checked by peers

GS13. work effectively in a team environment

Maintain a safe and healthy working environment:

Elements and Performance Criteria

Identify and report the risks identified

To be competent, the user/individual on the job must be able to:

PC1..    Identify activities which can cause potential injury through sharp objects, burns, fall, electricity, gas leakages, radiation, poisonous fumes, chemicals ,loud noise

PC2.     Inform the concerned authorities about the potential risks identified in the processes, workplace area/ layout, materials used etc

PC3.     Inform the concerned authorities about machine breakdowns, damages which can potentially harm man/ machine during operations

PC4.     Create awareness amongst other by sharing information on the identified risks

Create and sustain a Safe, clean and environment friendly work place

To be competent, the user/individual on the job must be able to:

PC5..    Follow the instructions given on the equipment manual describing the operating process of the equipments

PC6..    Follow the Safety, Health and Environment related practices developed by the organization

PC7.     Operate the machine using the recommended Personal Protective Equipments (PPE)

PC8. . Maintain a clean and safe working environment near the work place and ensure there is no spillage of chemicals, production waste, oil, solvents etc

PC9.     Maintain high standards of personal hygiene at the work place

PC10. Ensure that the waste disposal is done in the designated area and manner as per organization SOP.

PC11. Inform appropriately the medical officer/ HR in case of self or an employees illness of contagious nature so that preventive actions can be planned for others

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1. relevant standards, procedures and policies related to Health, Safety and Environment followed in the company

KU2. basic knowledge of Safety procedures( fire fighting, first aid) within the organization

KU3. knowledge of various types of PPEs and their usage

KU4. basic knowledge of risks/hazards associated with each occupation in the organization

KU5. how to safely operate various tools and machines and risksassociated with the tools/ equipment

KU6. knowledge of personal hygiene and how an individual an contribute towards creating a highly safe and clean working environment

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1.     write basic level notes and observations

GS2.     read safety instructions put up across the plant premises

GS3.     read safety precautions mentioned in equipment manuals and panels to understand the potential risks associated

GS4.     effectively communicate information to team members

GS5.     informemployees in the plant and concerned functions about events, incidents & potential risks observed related to Safety, Health and Environment.

GS6.     question operator/ supervisor in order to understand the safety related issues

GS7.     attentively listen with full attention and comprehend the information given by the speaker during safety drills and training programs

GS8.     use common sense and make judgments during day to day basis

GS9.             use reasoning skills to identify and resolve basic problems

GS10. use common sense and make judgments during day to day basis

GS11. use reasoning skills to identify and resolve basic problems

Repair and maintain the process control systems:

Elements and Performance Criteria

Inspection of process control and automation systems

To be competent, the user/individual on the job must be able to:

PC1..     prepare a PM schedule for the process control and automation systems listed below installed manufacturing process wise based on recommendations of the OE and past experience Limit switches VFDs HMIs SCADA PLCs Robotics

PC2..     based on the schedule , inspect the systems and identify the replacements in the systems

PC3..     if required , attend to the breakdown of systems during manufacturing processes in operation

PC4..     ensure that all the systems are integrated through a computer interface

PC5..     coordinate with the system vendor and arrange for procurement of critical spares

PC6..     store the spares received in plant at the designated locations of the warehouse for maintenance items in coordination with stores manager

PC7..     ensure that the software used for system interfacing are upgraded as per the requirement

PC8..     coordinate with machine/systems/robot vendors and if required , in consultation with sourcing department , finalize an amc for upkeep of the machines/systems/robots etc.

PC9..     use appropriate ppe, material handling equipment and tools and carry out the task .

PC10.. use recommended methods, consumables, tools,CDs for electrical / electronic connections verification of continuity joints, including soldered software program installations and upgradations

PC11.. take support from technician, experts, user , team members from maintenance during the activity if required

PC12.. clock the time for the task so that the scheduling and planning can be improved in future

PC13.. when carrying out the installation/ shifting activity record the time and unplanned tasks encountered in the activity

PC14.. discuss with seniors in manufacturing, maintenance for improving the activity to ensure all points are adequately considered

Carrying breakdown maintenance

To be competent, the user/individual on the job must be able to:

PC15.. open the process control and automation systems under supervision of maintenance manager and if required , replace the spare parts as per the schedule

PC16.. check / confirm internal conditions of wiring , motherboards, software/ hardware malfunctioning, circuit failures etc. to verify working status to expected conditions.

