Free Machining Technician Level 3 Course (6Months)

Machining Technician Level 3:

Brief Job Description

Machining Technician Level 3 is often called Assistant Machinist, Junior Machinist, Lathe Operator, Apprentice Machinist, Semi-Skilled Operator. This role primarily involves supporting the machine operator in all premachining activities, machining of the actual part, ad hoc repair work like in auto service stations, gauging, de-burring and inspection activities.

Personal Attributes

The individual should have the ability of operation monitoring i.e., observing gauges , dials etc., maintaining arm steadiness, ability to quickly move hand to grasp and assemble objects (Dexterity), reading, writing and communication skills and sensitivity towards safety for self and equipment.

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

Maintain 5S at the work premises:

Elements and Performance Criteria

Ensure sorting

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

PC1..    follow the sorting process and check that the tools, fixtures & jigs that are lying on workstations are the ones in use and unnecessary items are not cluttering the workbenches or work surfaces.

PC2..    ensure segregation of waste in hazardous/ non hazardous waste as per the sorting work instructions

PC3..    follow the technique of waste disposal and waste storage in the proper bins as per sop

PC4..    segregate the items which are labelled as red tag items for the process area and keep them in the correct places

PC5.     sort the tools/ equipment/ fasteners/ spare parts as per specifications/ utility into proper trays, cabinets, lockers as mentioned in the 5s guidelines/ work instructions

PC6. .  ensure that areas of material storage areas are not overflowing

PC7.     properly stack the various types of boxes and containers as per the size/ utility to avoid any fall of items/ breakage and also enable easy sorting when required

PC8.     return the extra material and tools to the designated sections and make sure that no additional material/ tool is lying near the work area

PC9.     follow the floor markings/ area markings used for demarcating the various sections in the plant as per the prescribed instructions and standards

PC10.   follow the proper labeling mechanism of instruments/ boxes/ containers and maintaining reference files/ documents with the codes and the lists

Ensure proper documentation and storage ( organizing , streamlining)

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

PC11.   check that the items in the respective areas have been identified as broken or damaged

PC12.   follow the given instructions and check for labelling of fluids, oils. lubricants, solvents, chemicals etc. and proper storage of the same to avoid spillage, leakage, fire etc

PC13.   make sure that all material and tools are stored in the designated places and in the manner indicated in the 5s instructions

Ensure cleaning of self and the work place

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

PC14.   check whether safety glasses are clean and in good condition

PC15.   keep all outside surfaces of recycling containers are clean

PC16.. ensure that the area has floors swept, machinery clean and generally clean. in case of cleaning, ensure that proper displays are maintained on the floor which indicate potential safety hazards

PC17.. check whether all hoses, cabling & wires are clean, in goodcondition and clamped to avoid any mishap or mix up

PC18.. ensure workbenches and work surfaces are clean and in good condition

PC19.   follow the cleaning schedule for the lighting system to ensure proper illumination

PC20.   store the cleaning material and equipment in the correct location and in good condition

PC21.   ensure self-cleanliness – clean uniform, clean shoes, clean gloves, clean helmets, personal hygiene

Ensure sustenance

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

PC22.   follow the daily cleaning standards and schedules to create a clean working environment

PC23.   attend all training programs for employees on 5 s

PC24.   support the team during the audit of 5 s

PC25.   participate actively in employee work groups on 5s and encourage team members for active participation

PC26.   follow the guidelines for what to do and what not to do to build sustainability in 5s as mentioned in the 5s check lists/ work instructions

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.    relevant standards, procedures and policies related to 5S followed in the company

KU2.    have basic knowledge of 5S procedures

KU3.    know various types 5s practices followed in various areas

KU4.    understand the 5S checklists provided in the department/ team

KU5.    have skills to identify useful & non useful items

KU6.    have knowledge of labels , signs & colours used as indicators

KU7.    knowledge on how to sort and store various types of tools, equipment, material etc.

KU8.    know , how to identify various types of waste products

KU9.    understand the impact of waste/ dirt/ dust/unwanted substances on the process/ environment/ machinery/ human body

KU10. have knowledge of best ways of cleaning & waste disposal

KU11. understand the importance of standardization in processes

KU12. understand the importance of sustainability in 5S

KU13. have knowledge of TQM process

KU14. have knowledge of various materials and storage norms

KU15. understand visual controls, symbols, graphs etc.

