Free Composite Repair Technician Course (6months)

Composite Repair Technician:

Composite Repair Technician is responsible for carrying our aircraft composite repairs

Brief Job Description Composite Repair Technician: The Composite Repair Technician role entails carrying out various types of machining operations and will be responsible for machining composite parts, foams, cores, epoxy/ metallic tools, NC fixtures, templates, composite master models. Personal Attributes: key attributes for Composite Repair Technician would include good communication skills, excellent written communication skills and good interpersonal skills with a keen eye for details.

Safety and security procedures:

Comprehending the safety and security procedures

PC1. comply with the organisation’s safety and security policies and procedures

PC2. comply with the regulatory guidelines on safe conduct of operations and maintenance of conditions to thwart any acts of unlawful interference

PC3. report any identified breaches of safety, and security policies and procedures to the designated person

PC4. coordinate with other resources at the workplace (within and outside the organisation) to achieve safe and secure environment

PC5. identify and mitigate any safety and security hazards like illness, accidents, fires or acts of unlawful interference if it falls within the limits of individual’s authority

PC6. report any hazards outside the individual’s authority to the relevant person in line with organisational procedures and regulatory guidelines

PC7. follow organisation’s emergency procedures for accidents, fires or acts of unlawful interference

PC8. identify and recommend opportunities for improving health, safety, and security to the designated person

PC9. complete all health and safety records are updates and procedures well defined

Knowledge and Understanding

Organisational

Context

KA1. hazard identification and risk management as defined within the organisational policy and procedures

KA2. regulatory requirements and organisation’s procedures for maintenance of safety and security standards and individual’s role and responsibilities in relation to this

KA3. how and when to report hazards

KA4. the limits of responsibility for dealing with hazards

KA5. the organisation’s emergency procedures for different emergency situations and the importance of following these

KA6. importance of maintaining high standards of safety and security

KA7. implications that any non-compliance with safety and security may have on individuals and the organisation

Technical

Knowledge

KB1. different types of breaches of safety and security and how and when to report these

KB2. evacuation procedures for workers and passengers

KB3. how to summon medical assistance and the emergency services, where necessary

KB4. how to use the health, safety and accident reporting procedures and the importance of these

KB5. regulatory guidelines on dealing with safety and security emergencies

Core Skills/ Generic Skills

Writing Skills
The user/ individual on the job needs to know and understand how to: SA1. complete accurately well written report in English language detailing the situations of emergency with attention to detail  
Reading Skills
The user/individual on the job needs to know and understand how to: SA2. read instructions/guidelines/procedures/rules  
Oral Communication (Listening and Speaking skills)
The user/individual on the job needs to know and understand how to: SA3. listen to and orally communicate information with all concerned  

Professional Skills

Decision Making
The user/individual on the job needs to know and understand how to: SB1. make decisions on a suitable course of action or response if permitted by the authority matrix .

Plan and Organise
The user/individual on the job needs to know and understand:
SB2. monitor efficient functioning of all activities
SB3. plan and organise work to achieve targets and deadlines
 
Customer Centricity
The user/individual on the job needs to know and understand how to:
SB4. communicate with passengers and other stakeholders in a courteous manner
SB5. maintain cordial work relationship
 
Problem Solving
The user/individual on the job needs to know and understand how to:
SB6. identify trends/common causes for errors and suggest possible solutions to the supervisor / management
SB7. identify and correct errors
 
Analytical Thinking
The user/individual on the job needs to know and understand how to:
SB8. analyse best possible solutions (cost, time, effort, etc.) suited for operations
 
 
Critical Thinking
The user/individual on the job needs to know and understand how to:
SB9. concentrate on task at hand and complete it without errors
SB10. apply balanced judgments to different situations
 
 