PC17.. discuss with the user/ operator to learn about problems /unusual phenomenon noticed in the systems

PC18.. change the maintenance due / status sticker on the equipment.

PC19.. to attend the breakdown maintenance verify in appropriate sequence for the equipment charge leakage/ short circuit from parts breakage of wires, clamps unusual contact of electrical wires with moving parts erratic / problematic performance any problem condition as reported in the complaint

PC20.. execute sequence of activities for changing , correcting the situation after opening, verifying contact/ insulation conditions, failure of internal wires etc. and ensure the circuit elements, consumables are available at the work place.

PC21.. use appropriate ppe, material handling equipment and tools and carry out the task .

PC22.. use recommended methods, consumables, tools,CDs for electrical / electronic connections verification of continuity joints, including soldered software program installations and upgradations

PC23.. take support from technician, experts, user , team members from maintenance during the activity if required

PC24.. clock the time for the task so that the scheduling and planning can be improved in future

PC25.. when carrying out the installation/ shifting activity record the time and unplanned tasks encountered in the activity

PC26.. discuss with seniors in manufacturing, maintenance for improving the activity to ensure all points are adequately considered

Maintain the documentation

To be competent, the user/individual on the job must be able to:

PC27.. maintain a record of all the vendor and system 2d/3d- as built drawings , equipment operation related diagrams , program codes etc. in a legible and safe condition

PC28.. maintain the history of the equipment for the pm/breakdown maintenance activities in log book/history sheets / erp

PC29.. prepare the documents required for process control and automation as per the quality management system (qms) requirements

PC30.. ensure that all the documents for qms are controlled and easily traceable for future requirements too

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.     company manufacturing processes & the equipment in use

KU2.     existing layout for the processes

KU3.     sequence of operations for each process

KU4.     contract agencies for maintenance activities outsourcing in the company

KU5.     complete knowledge of the process in consideration

KU6.     process control and automation systems installed for the processes

KU7.     type of systems being used for the process

KU8.     electrical -wiring drawings of existing layout/ equipment/systems

KU9.     operation of electrical equipments viz motors etc . being used for the process

KU10. robotic instruments used for process

KU11. PLC , SCADA , & electrical elements operation ,testing

KU12. Trouble shooting/ fault finding in Pneumatic, Hydraulic, Electrical control system elements

KU13. QMS system requirements

KU14. material and information flow of the process

KU15. Problem solving techniques TOPS 8D 7 QC tools etc

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1. read the information displayed at the workplace

GS2. draft a pictorial representation of the existing layout for better comprehension

GS3. interpret the outputs obtained from process control systems like PLC , SCADA, HMI etc.

GS4. communicate with shop floor workers gathering inputs/requirements

GS5. coordinate with the shop floor workers , colleagues and enter the information related to maintenance activities in hard and soft copy as desired

GS6. interact with workers and gather all the information related to process requirements

GS7. share operation knowledge with co-workers

GS8. execute the PM of the process control and automation systems in an effective manner and on timely basis

GS9. provide inputs to maintenance manager for developing more economic and feasible measures for controlling the process parameters and specifications using the best systems

Plan and arrange for installation of new systems:

Elements and Performance Criteria

Requirements gathering

To be competent, the user/individual on the job must be able to:

PC1..     under supervision of the maintenance/ Process Engineering manager , identify the requirements for following process control and automation systems manufacturing process wise based on the organizations production capacity expansion/new capacity addition plans Limit switches VFDs HMIs SCADA PLCs Robotics RFIDs

PC2..     based on the requirements gathered , compute the individual quantity of the systems to be installed

PC3..     plan on the basis of standardization, modular arrangements etc.

