Free In charge Material Testing Course (6Months)
In charge Material Testing:
Brief Job Description
Individuals at this job need to administer metallurgical testing, physical & chemical testing and failure analysis of materials for fabrication of parts and other components that finally go into Manufacturing of different products.
Personal Attributes
The individual should be willing to working a laboratory environment for long hours. The individual should possess strong decision making skills. The individual should also be able to demonstrate skills for mathematical reasoning, critical thinking, technology design and comprehension.
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
Ensure implementation of 5S activities at the shop floor & the office area:
Elements and Performance Criteria
Ensure proper sorting of items at the work place
To be competent, the user/individual on the job must be able to:
PC1.. ensure all recyclable materials are put in designated containers
PC2. ensure no tools, fixtures & jigs are lying on workstations unless in use and no un-necessary items is lying on workbenches or work surfaces unless in use
PC3. ensure that the operators and other team members are segregating the waste in hazardous/ non hazardous waste as per the sorting work instructions
PC4. ensure that all the operators are following the technique of waste disposal and waste storage in the designated bins
PC5.. segregate the items which are labelled at red tag items for the process area and keep them in the correct places
PC6.. ensure that all the tools/ equipment/ fasteners/ spare parts are arranged as per specifications/ utility into proper trays, cabinets, lockers as mentioned in the 5s guidelines/ work instructions
PC7. check for return of any type of extra material and tools to the designated sections and make sure that no additional material/ tool is lying near the work area
PC8. . oversee removal of unnecessary equipment, storage, furniture, unneeded inventory, supplies, parts and material
PC9. ensure that areas of material storage areas are not overflowing
PC10. ensure proper stacking and storage of 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
Ensure proper documentation and storage – streamlining & organizing the workplace
To be competent, the user/individual on the job must be able to:
PC11. ensure that the team follows the given instructions and checks for labelling of fluids, oils lubricants, solvents, chemicals etc and proper storage of the same to avoid spillage, leakage, fire etc
PC12. make sure that all material and tools are stored in the designated places and in the manner indicated in the 5s instructions
PC13. ensure that organizing the workplace takes place with due considerations to the principles of wasted motions, ergonomics, work & method study .
Ensure cleaning of self and the work place
To be competent, the user/individual on the job must be able to:
PC14. ensure that the area has floors swept, machinery clean and is generally neat and tidy in case of cleaning, ensure that correct displays are maintained on the floor which indicate potential safety hazards
PC15.. ensure workbenches and work surfaces are clean and in good condition
PC16.. ensure adherence to the cleaning schedule for the lighting system to ensure proper illumination
PC17.. ensure all recyclable materials are put in designated containers
Ensure standardization
To be competent, the user/individual on the job must be able to:
PC18. ensure that daily cleaning standards and schedules to create a clean working environment are followed across the plant
PC19.. ensure all recyclable materials are put in designated containers
PC20. . ensure logical and user friendly documentation and file management for all activities across the plant and create guidelines around standardization of processes
PC21. ensure timely creation and sharing of the 5s checklists
PC22. ensure that the 5s manual are available as per the timelines Ensure sustenance
To be competent, the user/individual on the job must be able to:
PC23. ensure team cooperation during the audit of 5 s activities
PC24. ensure that workmen are periodically trained to address challenges related to 5s
PC25.. participate actively in employee work groups on 5s and encourage team members for active participation
PC26.. oversee that the staff/operators are trained and fully understand 5s procedures
PC27. . ensure that all the guidelines for what to do and what not to do to build sustainability in 5s are mentioned in the 5s check lists/ work instructions and are easily searchable
PC28. ensure continuous training of the team members on 5s in order to increase their awareness and support implementation
PC29. ensure that all visual controls, notice boards, symbols etc at the manufacturing place are created, working and are put up as per the requirement
Knowledge and Understanding (KU)
The individual on the job needs to know and understand:
KU1. relevant standards, procedures and policies related to 5Sfollowed 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. Have 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/unwantedsubstances on the process/ environment/ machinery/ humanbody
KU10. have knowledge of best and environment protective ways ofcleaning & 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. write information documents to internal departments/ internal teams
GS4. read 5S instructions put up across the plant premises
GS5. effectively communicate information to team members inform employees in the plant and concerned functions about 5S
GS6. question the process head in order to understand the 5S related issues
GS7. attentively listen with full attention and comprehend the information given by the speaker during 5S training programs
GS8. use common sense and make judgments during day to day basis
GS9. use reasoning skills to identify and resolve basic problems using 5S
GS10. persuade team members to follow 5 S
GS11. ensure that the team members understand the importance of using 5 S tool
GS12. use innovative skills to perform and manage 5 S activities at the work desk and the shop floor
GS13. exhibit inquisitive behaviour to seek feedback and question on the existing set patterns of work emerge, techniques in CA/CI around 5 S work practices
GS14. do what is right, not what is a popular practice
GS15. follow shop floor rules& regulations and avoid deviations
GS16. lead by example in the plant premises while performing activities related to 5S
GS17. ensure self-cleanliness on a daily basis
GS18. demonstrate the will to keep the work area in a clean and orderly manner
GS19. accept additional responsibility for self and the team
GS20. encourage self and other to take greater responsibilities for managing 5S
GS21. identify obstacles and bottlenecks in the process and find basic level solutions for removing these obstacles
GS22. use previous experience in resolving problems and taking decisions
GS23. make timely and independent decisions on the line/ shift within the boundaries of the delegation matrix of the organization
Perform testing and validation of materials:
Elements and Performance Criteria
Metallurgical and chemical testing
To be competent, the user/individual on the job must be able to:
PC1.. maintain laboratory for performing testing and validation activities for materials of construction for various parts/components that are fitted into the final product like engine, chassis , forging and machining, suspension , brakes etc.