Carrying out pre-machining activities for composites
Performance Criteria
 
Understanding the assembly process
 
PC1. collect NC program with Controlled Copy from supervisor
PC2. verify part no., NC program no., & NC machining fixture no. and related revision & issue as mentioned in the route book
PC3. ensure NC trimming fixtures are certified and measuring instruments are calibrated
PC4. sand the burrs on the component if any so that it sits on the fixture properly, carry out manual reaming to ensure that locating pins enter in tooling holes
PC5. check raw condition of the material by referring inspection report
PC6. skim cut using manual programming in case of foam/core/composite master model machining cut the block as per NC setup sheet 
PC7. carry out basic maintenance of machine
PC8. clean the machine bed using vacuum cleaner and wipe with cloth
PC9. load the trim fixture on the machine bed after cleaning the bottom resting surface using oil stone and wipe with cloth. Ensure that there are no foreign objects present
PC10. load the cutting tools in tool holders and load the holders in the tool magazine as per NC set up sheet
PC11. measure the tool length and tool run-out for all tools and record in Log book. Ensure that tool run out is within the tolerance
PC12. clean the trim fixture with soft cloth and apply the grease (Molykote) on the seals and wipe gently. Ensure that seals are in proper condition & position
PC13. load the composite component manually or through hoist and position the same securely over the machining fixture. In case of vacuum fixture apply the vacuum, tap test, check gap using feeler gauge. Ensure vacuum pressure is minimum 700mbar. For mechanical clamping use Allen screw/ nut bolt
PC14. apply re-release agent on the component and apply quick setting adhesive to fill the gap between the component and fixture in order to avoid delamination
PC15. check & ensure correct work offset & Tool offset/Tool compensation, Tool number
PC16. check regularly for the tool bluntness, edge built up & chipping of tool cutting edges
 
PC17. check the quality of compressed air supply to the machine in order to avoid moisture ingress in composite parts/cores/foams
PC18. clearly understand the Dos & Don’ts of the manufacturing process as defined in SOP/work instructions or defined by supervisors
 
Knowledge and Understanding
 
 
Organisational
 
Context
KA1. relevant standards & procedures followed in the Company
KA2. different types of products manufactured
KA3. different types of composite parts/ tools available
KA4. process flow/ routing of various components in the composite shop/ organisation
 
Technical
Knowledge
KB1. different types of machining processes
KB2. different types of cutting tools, NC machining fixture, used in the machining process and their identification
KB3. reading of engineering drawings / setup sheets
KB4. basic knowledge of composite materials
KB5. basic fundamentals of machines & mechanics
KB6. how to read machine drawing and machining the part to create the output as defined in the machine drawing
KB7. all functions of CNC Machine, safety features, preliminary checking of the CNC Machine
KB8. interpretation of CNC programmes
KB9. tool presenter, CNC Tool holders and CNC Controllers
KB10. editing the CNC Programme on the Machine Control
KB11. knowledge on minor maintenance as per check list
KB12. basic principles of 5S manufacturing-cleaning, sorting, scrap handling etc.
KB13. application of coolant & lubricants
KB14. basic arithmetic and calculation methods for tolerance limits
 
 
Core Skills/ Generic Skills
Writing Skills
The user/ individual on the job needs to know and understand how to:
SA1. write basic level notes and observations
SA2. draw basic level drawings and charts
 
Reading Skills
The user/individual on the job needs to know and understand how to:
SA3. read and comprehend documents, manuals
SA4. interpret/ comprehend the information given in documents and monitoring tools
SA5. read and interpret symbols given on equipment’s and work area
SA6. read programs and interpret
 
Oral Communication (Listening and Speaking skills)
The user/individual on the job needs to know and understand how to:
SA7. discuss task lists and job requirements with co-workers
SA8. effectively communicate information to team members
SA9. interact with supervisor and understand the nature of problem
SA10. attentively listen with full attention and comprehend the information given by the speaker
 
 
 
Professional Skills
Decision Making
The user/ individual on the job need to know and understand:
SB1. judge when to ask help from supervisor
SB2. suggest options to developers in case of any issue is observed during operation.


Plan and Organise
The user/individual on the job needs to know and understand:
SB3. plan work assigned on a daily basis and provides estimates of time required for each piece of work
 
Customer Centricity
The user/individual on the job needs to know and understand how to:
SB4. ensure that customer needs are assessed and every effort is made to provide satisfactory service
 
Problem Solving
The user/individual on the job needs to know and understand how to:
SB5. recognise a work place problem or a potential problem and take action
SB6. determine problems needing priority action
SB7. gather information and provide assistance as required to solve problems
SB8. refer problems outside area of responsibility to approach person
 
Analytical Thinking
The user/individual on the job needs to know and understand how to:
SB9. analyse best possible solutions (cost, time, effort, etc.) sui ted for operations
 
Critical Thinking
The user/individual o n the job needs to know and understand how to:
SB10. analyse, evaluate and apply information gathered from observation, experience, reasoning or communication to act efficiently
 
 