Coordinate with Sourcing department for system trials

To be competent, the user/individual on the job must be able to:

PC4..     identify from the existing vendor base for the new systems procurement

PC5..     send the required drawings for the systems along with rfq to vendors and based on the quotation received , approve the most conforming vendor

PC6..     in case of the existing vendor non-competency for providing the new system , identify and approve the most economically feasible and technologically advanced vendor

PC7..     visit the approved vendors site and review the trial system run at its facility

PC8..     suggest modification (if any) in the new system for meeting the requirements

PC9..     conduct re-trials with the modified system as per convenience of vendor and approve the final system for installation communicate to the maintenance manager the system trial progress and seek feedback, if required

PC10.. based on the feedback received , finalize the technical specifications for the new system and instruct the vendor for system installation within the desired process of the organization

Procure and install the new system

To be competent, the user/individual on the job must be able to:

PC11.. raise the purchase order (p.o.) and procure the system in the organization

PC12.. inspect the system components for physical damages and if required , reject the damaged components with subsequent procurement of the fresh component

PC13.. in coordination with the vendor representative , install the new system within the desired locations in manufacturing processes

PC14.. on completion of installation , test run the entire system and identify the discrepancies (if any)

PC15.. in case of discrepancies observed , in team suggest and implement the countermeasure and re-run the system

PC16.. repeat steps pc13. to pc15. till the system is free from any discrepancies

PC17.. understand from the vendor the software coding , programming logic , electrical connections logic, hardware requirements, robotic parameters and its operation sequence etc. as per the applicability of the system. get these appropriately documented for future references

PC18.. communicate the progress to the maintenance manager and if required , run the system in his presence and seek feedback

PC19.. based on the feedback , resolve the minor discrepancies observed (if any) and finally submit the necessary system related documents and invoices to souring/purchase department

PC20.. continuously monitor the system functioning and if required consult the vendor for any issues observed

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.     company manufacturing processes & the equipment in use

KU2.     existing layout for the processes

KU3.     sequence of operations for each process

KU4.     protocol for new system installation followed in the company

KU5.     approved vendor database for the process and automation systems

KU6.     complete knowledge of the process in consideration

KU7.     process control and automation systems installed for the processes

KU8.     type of systems being used for the process

KU9.     electrical -wiring drawings of existing layout/ equipment/systems

KU10. operation of electrical equipments viz motors etc . being used for the process

KU11. robotic instruments used for process

KU12. PLC , SCADA , & electrical elements operation ,testing

KU13. Trouble shooting, fault finding for electrical, Pneumatic, hydraulic controls

KU14. QMS system requirements

KU15. material and information flow of the process

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1.     read the information displayed at the workplace

GS2.     draft a pictorial representation of the existing layout for better comprehension

GS3.     interpret the outputs obtained from process control systems like PLC , SCADA, HMI etc.

GS4.     communicate with shop floor workers gathering inputs/requirements

GS5.     coordinate with the shop floor workers , colleagues and enter the information related to maintenance activities in hard and soft copy as desired

GS6.     communicate with Sourcing and Purchase department for system trials, procurement and installation

GS7.     interact with workers and gather all the information related to process requirements

GS8.     share operation knowledge with co-workers

GS9.     coordinate with shop floor workers and team for performing the new system installation activity efficiently

GS10. execute the requirements gathering and installation for the process control and automation systems in an effective manner and on timely basis

GS11. plan the new system trials and installation in the process without disrupting the production schedule for the process

GS12. provide inputs to maintenance manager for developing more economic and feasible measures for controlling the process parameters and specifications using the best systems

GS13. decide the most economically and technologically feasible automation and process control system for the designated manufacturing process

GS14. identify the major alternate/new vendors for the new system procurement

GS15. assess the problem, evaluate the possible solution(s) and use an optimum /best possible solution(s)

GS16. identify immediate or temporary solutions to resolve delays and crisis situations

Assessment Guidelines

1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each Element/ Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of marks for Theory and Skills Practical for each Element/ PC.

• The assessment for the theory part will be based on knowledge bank of questions created by the SSC.

• Assessment will be conducted for all compulsory NOS, and where applicable, on the selected elective/option NOS/set of NOS.

• Individual assessment agencies will create unique question papers for theory part for each candidate at each examination/training center (as per assessment criteria below).

• Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/ training center based on these criteria.

• To pass the Qualification Pack assessment, every trainee should score the Recommended Pass % aggregate for the QP.

• In case of unsuccessful completion, the trainee may seek reassessment on the Qualification Pack.