Free Executive Proto Manufacturing Course (6Months)

Executive Proto Manufacturing:

Brief Job Description

Individuals at this job need to coordinate with different departments and functions for Manufacturing and R&D of prototype vehicle/parts that will finally be used for testing and validation.

Personal Attributes

The individual should be willing to work at shop floor for long hours. The individual should possess coordination and interpersonal skills. The individual should also be able to demonstrate skills for information ordering, imagination, analytical reasoning, technology, customer orientation, oral expression and comprehension.

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

Develop the prototype for existing product modification:

Elements and Performance Criteria

Design release for proto parts/vehicle

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

PC1..    coordinate internally with r&d for the design release of proto vehicle/parts of the existing model

PC2..    check what are the changes in product have been made by R&D with respect to existing model in terms of – product design changes – product dimensional changes- product material strength/composition changes

PC3..    ensure co-ordination & communication/documentation of those changes suggested by r&d team for in-house and vendor sourcing of the required parts

PC4..    sign off the proto- stage after release as per SOP

In-house and sourcing from vendor for proto parts

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

PC5..    check based on the change suggested whether modified part is being manufactured in- house or sourced from different vendor

PC6..    release the modified part design to in-house manufacturing unit or to the vendor depending upon from where modified part can be sourced

PC7..    coordinate with in-house manufacturing unit and vendor for timeline for delivering modified parts based on parts modification feasibility

PC8..    ensure that parts are getting delivered to the r&d department meeting the timeline requirement

Coordinate for Proto manufacturing and validation

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

PC9..    coordinate with production team for proto manufacturing as per design released by r&d department; ensure adequate numbers as may be required for customer/ verification and validation are planned.

PC10.. based on production schedule inform the time line to the testing and validation team for proto testing and validation

PC11.. handover the proto vehicle/part to the testing validation team after production of the same

PC12.. co-ordinate with materials lab, qa, standards room etc for verification of the dimensional and material /special characteristics as necessary for the change in the design at appropriate stage.

PC13.. keep records maintaining traceability to facilitate interpretation of test results later.

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1. product portfolio of organization

KU2. the manufacturing processes of organization

KU3. the list of approved vendors for the outsourced materials

KU4. protocol for communication with various department

KU5. personnel and other HR policies of the organization

KU6. good understanding of prototyping and testing process

KU7. understanding on homologation and validation process

KU8. knowledge in tools like CAD, CAM,PRO -E etc

KU9. information systems like SAP, ERP,PLM etc.

Generic Skills (GS)

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

GS1.    read and understand the usage of different parts in the vehicle

GS2.    good product knowledge and strong coordination skill

GS3.    document all the prototyping activities findings in form of MS Word documents , MS Excel spreadsheets etc.

GS4.    communicate with the concerned departments for gathering part/component drawings and other related information

GS5.    follow up with concerned manufacturing unit on the progress of prototype development

GS6.    work effectively with the NPD team members for ensuring proto manufacturing in a timely and efficient manner

GS7.    share operation knowledge with colleagues and peers

GS8.    escalate on immediate basis in case parts are timely not available in-house or at the vendor end

GS9.    work with punctuality and commitment

GS10. identify problems (technical and non-technical), disruptions and delays

Develop the prototype based on future business plan:

Elements and Performance Criteria

Coordinate with R&D for new proto design release

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

PC1.    coordinate internally with R&D for the design release of proto vehicle/parts of the new product based on customer/market requirement

PC2.    see the simulation of the complete product for better understanding about the new proto

PC3.    support in evaluating the design from manufacturing/assembly line perspective on the early stage of the project

PC4.    coordinate in bridging the gap, if any, related to new proto development between design team and product team

PC5.    ensure documentation of new product requirement suggested by R&D team

PC6.    sign off the proto- stage after release of SOP

Sourcing of new proto parts

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

PC7.    check and record what are new product required for new proto manufacturing

PC8.    coordinate with strategic sourcing for development and sourcing of new parts as per design release

PC9.    order the parts for prototype assembly according to design release

PC10. coordinate with in-house manufacturing unit and vendor for timeline for delivering modified parts based on parts modification feasibility

PC11. ensure parts are getting delivered to the R&D department meeting the timeline requirement

Coordinate for Proto manufacturing and validation

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

PC12. coordinate with production team for new proto manufacturing as per design released by R&D department; ensure adequate numbers as may be required for customer/ verification and validation are planned.

PC13. based on production schedule inform the time line to the testing and validation team for proto testing and validation

PC14. handover the proto vehicle/part to the testing validation team after production of the same Co-ordinate with Materials Lab, QA, standards Room etc for verification of the dimensional and material / special characteristics as necessary for the change in the design at appropriate stage . Keep records maintaining traceability to facilitate interpretation of test results later.

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.    roles, responsibilities and scope of work for different departments

KU2.    product portfolio of organization

KU3.    the manufacturing processes of organization

KU4.    the list of approved vendors for the outsourced materials

KU5. protocol for communication with various department

KU6 Personnel and other HR policies of the organization

KU7. good understanding of prototyping and testing process

KU8.   understanding on homologation and validation process

KU9. knowledge in tools like CAD, CAM,CAE,PRO-E etc

KU10. information systems like SAP, ERP etc

KU11. knowledge of simulation software, DFMEA, APQP

Generic Skills (GS)

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

GS1.    read and understand the usage of different parts in the vehicle

GS2.    good product knowledge and strong coordination skill

GS3.    document all the prototyping activities findings in form of MS Word documents , MS Excel spreadsheets etc.

GS4.    communicate with the concerned departments for gathering part/component

GS5.    follow up with concerned manufacturing unit on the progress of product medication

GS6.    writing and reading skill to communicate the modification suggested

GS7.    work effectively with the team members for ensuring proto manufacturing in a timely and efficient manner

GS8.    share operational knowledge with colleagues and peers

GS9.    work on escalation on immediate basis in case parts are timely not available in-house or at the vendor end

GS10. work with punctuality and commitment

GS11. identify problems (technical and non-technical), disruptions and delays

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.