Free Equipment Designer Level 5 Course (6Months)
Equipment Designer Level 5:
Brief Job Description
Also known as Tool Designer .Individuals at this job need to design details of the equipment- mechanisms, fixtures, tools, gauges and other instruments for Manufacturing measuring the quality standards of the production process.
Personal Attributes
This job requires the individual to work independently and be judicious in making 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, imagination, oral expression, analytical approach, deductive reasoning and comprehension.
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
Maintain 5S at the work premises:
Scope
The individual needs to. Ensure sorting, streamlining & organizing, storage and documentation, cleaning, standardization and sustenance across the plant and office premises of the organization
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
Design, fixtures,workstation and its mechanisms:
Elements and Performance Criteria
Preparing thedrawings
To be competent, the user/individual on the job must be able to:
PC1. analyze the requirement for a new equipment such as workstation mechanisms within online gauge fixtures & associated parts tools & dies for Metal forming processes for facilitating the process of manufacturing for broad classification of process types such as assembly Process machining Process basic metal forming Casting, Forging, Sheet metal etc special processes- Polymer parts, welding, Surface/ Heat treatment
PC2. finalize the dimensions for the new equipment based on the process requirement, space constraints, aux. main equipment selected for the process by the Process Engineer
PC3. prepare the drawings for the required equipment using CAD software
PC4. share the drawings for the new equipment to the in house tool room or third party agency whichever applicable for preview & later for fabrication
PC5. use the equipment prepared above for process and identify the sequence of equipment operation
PC6. based on the sequence of operations and the manufactured product end requirements , devise the mechanism of working for the equipment
PC7. if required , use simulation software for understanding the equipment operation and review the drawings
PC8. in case of robotics/ automation application for equipment functioning , finalize the operation sequence program in consultation with the process engineer
PC9.. get the outline , dimensions and other details for selected equipment to be used such as motors, sensors, automation parts, etc. for layout preparation
PC10.. repeat the above process till the final equipment dimensions ,profile ,mechanism of operation etc. are finalized.
PC11. if required , in consultation with Process Designer/ manager use outside Tool Room agency for design , and manufacture of tools, fixtures . Transfer necessary layout & other information to such agency. Make sure that typical allowances for trimming, shrinkage and warpage etc. are considered based on past experience of the metal forming process.
PC12.. once finalized , then inform the in house tool room or third party agency for reviewing the complete equipment profile , dimensions and accordingly if required update the drawings
PC13. for any on-line gauges designed as part of this exercise ensure GD & T requirements are adhered to.
Knowledge and Understanding (KU)
The individual on the job needs to know and understand:
KU1. company manufacturing processes
KU2. sequence of operations
KU3. activity/ Process Flow
KU4. development Process in the organization
KU5. technical and functional requirements for tools, online gauges, fixtures etc.
KU6. all the economic factors involved in the activity
KU7. previous similar design & achieved data for QCT
Generic Skills (GS)
User/individual on the job needs to know how to:
GS1. read the equipment literature & understand its features.
GS2. compile all the data related to main & auxiliary equipment required in theprocesses
GS3. communicate with the equipment operator to take inputs for finalizing the drawings of the equipment
GS4. Communicate with third party consultants used for die design/ manufacture on simultaneous engineering basis.
GS5. share operation knowledge with co-workers
GS6. plan the execution of equipment designing activity ; long term and short term activities so that he can finish the task activity wise in the stipulated time
GS7. analyze the way in which job is being performed and think of some other suitable method in order to optimize the QCT while performing the work
GS8. co-ordinate and link practical aspects of own work as inputs for the designactivity
Release the drawings and manage the documentation for engineering change:
Elements and Performance Criteria
Release of tool drawings
To be competent, the user/individual on the job must be able to:
PC1.. complete the parts- list and drawings / specifications for all the items required for the Equipment.
PC2.. release the drawings of the equipment to Production department/ In House / external Tool Room as per SOP and monitor its development for any revisions, clarity required etc
PC3. in case of any problem encountered while development of the equipment, usage by Production during process , probe the reasons and if required , modify/re-design in coordination with in house tool room or third party agency, based on the severity of problem
Documentation for change management
To be competent, the user/individual on the job must be able to:
PC4. . case of an Engineering Change Note for a design change OR a process change for CA/ CI activity review the impact on fixture parts / mechanism and decide the action of Rework / re make based on cost and time available / production schedules on the equipmen Co-ordinate activities related to WIP , stocks during ECN Mnaagement ; record these on the ECN document
PC5. based on the above make the changes in drawing / part-list and order the parts/ rework with help of Validation/ Process engineer
PC6. make final changes in documentation after trials by validation agency are declared successful and release the change documents as per SOP
PC7. in consultation with the process engineer / CFT meeting output share the finalized documents for equipment & PF FMEA ,CP with the end users
Knowledge and Understanding (KU)
The individual on the job needs to know and understand:
KU1. company manufacturing processes
KU2. sequence of operations
KU3. norms established CP
KU4. technical and functional requirements for tools, online gauges,fixtures etc
KU5. all the economic factors involved in the activity
KU6. previous similar design & achieved data for QCT
KU7. PFMEA/CP/WI documents
KU8. APQP,PPAP
KU9. ECN/PCN documentation requirements
Generic Skills (GS)
User/individual on the job needs to know how to:
GS1. interpret and prepare the PFMEA/CP documents as per the TSrequirements
GS2. communicate with Production department for drawings releaseand equipment modification/re-designing
GS3. communicate with the process engineer for documents review
GS4. assist Production department if required for equipment operation
GS5. share operation knowledge with co-workers
GS6. coordinate and take inputs from the shop floor workers for devising alternative methods for work content reduction using the equipment
GS7. plan the equipment drawings release activity so that he can finish the activity in the stipulated time
GS8. equipment modification/re-designing
GS9. change in PFMEA/CP/WI documents in case of changemanagement
GS10. assess the problem, evaluate the possible solution(s) and use anoptimum /best possible solution(s)
GS11. identify immediate or temporary solutions to resolve delays andcrisis situations
GS12. how to learn from past mistakes to resolve technical and nontechnical problems
Assessment Guidelines:
- 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.