Maintain 5S at the work premises
Performance Criteria
 
Setting up machine as per work instruction
 
PC1. verify part no., NC program no., & NC machining fixture no. and related revision & issue as mentioned in the route book
PC2. check & ensure correct work offset & Tool offset/Tool compensation in case of a CNC Machine
PC3. record datum’s before starting and after completion of part
PC4. check the sharpness of the cutting tools visually
PC5. dry run all the programs with close observation for the prove out of the part. Move axes to see whether spindle is colliding with the fixture/clamps/job &adjust accordingly. In case of any abnormality consult Supervisor/ NC Programmer
PC6. ensure the component is well supported in order to avoid exit delaminating in case of drilling
PC7. check regularly for the tool bluntness, edge built up & chipping of tool cutting edges
PC8. clearly understand the Dos & Donts of the manufacturing process as defined in SOP/work instructions or defined by Supervisors
 
Perform machining on the component
 
PC9. start the Turning/Milling/boring/drilling CNC Machine for operation
PC10. select the right cutting tools as per tooling instructions and as per work/Supervisor’s instruction
PC11. ensure the clear understanding of the properties of the composite parts for machining activities
PC12. ensure that the right command and programme number are entered in the CNC Machine as defined machining parameter
PC13. check machine Zero & work zero before start of the machine & after power failure
PC14. operate hand wheels/ control knobs in order to feed the component in case of manual machining operation
PC15. use dust extraction vacuum in order to evacuate composite debris and to cool the cutting tool
PC16. brush or spray lubricate material on work pieces where required
PC17. take appropriate action in case of any irregularities e.g.: Power failure, rejection, Tool breakage etc.
 
PC18. deburr the machined composite parts using emery sheets
PC19. execute radio probe programme in order to inspect the component in machine itself
PC20. offload the machined composite parts from the fixture/bed by using proper material handing device or by hand for small parts
PC21. use proper personal protective equipment’s (PPE)- Gloves, nose mask, goggles, cap, apron etc. while machining composites to ensure safety from composite dust
 
Observe/ record the machining operations
 
PC22. observe machine operations to detect defects if any in the component manufactured
PC23. observe the machine operations for any malfunctions and immediately inform the Supervisor/Maintenance Team of any malfunction observed to prevent damage to the machine or component
PC24. ensure recording of operational data such as pressure readings, length of strokes, feed rates, speed etc. in the format specified by the Supervisor
PC25. ensure tool replacement as per recommended tool life in number of pieces
PC26. ensure reading of key dimensions on control charts/SPC record; provide required tool offsetting with the help of supervisor on correct side based on the reading
 
Carrying out self inspection & 1st off inspection
 
PC27. ensure checking of the dimensions during the machining process considering the stock available
PC28. record the measured dimensions in the log book/control charts
PC29. check all dimensions after machining as per drawing & ensuring the correct dimensions
PC30. carry out any rework on the parts in case of deviations
PC31. ensure only calibrated instruments & gauges are used for inspection
PC32. first off proving by offering the 1st off part to the Inspector & getting it accepted before taking up the batch production
 
Knowledge and Understanding
 
 
Organisational
 
Context
KA1. relevant standards & procedures followed in the company
KA2. different types of products manufactured by the company
KA3. different bagging processes for different parts
KA4. process flow/ routing of various components in the composite shop/ organisation
 
Technical
Knowledge
KB1. different types of machining processes
KB2. different types of cutting tools, NC machining fixture, used in the machining process and their identification
KB3. reading of engineering drawings / setup sheets
KB4. details of basic composites
KB5. basic fundamentals of machines & mechanics
KB6. how to read machine drawing and machining the part to create the output as defined in the machine drawing
 
KB7. all functions of CNC Machine, safety features, preliminary checking of the CNC Machine
KB8. interpretation of CNC programmes
KB9. tool pre-setter, CNC Tool holders and CNC Controllers
KB10. editing the CNC Programme on the Machine Control
KB11. metal properties/metallurgy
KB12. gear changing technique and minor maintenance as per check list
KB13. basic principles of 5S manufacturing-cleaning, sorting, scrap handling etc.
KB14. application of coolant & lubricants
KB15. basic arithmetic and calculation methods for tolerance limits.
 
