Rita Charitable Trust

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

forgings-hammer- drop-forging- aerospace.jpg - Aubert&Duval Site

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:

  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.