Rita Charitable Trust

Capping Operator ( 6 Month Diploma )

Capping Operator

 Capping Operator

Capping Operator: The Capping Operator fixes the welded caps to ceramic
substrate by semi-automatic or manual methods using toggle press machine
or hand tools.
Brief Job Description: The individual at work is responsible for cap punching
by press fitting the welded caps to the ceramic rod for providing end
terminals on either side for winding, which is done either manually or by semi
automated methods using toggle press machine or hand tools.
Personal Attributes: The job requires the individual to have ability to work in
process driven environment.

Press fit welded caps to ceramic rod

Press fit welded caps to ceramic rod
Press fit welded caps to ceramic rod


Description

This OS unit is about cap punching by press fitting the welded caps to the ceramic rod
for providing end terminals, which is done either by semi-automated methods or
manually, using toggle press machine or hand tools.
Scope

This unit/task covers the following:
 Understand the work requirement
 Perform capping by press fitting
 Check visually
 Undertake preventive maintenance of machine and equipment
 Achieve productivity and quality standards

Understanding work requirement

Understanding work requirement

Performance Criteria

To be competent, the user/individual on the job must be able to:
coordinate with supervisor to understand the day’s target
read job sheet for specifications for the lot received
Performing capping

To be competent, the user/individual on the job must be able to:
collect caps and capacitors to be capped from the store
set up the semi-automated machine
fix the jig of specified rod size to be punched to the bottom of toggle press
adjust the pressing height of upper level as specified in job sheet
fix the rod to the cap with full force
check the gap between rod and cap
place the welded cap on the jig
press hand lever of the toggle press machine to press fit both caps onto rod
for semi auto method
fit the cap onto the rod using hand tools such as wrenches, punchers, etc., for
manual method
ensure to hold the rod tightly while capping
unload the cap punched rod
avoid loose or cross fitting of the cap
ensure that the cap does not crack while press fit
ensure the winding length after fitting welded caps on both sides is correct
and uniform and is as per job sheet specifications
ensure the punched cap rod withstands weight
Visual checking

To be competent, the user/individual on the job must be able to:
ensure the cap is fitted or fixed firmly such that it does not come out easily
check on the capping performed visually to ensure conformance to
specifications
perform any corrections where needed
Undertaking
preventive
maintenance
To be competent, the user/individual on the job must be able to:
perform regular cleaning of the equipment and work area as per company
and manufacturer specifications

Achieving productivity and quality standards

To be competent, the user/individual on the job must be able to:
achieve 100% target number to be capped
ensure zero defect and wastage
deliver to the next stage on time

Organizational Context

Organizational Context

The individual on the job needs to know and understand:
company’s policies on: incentives, delivery standards and personnel
management
work flow involved in production process of the company
importance of the individual’s role in the workflow
reporting structure
profile of clients
component stocking policy
safety and quality standards followed in the organization

Technical Knowledge

The user/individual on the job needs to know and understand:
basic electronics and component identification
toggle press machine functioning and controls
setting up and loading required materials for capping into the machine
capping techniques and requirements such as gaps to be left between rod
and cap
height requirements and its adjustments in toggle press for performing
capping
using hand tools such as wrenches, punchers, etc.
ohm value and tolerances
colour codes and polarity of components
regulation of operating speed
raw materials, production processes, quality control, costs, and other
techniques
machines and tools, including their designs, uses, repair, and maintenance
Electro-static discharge (ESD) precautions and 5S standards
commonly occurring machine and component defects

Reading and Writing Skills
The user/individual on the job needs to know and understand how:
to maintain logs and records
to read job sheet
to operate computer
to read production schedules and operations manuals
to document the outcome
Communication Skills
The user/individual on the job needs to know and understand how:
to effectively communicate with the supervisor on the process issues
to effectively communicate maintenance issues to the maintenance personne

Press fit welded caps to ceramic rod

Team work and Multitasking
The user/individual on the job needs to know and understand how:
to be able to work on multiple lots at a time, as instructed
to work as a team and deliver on time to next work process
Professional Skills Reflective Thinking
The user/individual on the job needs to know and understand how:
to reduce repetitive errors
to improve work process
Analytical Thinking
The user/individual on the job needs to know and understand how:
to promptly to resolve problems
to enhance machine performance
Using Tools and Machines
The user/individual on the job needs to know and understand how:
to operate the capping or toggle press machine to press fit the welded caps to
the ceramic rod
to use hand tools such as wrenches, punchers, etc. for capping manually
Critical Thinking
The user/individual on the job needs to know and understand how:
to spot process disruptions and delays
to interpret instructions furnished in written, oral or schedule form
Problem solving and Troubleshooting
The user/individual on the job needs to know and understand how:
to identify and resolve problem during capping process
to troubleshoot and correct mechanical problems

Work with superiors and colleagues
Description This OS unit is about communicating, coordinating and maintaining proper
relationship with colleagues and seniors in order to achieve smooth work flow
Scope This unit/ task covers the following:
 Interact with supervisor or superior
 Coordinate with colleagues
Performance Criteria(PC) w.r.t. the Scope
Element Performance Criteria
Interacting with
supervisor
To be competent, the user/ individual must be able to:
understand work requirements by receiving instructions from reporting
supervisor
understand standard operating procedure of the company
escalate problems that cannot be handled including repetitive PCB defects,
machine failures, potential hazards, process disruptions, repairs and
maintenance of machine
report work completed and receive feedback on work done
resolve personnel issues
rectify errors as per feedback and minimize mistakes to zero in future
communicate about process flow improvements, quality of output, product
defects received from previous process, repairs and maintenance of tools and
machinery as required and find technical solutions on specific issues
handover completed work and deliver the work of expected quality despite
constraints
Interacting with
colleagues
To be competent, the user/ individual must be able to:
collect required spares and raw materials from tool room or stores
deposit unused or faulty materials, parts and tools to stores
assist colleagues where necessary and as per capability
resolve conflicts with colleagues at work to achieve smooth workflow
complete rework in time based on feedback from quality or process
departments
put team over individual goals
Knowledge and Understanding (K)
Organizational Context

The individual on the job needs to know and understand:
company’s policies on: incentives, delivery standards, and personnel
management
work flow involved in company’s process
importance of the individual’s role in the workflow
reporting structure