 
Core Skills/ Generic Skills
Writing Skills
The user/ individual on the job needs to know and understand how to:
SA1. write basic level notes and observations
SA2. draw basic level drawings and charts
 
Reading Skills
The user/individual on the job needs to know and understand how to:
SA3. Read and comprehend documents and manuals
SA4. Interpret/ comprehend the information given in documents and monitoring tools
SA5. Read and interpret symbols given on equipmen’s and work area
SA6. Read programs and interpret
 
Oral Communication (Listening and Speaking skills)
The user/individual on the job needs to know and understand how to:
SA7. discuss task lists and job requirements with co-workers
SA8. effectively communicate information to team members
SA9. question the supervisor in order to understand the nature of the problem and to clarify queries
SA10. attentively listen with full attention and comprehend the information given by the speaker
 
 
 
Professional Skills
Decision making
The user/ individual on the job needs to know and understand:
SB1. judge when to ask help from supervisor
SB2. suggest options to developers in case of any issue is observed during operation
 
Plan and Organise
The user/individual on the job needs to know and understand:
SB3. plan work assigned on a daily basis and provide estimates of time required for each piece of work
 
Customer Centricity
The user/individual on the job needs to know and understand:
SB4. ensure that customer needs are assessed and every effort is made to provide satisfactory service
 
Problem Solving
The user/individual on the job needs to know and understand how to:
SB5. recognise a work place problem or a potential problem and take action
SB6. determine problems needing priority action
SB7. gather information and provide assistance as required to solve proble ms
SB8. refer problems outside area of responsibility to approach person
 

Analytical Thinking
The user/individual on the job needs to know and understand how to:
SB9. analyse best possible solutions (cost, time, effort, etc.) suited for operations
 
Critical Thinking
The user/individual on the job needs to know and understand how to:
SB10. analyse, evaluate and apply information gathered from observation, experience, reasoning or communication to act efficiently.
 
 
Ensure sorting
 
PC1. follow the sorting process and check that the tools, fixtures & jigs that are lying on workstations are the ones in use and un- necessary 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 labeled 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
 
Ensure proper documentation and storage (organising, streamlining)
 
PC10. follow the proper labeling mechanism of instruments/ boxes/ containers and maintaining reference files/ documents with the codes and the lists
PC11. check that the items in the respective areas have been identified as broken or damaged
PC12. follow the given instructions and check for labeling 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
 
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 good condition 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
 
PC22. follow the daily cleaning standards and schedules to create a clean working environment
PC23. attend all training programs for employees on 5S
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
 
Technical
Knowledge
KB1. have basic knowledge of 5S procedures
KB2. know various types 5s practices followed in various areas
KB3. understand the 5S checklists provided in the department/ team
KB4. have skills to identify useful & non useful items
KB5. have knowledge of labels, signs & colours used as indicators
KB6. have knowledge on how to sort and store various types of tools, equipment, material etc.
KB7. how to identify various types of waste products
KB8. understand the impact of waste/ dirt/ dust/unwanted
KB9. substances on the process/ environment/ machinery/ human body
KB10. have knowledge of best ways of cleaning & waste disposal
KB11. understand the importance of standardization in processes
KB12. understand the importance of sustainability in 5S
 
KB13. have knowledge of TQM process
KB14. have knowledge of various materials and storage norms KB18. understand visual controls, symbols, graphs etc.
 
 
Professional Skills
Judgmental Thinking
The user/individual on the job needs to know and understand how to:
SB1. use common sense and make judgments during day to day basis
SB2. use reasoning skills to identify and resolve basic problems using 5S
 
Persuasion
The user/individual on the job needs to know and understand:
SB3. persuade co team members to follow 5 S
SB4. ensure that the co team members understand the importance of using 5S tool
 
Creativity
The user/individual on the job needs to know and understand:
SB5. use innovative skills to perform and manage 5S activities at the work desk and the shop floor
SB6. exhibit inquisitive behavior to seek feedback and question on the existing set patterns of work
 
Self-Discipline
The user/individual on the job needs to know and understand how to:
SB7. do what is right, not what is a popular practices
SB8. follow shop floor rules& regulations and avoid deviations; make 5S an integral way of life
SB9. ensure self-cleanliness on a daily basis
SB10. demonstrate the will to keep the work area in a clean and orderly manner
 
 
 