Generic Skills (GS)

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

GS1.    write basic level notes and observations

GS2.    note down observations (if any) related to the process

GS3.    read 5S instructions put up across the plant premises

GS4.    effectively communicate information to team members inform employees in the plant and concerned functions about 5S

GS5.    question the process head in order to understand the 5S related issues

GS6.    attentively listen with full attention and comprehend the information given by the speaker during 5S training programs

GS7.    use common sense and make judgments during day to day basis

GS8.           use reasoning skills to identify and resolve basic problems using 5S

GS9.           persuade co team members to follow 5 S

GS10. ensure that the co team members understand the importance of using 5 S tool

GS11. use innovative skills to perform and manage 5 S activities at the work desk and the shop floor

GS12. exhibit inquisitive behaviour to seek feedback and question on the existing set patterns of work

GS13. do what is right, not what is a popular practices

GS14. follow shop floor rules& regulations and avoid deviations; make 5S an integral way of life

GS15. ensure self-cleanliness on a daily basis

GS16. demonstrate the will to keep the work area in a clean and orderly manner

Assist in Carrying out pre-machining activities:

Elements and Performance Criteria

Understanding the component requirements

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

PC1. . understand the output product requirement by reading the engineering drawing specified in the work instructions/ work order

PC2. . clearly understanding the does and donts of the manufacturing process as defined in SOPs/ work instructions or defined by supervisors

PC3. . reading the control panel instructions/ job orders to determine the correct output product specifications

PC4. . understanding the tooling instructions as specified in the Operating Manual/ work Instructions or Standard Operating Procedures

PC5..   selection of proper coolant and lubricant required for machining the required component

Checking the dimensions for the component To be competent

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

PC6. . set the machine stops or guides as per the specified lengths indicated through scales or work instructions

PC7. . measure and mark reference points/ cutting lines on the work pieces, using compasses, calipers, rulers and other measuring tools

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1. relevant standards and procedures followed in the company

KU2. different types of products manufactured by the company

KU3. different types of machining processes

KU4. different types of tools used in the machining process with respect to type of process to be conducted

KU5. basic principles of 5 S in manufacturing Cleaning, sorting etc

KU6. the application of coolant and lubricants

KU7. basic Arithmetic and calculation methods

Generic Skills (GS)

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

GS1.    read and interpret workplace related documentation

GS2.           read and interpret engineering drawings and sketches

GS3.           write basic level notes and observations

GS4.    draw basic level drawings and charts

GS5.    discuss task lists and job requirements with team members

GS6.    discuss with operator/ supervisor in order to understand the nature of the problem

GS7.    attentively listen and comprehend the information given by the technician/team members

GS8.    analyse a given situation and decide on an appropriate action for completing the task within resources

GS9.    plan work assigned on a daily basis and provide estimates of time required for each piece of work

GS10. prioritize actions to achieve required outcomes

GS11. follow instructions and work on areas of improvement identified

GS12. complete the assigned tasks with minimum supervision

GS13. complete the job defined by the supervisor within the timelines and quality norms

GS14. meet or exceed customer/team expectations

GS15. analyse a problem and attempt to find an acceptable solution and take help of concerned people if required

GS16. analyse the complexity of work to determine how it can be successfully carried out

GS17. anticipate and analyse a given situation from all aspects

GS18. apply own judgement to identify solutions in different situations

Support the operator in performing machining operations:

Elements and Performance Criteria

Setting up machine as per work instructions

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

PC1. .   assist in machine setting, adjusting machine tools in order to perform machining operations and for meeting dimensional and other parameters within the specified tolerance limit specified in the drawing/design standards

PC2. .   support the operator in aligning and holding fixtures, cutting tools etc. onto the machine

PC3. .   support in positioning / securing/ aligning cutting tools in tool holders of the machine, by using hand tools and by verify their positions with measuring instruments

Support the machinist/ operator in performing machining on the component

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

PC4..     start lathe or turning/ drilling/ milling machine for operations

PC5. .   support the machinist in selecting required cutting tools

PC6..     operate hand wheels or valves in order to feed the component and allow cooling and lubricating of the same as per the instructions given by the machinist/supervisor

PC7. .   turn on the coolant valves and start their flow to maintain temperature in the lathe machine chamber

PC8. .   move tool holders manually or by turning the hand wheels in order to feed tools along the machined component/ piece

Observe/ Record the machining operations

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

PC9. .   observe machine operations to detect defects in the component manufactured

PC10. . observe the machine operations for any malfunctions and immediately inform the supervisor if observed so

PC11..   support the operator in recording operational data such as pressure readings, length of strokes, feed rates, speed etc in the formats specified by the supervisors

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1. relevant standards and procedures followed in the company

KU2. different types of products manufactured by the company

KU3. different types of machining processes and the related toolings,equipment and measuring instruments

KU4. basic principles of 5 S in manufacturing Cleaning, sorting etc. KB3. the application of coolant

KU5. drawing , design standard and basic arithmetic

Generic Skills (GS)

