Free Forging Operator Course (6Months)
Forging Operator
Brief Job Description
This role primarily involves managing the specifications of the metal bars, setting up and operating the machinery for forging and producing the output in line with the desired specifications.
Personal Attributes
Reading, writing and communication skills, ability to plan and prioritize, quality consciousness, safety orientation, Physique to sustain strenuous conditions, ability and desire to work in high temperature areas, ability to use fingers and both hands and feet with ease to complete the assigned task (Dexterity), high precision and sensitivity to problem solving 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
Understand job requirements and related processes:
Elements and Performance Criteria
Understand the work order and the process requirements
To be competent, the user/individual on the job must be able to:
PC1.. understand the work order ( work output) required from the process and discuss the same with the supervisor/ metallurgist
PC2.. refer all sketches/ work orders/ process related documents to understand dimensions and properties of the required work output
PC3.. understand the process requirements in terms of temperature of the furnace, cycle time for various temperature levels & time duration during the heating stages, pressing, cooling and quality check operations as mentioned in the work instruction/ sop/ control diagrams
PC4.. understand from the work instructions the type of die to be used for the forging process
PC5.. clearly understanding the does and donts of the manufacturing process as defined in SOPs/ work instructions or defined by supervisors
Arrange for the material to be forged and apparatus required for the same
To be competent, the user/individual on the job must be able to:
PC6.. understand forging techniques and their order of operations to be adopted for completing the work order from the supervisor by referring the work instruction document/ sop manual
PC7.. note down the various parameters like temperature of the furnace, cycle time for various temperature levels & time duration during the heating, pressing, cooling etc. before starting the process
PC8.. understand the material required (like metal bars for forging) and the equipment availability
i.e. dies, stampings, lifting equipment etc. for executing the activity
PC9.. ensure that the required material is procured from the store before starting the process
Clean the various machines involved in the forging process
To be competent, the user/individual on the job must be able to:
PC10.. ensure cleaning of dies by spraying or brushing surfaces with parting agents to ensure smoothness and prevent sticking or seepage
PC11.. ensure that the various machines like cutters, robots, presses, etc. are free from oil, grease, dirt at the start
PC12.. clean the area around the apparatus for any oil, grease, combustible substances etc. so as to prevent any accident
Check materials and apparatus for Operations
To be competent, the user/individual on the job must be able to:
PC13.. set the parameters in line with the work instructions/ sops
PC14.. setup the apparatus as per the selected forging requirements and the forging standards used in the automobile industry
PC15.. adjust the temperature, pressure and other parameters of the apparatus as per the values given in work instructions/ sops
Escalations of queries on the given job
To be competent, the user/individual on the job must be able to:
PC16.. refer the queries to a competent internal specialist if they cannot be resolved by the operator on own
PC17.. obtain help or advice from specialist if the problem is outside his/her area of competence or experience
PC18.. confirm self-understanding to the specialist once the query is resolved so that all doubts & queries can be resolved before the actual process execution
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. functional processes like Procurement, Store management, inventory management, quality management and key contact points for query resolution
KU4. different types of forging techniques like Hot forging, Warm Forging and Cold forging and the difference between different processes
KU5. different parameters pertinent to forging process like temperature of the furnace, cycle time for various temperature levels & time duration during the heating, pressing, cooling etc. and the impact of these parameters on the process and properties of output
KU6. different types of tools and machinery for forging
KU7. metallurgical properties of the metals used for the forging process
KU8. geometry and dimension measurement using various techniques
KU9. sketches and engineering drawings
KU10. final product output and hence decide on the key steps to be followed
KU11. different types of cleaning techniques, forging processes and associated equipment
KU12. measuring instruments like verniercalipers, micrometres
KU13. hazards and safety aspects involved in moulding activities and usage of relevant PPEs
Generic Skills (GS)
User/individual on the job needs to know how to:
GS1. note down observations (if any) related to heating and pressing of the metal bars and share the same with the supervisor
GS2. note down the production data for the respective shifts in the log sheets/ online ERP as per applicability in the organization
GS3. write drawings to internal customers on the requirement of apparatus, hand toolsetc.
GS4. read and interpret engineering drawing and sketches
GS5. read and interpret symbols and measurements instruments
GS6. read equipment manuals and process documents to understand the equipment and processes bette
GS7. read internal information drawings sent by internal customers ( other functions within the organization)
GS8. discuss task lists, schedules, and work-loads with co-workers
GS9. effectively communicate with the team members
GS10. question internal customers/ Forging shop supervisor appropriately in order to understand the nature of the problem and make a diagnosis
GS11. attentively listen with full attention and comprehend the information givenby the speaker
GS12. plan and organize the work order and jobs received from the internal customers
GS13. organize all process/ equipment manuals so that sorting out information is fast
GS14. support the supervisor in scheduling tasks for helper grade
GS15. use common sense and make judgments during day to day basis
GS16. use reasoning skills to identify and resolve basic problems
GS17. use intuition to detect any potential problems which could arise during operations
GS18. follow instructions and work on areas of improvement identified
GS19. complete the assigned tasks with minimum supervision
GS20. complete the job defined by the supervisor within the timelines and quality norms
GS21. detect problems in day to day tasks
GS22. support supervisor in using specific problem solving techniques and detailing out the problems
GS23. discuss possible solution with the supervisor for problem solving
GS24. make decisions in emergency conditions in case the supervisor is not available( as per the authority matrix defined by the organization)
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.
- In case of unsuccessful completion, the trainee may seek reassessment on the Qualification Pack.