 
 Model Curriculum
Composite Repair Technician
 
Follow safety and security procedures
 
comprehend the organisation’s safety and security policies and procedures
 comprehend the regulatory guidelines on safe conduct of operations and maintenance of conditions to thwart any acts of unlawful interference
 report any identified breaches of safety, and security policies and procedures to the designated person
 coordinate with other resources at the workplace (within and outside the organization) to achieve safe and secure environment
 identify and mitigate any safety and security hazards like illness, accidents, fires or acts of unlawful interference if it falls within the limits of individual’s authority
 report any hazards outside the individual’s authority to the relevant person in line with organisational procedures and regulatory guidelines
 follow organisation’s emergency procedures for accidents, fires or acts of unlawful interference
 identify and recommend opportunities for improving health, safety, and security to the designated person
 complete all health and safety records are updates and procedures well defined
 
Carrying out pre-machining activities for composites
 
collect NC program with Controlled Copy from supervisor
 verify part no., NC program no., & NC machining fixture no. and related revision & issue as mentioned in the route book
 ensure NC trimming fixtures are certified and measuring instruments are calibrated
 sand the burrs on the component if any so that it sits on the fixture properly, carry out manual reaming to ensure that locating pins enter in tooling holes
 check raw condition of the material by referring inspection report
 cut the block as per NC setup sheet, skim cut using manual programming in case of foam/core/composite master model machining
 
carry out basic maintenance of machine
 clean the machine bed using vacuum cleaner and wipe with cloth
 load the trim fixture on the machine bed after cleaning the bottom resting surface using oil stone and wipe with cloth. Ensure that there are no foreign objects present
 load the cutting tools in tool holders and load the holders in the tool magazine as per NC set up sheet
 measure the tool length and tool run-out for all tools and record in Log book. Ensure that tool run out is within the tolerance
 clean the trim fixture with soft cloth and apply the grease (Molykote) on the seals and wipe gently. Ensure that seals are in proper condition & position
 load the composite component manually or through hoist and position the same securely over the machining fixture. Apply the vacuum, tap test, check gap using feeler gauge in case of vacuum fixture.
 Ensure vacuum pressure is minimum 700mbar. For mechanical clamping use Allen screw/ nut bolt
 Ensure the component is well supported in case of drilling.
 Apply re-release agent on the component and apply quick setting adhesive to fill the gap between the component and fixture in order to avoid delamination
 check & ensure correct work offset & Tool offset/Tool compensation, Tool number
 check regularly for the tool bluntness, edge built up & chipping of tool cutting edges
 check the quality of compressed air supply to the machine in order to avoid moisture ingress in composite parts/cores/foams
 ensure clear understanding the Dos & Don’ts of the manufacturing process as defined in SOP/work instructions or defined by supervisors
 
Performing different composites machining operations
 
verify part no., NC program no., & NC machining fixture no. and related revision & issue as mentioned in the route book
 check & ensure correct work offset &
 
Tool offset/Tool compensation in case of a CNC Machine
 record datum’s before starting and after completion of part
 check the sharpness of the cutting tools visually
 dry run all the programs with close observation for the prove out of the part. Move axes to see whether spindle is colliding with the fixture/clamps/job &adjust accordingly.
 Consult Supervisor/ NC Programmer in case of any abnormality.
 Ensure the component is well supported in order to avoid exit delaminating.
 check regularly for the tool bluntness, edge built up & chipping of tool cutting edges
 clearly understand the Dos &Donts of the manufacturing process as defined in SOP/work instructions or defined by Supervisors
 start the Turning/Milling/boring/drilling CNC Machine for operation
 select the right cutting tools as per tooling instructions and as per work/Supervisor’s instruction
 ensure the clear understanding of the properties of the composite parts for machining activities
 ensure that the right command and programme number are entered in the CNC Machine as defined machining parameter
 check machine Zero & work zero before start of the machine & after power failure
 operate hand wheels/ control knobs in order to feed the component in case of manual machining operation
 use dust extraction vacuum in order to evacuate composite debris and to cool the cutting tool
 brush or spray lubricate material on work pieces where required
 take appropriate action in case of any irregularities e.g.: Power failure, rejection, Tool breakage etc.
 deburr the machined composite parts using emery sheets
 execute radio probe programme in order to inspect the component in machine itself
 offload the machined composite
 
parts from the fixture/bed by using proper material handing device or by hand for small parts
 use proper personal protective equipment’s (PPE)- Gloves, nose mask, goggles, cap, apron etc. while machining composites to ensure safety from composite dust
 observe machine operations to detect defects if any in the component manufactured
 observe the machine operations for any malfunctions and immediately inform the Supervisor/Maintenance Team of any malfunction observed to prevent damage to the machine or component
 ensure recording of operational data such as pressure readings, length of strokes, feed rates, speed etc. in the format specified by the Supervisor
 ensure tool replacement as per recommended tool life in number of pieces
 ensure reading of key dimensions on control charts/S record; provide required tool offsetting with the help of supervisor on correct side based on the reading
 ensure checking of the dimensions during the machining process considering the stock available
 record the measured dimensions in the log book/control charts
 check all dimensions after machining as per drawing & ensuring the correct dimensions
 carry out any rework on the parts in case of deviations
 ensure only calibrated instruments & gauges are used for inspection
 proove the 1st off part to the Inspector & getting it accepted before taking up the batch production
 