PC2.. ensure that the laboratory is well equipped to perform testing of materials like material confirmation,microstructure analysis, surface/material defects, hardness, tensile strength etc.
PC3.. ensure that the sample of each part/component has been prepared based on the process requirements
PC4.. monitor the procedures for performing tests being done by associates and ensure strict compliance to hse requirements
PC5.. discuss with each associate the test findings and ensure its documentation&communication
.
PC6.. coordinate with the process owner and establish traceability upto the validation samples so that results can be co-related.
PC7.. ensure that the testing and validation results are being documented as per the ISO/IEC17025/NABL requirements
PC8.. in case , the material is non-conforming , then quarantine it and participate to perform failure analysis of the material in its manufacturing process.
Failure analysis
To be competent, the user/individual on the job must be able to:
PC9.. ensure that the data pertaining to the suspected material for field failures has been collated properly for further analysis
PC10.. ensure that the associates are having all the process documents pertaining to the suspected material like PFMEAs , failure reports , material inspection reports etc.
PC11.. based on the criticality and failure occurrence of the suspected failed part/component , decide the method of failure analysis; destructive testing or non destructive testing( NDT)
PC12.. in case of destructive testing ,ensure the cutting of a section of the suspected part and perform the testing like corrosion analysis , stress analysis etc.
PC13.. while in case of ndt ,ensure usage of techniques like electromagnetic radiation , spectroscopy , sound etc. for examining the suspected material
PC14.. in both cases ,jointly analyze, validate and ensure the documentationof the results
PC15.. discuss the findings with r&d department and seek their inputs
PC16.. based on the discussions inform the concerned process department and ensure that in case of rejection , the complete batch of the rejected material part is quarantined/ recalled.
PC17.. in case of rejection , internally with team perform testing and decide the most conforming material for the part in discussions with sourcing and r&d
PC18.. finalize the material and accordingly based on validation , approve the material of sample part and generate a process change note (PCN) in SAP/ERP for implementation of the new material part
Resource management New Technology
To be competent, the user/individual on the job must be able to:
PC19.. recruit sufficient amount of staff in coordination with hr department for carrying out the various activities in material lab department
PC20.. ensure that the new joinare trained by the existing staff members in an efficient and timely manner and talent to practice various techniques are available.
PC21.. follow up with QA/ senior management for requirement of new testing equipments
PC22.. procure new equipmentsas per requirement and monitor the working, calibration and maintenance of existing equipments
PC23.. be in touch with new developments in evaluation techniques, materials etc and factor these at appropriate stages viz new developments, recruitments
Knowledge and Understanding (KU)
The individual on the job needs to know and understand:
KU1. product portfolio of organization
KU2. the manufacturing processes of organization
KU3. the list of approved vendors for the outsourced materials
KU4. protocol for communication regarding change of material for an outsourced material
KU5. Personnel and other HR policies of the organization
KU6. raw materials being used for manufacturing of each product
KU7. physical, chemical and metallurgical properties of each material
KU8. storage conditions required for each material
KU9. material handling equipments used for loading and unloading activity
KU10. testing and validation techniques used
KU11. failure analysis techniques used for examining materials samples
KU12. ISO/IEC17025/, NABLsystem requirements
KU13. information systems like SAP, ERP etc.
Generic Skills (GS)
User/individual on the job needs to know how to:
GS1. read and understand the usage of different tools and techniques for material testing
GS2. interpret the analysis reports for various failures like stress , corrosion etc
GS3. document all the testing and validation activities findings in form of MS Word documents , MS Excel spreadsheets etc.