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

GS1.    read documents and notes

GS2.    interpret/ comprehend the information given in the drawing and documents

GS3.    read and interpret symbols given on equipments and work area

GS4.    write basic level notes and observations

GS5.    draw basic level drawings and charts

GS6.    discuss task lists and job requirements with team members

GS7.    discuss with operator/ supervisor in order to understand the nature of the problem

GS8.    attentively listen and comprehend the information given by the technician/team members

GS9.    judge when to ask for help from a supervisor

GS10. suggest options to operators in case any issue is observed during operations

GS11. use reasoning skills to identify and resolve basic problems

GS12. plan work assigned on a daily basis and provide estimates of time required for each piece of work

GS13. follow instructions and work on areas of improvement identified

GS14. complete the assigned tasks with minimal supervision

GS15. complete the job defined by the supervisor within the time line and quality norms

GS16. meet or exceed internal/external customer/team expectations

GS17. recognise a workplace problem or a potential problem and take action

GS18. determine problems needing priority action

GS19. refer problems outside area of responsibility to appropriate person

GS20. gather information and provide assistance as required to solve problems

GS21. anticipate and analyse a given situation from all aspects

GS22. analyse, evaluate and apply the information gathered from observation, experience, reasoning, or communication to act efficiently

Support the operator in conducting all post machining operations:

Elements and Performance Criteria

Perform minor machine maintenance activities

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

PC1..     maintain the machine in proper operational condition

PC2. .   perform minor machine maintenance activities such as oiling or cleaning machine and its components as per schedules

PC3. .   adding coolant and lubricant in machine reservoir

Perform de burring activity on the machined components

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

PC4. .   use correct tool for removing the extra burrs, sharp edges, rust and chips from the metal surface

PC5. .   use files, hand grinders, wire brushes, or power tools for performing de burring operations.

Ensure usage of Personal Protective equipment like eye glasses and hand gloves

PC6. .   perform shot blasting/ vibro processes for completing de-burring operations for automated processes

Check quality of machined component (Gauging)

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

PC7. .   support the operator in inspection of the finished component and verify conformance as per Control Plan/ Work Instruction

PC8. .   use devices like micrometers, vernier calipers, gauges, rulers and any other inspection equipment for measurement with valid calibration status

PC9. .   support the operator in noting down the observations during inspection process and identify pieces which comply with the specified standards

PC10. . separate the defective pieces into two categories pieces which can be repaired/ modified and pieces which are beyond repair and maintain records of each category

PC10. . separate the defective pieces into two categories – pieces which can be repaired/ modified and pieces which are beyond repair and maintain records of each category

Assist the operator in the tool change process

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

PC11. . assist the operator in changing different worn machine accessories, such as cutting tools (as per tool life listed, recommended) and brushes, other hand tools

PC12. . replace machine part as per work instructions, using hand tools or notify supervisor/ engineering personnel for taking corrective actions

PC13..   observe the tool change cycle in order to ensure that the selected tool is transferred to the spindle from magazine after the previous tool is transferred to the magazine from the spindle for automated process

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1. relevant standards and procedures followed in the company

KU2. different types of products manufactured by the company

KU3. different types of equipments and tools used in the machining process and de-burring process

KU4. basic principles of 5 S in manufacturing Cleaning, sorting etc

KU5. the application of coolant and lubricants

KU6. drawing , design standard and basic arithmetic

Generic Skills (GS)

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

GS1.    read /interpret/ Comprehend the information given in the documents and notes

GS2.           read /interpret/ Comprehend symbols given on equipments and in work area

GS3.           write basic level notes and observations

GS4.    draw basic level drawings and charts

GS5.    discuss task lists and job requirements with team members

GS6.    discuss with operator/ supervisor in order to understand the nature of the problem

GS7.    attentively listen and comprehend the information given by the technician/team members

GS8.    analyse information and evaluate actions with the operator to solve problems e.g. inspection results, rework status

GS9.    use reasoning skills to identify and resolve basic problems

GS10. escalate problem beyond individuals scope

GS11. plan work assigned on a daily basis and provide estimates of time required for each piece of work

GS12. prioritize actions to achieve required outcomes

GS13. follow instructions and work on areas of improvement identified

GS14. complete the assigned tasks with minimum supervision

GS15. complete the job defined by the supervisor within the timelines and quality norms

GS16. meet or exceed internal/external customer/team expectations

GS17. recognise a workplace problem or a potential problem and take action

GS18. determine problems needing priority action

GS19. refer problems outside area of responsibility to appropriate person

GS20. gather information and provide assistance as required to solve problems

GS21. anticipate and analyse a given situation from all aspects

GS22. analyse, evaluate and apply the information gathered from observation, experience, reasoning, or communication to act efficiently

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.