Performing post machining operations for composites
 
compare datum’s after completion of part with the previous value
 deburr the machined composite parts using emery sheets
 cut the lugs manually. Round off sharp corners wherever required
 execute radio probe programme in order to inspect the component before unloading
 
measure cut-out dimension, thickness using Vernier calliper and micrometer
 offload the machined composite parts from the fixture/bed by using proper material handing device or by hand for small parts
 cover the machined component using bubble sheet
 clean the machine bed using vacuum cleaner and wipe with cloth
 switch off dust extraction system and vacuum supply after completion of machining
 record the measured dimensions in the log book/control charts
 check all dimensions after machining as per drawing & ensuring the correct dimensions
 carry out any rework on the parts in case of deviations
 
Maintain 5S at the work premises
 
the sorting process and check that the tools, fixtures & jigs that are lying on workstations are the ones in use and un- necessary items are not cluttering the workbenches or work surfaces.
 ensure segregation of waste in hazardous/ non Hazardous waste as per the sorting work instructions
 follow the technique of waste disposal and waste storage in the proper bins as per SOP
 segregate the items which are labeled as red tag items for the process area and keep them in the correct places
 sort the tools/ equipment/ fasteners/ spare parts as per specifications/ utility into proper trays, cabinets, lockers as mentioned in the 5S guidelines/ work instructions
 ensure that areas of material storage areas are not overflowing
 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
 return the extra material and tools to the designated sections and make sure that no additional material/ tool is lying near the work area
 follow the floor markings/ are a markings used for demarcating the various sections in the plant as per
 
the prescribed instructions and standards
 follow the proper labeling mechanism of instruments/ boxes/ co ntainers and maintaining reference files/ documents with the codes and the lists
 check that the items in the respective areas have been identified as broken or damaged
 follow the given instructions and check for labeling of fluids, oils, lubricants, solvents, chemicals etc. and proper storage of the same to avoid spillage, leakage, fire etc.
 make sure that all material and tools are stored in the designated places and in the manner indicated in the 5S instructions
 check whether safety glasses are clean and in good condition
 keep all outside surfaces of recycling containers are clean
 ensure that the area has floors swept, machinery clean and generally clean.
 Ensure that proper displays are maintained on the floor which indicate potential safety hazards in case of cleaning,
 check whether all hoses, cabling & wires are clean, in good condition and clamped to avoid any mishap or mix up
 ensure workbenches and work surfaces are clean and in good condition
 follow the cleaning schedule for the lighting system to ensure proper illumination
 store the cleaning material and equipment in the correct location and in good condition
 ensure self-cleanliness – clean uniform, clean shoes, clean gloves, clean helmets, personal hygiene
 follow the daily cleaning standards and schedules to create a clean working environment
 attend all training programs for employees on 5S
 support the team during the audit of 5 S
 participate actively in employee work groups on 5S and encourage team members for active participation
 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
 
 
Unique equipment used;
 personal protective equipment (PPE) (consisting of safety jacket, safety goggles, ear plugs, gloves, safety shoes & safety helmet)
 Specialist video/2D or 3D computer aided instructional packages
 typical turning/Milling/boring/drilling machines
 Turning/Milling/boring/drilling CNC Machines
 Common & special tool kits
 Common & special gauges and testers
 Fire extinguisher
 Ventilating equipment
 Mask
 Vacuum cleaner
 
 
 
Guidelines for Assessment
1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each 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 PC
2. The assessment for the theory part will be based on knowledge bank of questions created by the SSC
3. Individual assessment agencies will create unique question papers for theory part for each candidate at each examination/training centre (as per assessment criteria below)
4. Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/training center based on this criteria
5. To pass the Qualification Pack, every trainee should score a minimum of 70% in aggregate
6. The marks are allocated PC wise, however, every NOS will carry a weightage in the total marks allocated to the specific QP