GS4. communicate with the concerned departmentsfor gathering part/component failure data
GS5. follow upwith team members for monitoring the progress of activities
GS6. conduct meetings with R&D head/top management in case of any issues pertaining to results obtained
GS7. ensure that the corrective actions are implemented at both department and vendors end for resolution of non-conformities pertaining to material of the part/component
GS8. distribute workload among team members for ensuring testing and validation of material in a timely and efficient manner
GS9. share operation knowledge with colleagues
GS10. work on actions to be taken on immediate basis in case of frequent material rejections
GS11. work on the corrective and preventive actions for resolution of nonconformities pertaining to defective material
GS12. identify problems (technical and non-technical), disruptions and delays
GS13. identify cost effective methods of testing and examination of the material of sample part
GS14. take external support for technique/ equipment required but not available within the organization
Develop alternate material for improving the product quality:
Elements and Performance Criteria
Analysis of customer requirements
To be competent, the user/individual on the job must be able to:
PC1.. ensure the collection of data pertaining to the field failures of various parts/components due to material , PND- customer requirements, sor etc. from marketing and R&D department
PC2.. analyze the failure data and identify thepart ,type of material failed and frequency of failure
PC3.. based on analysis of failure data , prepare the list of non-conforming parts and select the most frequent and high cost value part
PC4.. keeping in view the customer requirements , prepare a database of the most conforming material for the part in consideration based on the application
PC5.. compare the identified materials with respect to physical , chemical properties , unit cost , performance improvement , availability etc. and select the most viable material for the part
PC6.. with support from the design team re-develop the drawings/ specifications of the part considering the results on the new material
Development and validation
To be competent, the user/individual on the job must be able to:
PC7.. collaborate with sourcing department and convene a meeting with the part supplier
PC8.. share with the supplier the new drawing of the part in SAP/ERP/PLM and communicate the requirements
PC9.. if required , seek inputs from supplier and finalize the drawings of the new material part
PC10.. discuss with the supplier the cost implications and accordingly finalize the commercial terms
PC11.. accordingly finalize a schedule for new material development and ensure its strict
adherence
PC12.. coordinate with sourcing department and ensure the development of the sample part with the new material
PC13.. in coordination with team , perform the various tests as per the standard operating procedures complying to the hse requirements
PC14.. validate the results obtained and in coordination with supplier ensure the resolution of the discrepancies
PC15.. document the results for the validation and share it with the r&d department and senior management ; participate in decision making process.
PC16.. participate , co-ordinate in the documentation/ release process with the design team with appropriate inputs
PC17.. monitor the new material performance by regularly analyzing the performance of the part during process and field by capturing the data from concerned departments
Knowledge and Understanding (KU)
The individual on the job needs to know and understand:
KU1. product portfolio and product mix of organization
KU2. the manufacturing processes of organization
KU3. vendor database for all the materials sourced by organization
KU4. protocol for communication regarding new materials development among the various departments of the organization
KU5. raw materials being used for manufacturing of each product
KU6. physical and chemical properties of each material
KU7. storage conditions required for each material
KU8. database for information aboutmaterials used
KU9. testing and validation techniques used
KU10. failure analysis techniques used for examining materials samples
KU11. ISO/IEC17025/, NABL system requirements
Generic Skills (GS)
User/individual on the job needs to know how to:
GS1. understand the data pertaining to the customer requirements
GS2. interpret the analysis reports for capturing information about the nonconforming parts
GS3. document all the testing and validation activities findings pertaining to ne material development in form of MS Word documents , MS Excel spreadsheets etc
GS4. communicate with the concerned departments for gathering part/component failure data
GS5. follow up with team members for monitoring the progress of activities
GS6. conduct meetings with R&D head/top management in case of any issues pertaining to results obtained
GS7. ensure that the corrective actions are implemented at both department and vendors end for resolution of non-conformities pertaining to new material sample part validation
GS8. communicate with the R&D department for discussion the findings of sample part validation
GS9. coordinate with various departments and ensure requisite data availability for field failures, customer complaints, warranty issues pertaining to failed material partetc
GS10. distribute workload among team members to ensure timely completion of new material development activity
GS11. share operation knowledge with colleagues
GS12. identify the best alternate material for a frequently failing part/component
GS13. resolve the discrepancies arising in new material sample part
GS14. identify problems (technical and non-technical), disruptions and delays
GS15. use escalation procedures
GS16. Keep abreast of special events such as holidays/ work calendars / maintenance shutdowns of suppliers& organization and plan accordingly so that the final schedules are adhered to
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.
