Free Furnace Operator Course (6Months)

Furnace Operator:

Brief Job Description

This role is responsible for loading of jigs/ work pieces into the furnace, maintaining process parameters as laid down in the Work Instructions/ SOPs, maintaining cycle time for different heat treatment phases , ensure proper quenching of the components and unloading the finished pieces into the designated area.

Personal Attributes

Technical knowledge of Metallurgy and heat treatment process, Reading, writing and communication skills, ability to plan and prioritize, quality consciousness, safety orientation, Dexterity, high precision, no colour blindness, ability and desire to work in difficult workplace involving high heat, ability to lift heavy work pieces.

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

Conduct regular cleaning and maintenance of the equipment:

Elements and Performance Criteria

Storing equipment in proper condition

To be competent, the user/individual on the job must be able to:

PC1..    arrange all equipment in a proper order as indicated in the equipment manual

PC2. . store equipment auxiliaries and spare parts in proper designated areas

PC3..    clearly tag process related equipment parts/ spare parts as per part number or serial number so that sorting of equipment becomes easy

PC4.     cover equipment so that there is limited dust collection and moisture contact

Regular cleaning of the equipments and work area

To be competent, the user/individual on the job must be able to:

PC5.     regularly clean the equipment and process auxiliaries to remove any dust, moisture, waste material which would have got collected on the equipment

PC6.     regularly open the equipment and clean the internal parts of the equipment

PC7.     regularly clean the working area under the process and create a healthy, clean and safe working environment

Conduct regular preventive maintenance of equipments

To be competent, the user/individual on the job must be able to:

PC8..    check the working of all bearing, rollers, shafts etc and oil all moving parts of the equipment on a periodic basis

PC9..    check the working of non moving parts and periodically conductpreventive maintenance to prevent machine failure

PC10. periodically check the equipment calibration and report any errors to the maintenance teams for rectification

Recording observations and preparing MIS

To be competent, the user/individual on the job must be able to:

PC11. prepare periodic log sheets of equipment maintenance dates, maintenance schedules and maintenance activity conducted on the equipment

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1. relevant standards and procedures followed in the company for the process of maintenance and equipment storage

KU2. functional processes like Procurement, Store management, inventory management, quality management and key contact points for query resolution

KU3. basic level maintenance and cleaning techniques

KU4. various solvents, chemicals, lubricants etc. used during the maintenance processes

KU5. procedure for arranging the equipment and spare parts in the prescribed manner including tagging and numbering of machine parts & spares

KU6. safety precautions to be taken during cleaning and maintenance activities

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1.     note equipment part codes, name tags etc. in the prescribed formats and records for the same

GS2.     note observations related to equipment performance, breakdown, cleaning and maintenance schedules etc. in the prescribed MIS format

GS3.     read equipment manuals and process documents to understand the equipment and processes better

GS4.     read instructions especially safety instructions related to equipment cleaning and maintenance

GS5.     discuss task lists and job requirements with co-workers

GS6.     effectively communicate information to team members

GS7.     listen and analyse any noise and vibrations in the equipment and report the same to the maintenance team for preventive action

GS8.     attentively listen with full attention and comprehend the information given by the speaker

GS9.     plan and organize the work order and jobs received from the Operator

GS10. organize all process/ equipment manuals so that sorting/ accessing information is easy as per the part/ machine number in the specified format in the designated area

GS11. use common sense and make judgments during day to day basis

GS12. 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 the 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. .     clearly understanding the does and donts of the manufacturing process as defined in sops/ work instructions or defined by supervisors

PC3. .     refer all sketches/ work orders/ process related documents to understand dimensions and properties of the required work output

PC4. .     understand the process requirements in terms of temperature of the furnace, pressure, cycle time for various temperature levels & time durations during the heat treatment operations as mentioned in the work instruction/ sop/ control diagrams

Arrange for the components to be heat treated as well as the combustion material as per the process requirement

To be competent, the user/individual on the job must be able to:

PC5..      understand the right heat treatment procedure and process to be adopted for completing the work order from the supervisor by referring the work instruction document/ sop manual

PC6. .     note down the various heat treatment parameters like temperature, pressure, cycle time, gas flow, coolant/ water flow before starting the heat treatment process

PC7. .     understand the material required and the equipment availability for executing the activity

PC8. .     ensure that the required material is procured from the store before starting the heat treatment process

Clean the furnace and the components before executing the heat treatment process

To be competent, the user/individual on the job must be able to:

PC9. .     ensure that the internal part of the furnace used for carburizing, tempering, annealing etc. process is cleaned before the starting of the process

PC10. . ensure that there are not traces of oil, grease, dirt in the heat treatment process at the start

PC11..    clean the area around the furnace for any oil, grease, combustible substances etc. so as to prevent any accident in the furnace surrounding

PC12..    clean the components which will required to be treated so as to remove traces of greases, oil, dirt etc.

Applying anti carburizing paste on surface which is not to be hardened

To be competent, the user/individual on the job must be able to:

PC13. . wash the components which need to be heat treated using an organic solvent

PC14. . ensure that all the oil which is present in the components is removed

PC15..    uniformly apply anti carburizing paste on the area which is not to be carburized

PC16. . ensure that the applied paste dries within the timelines mentioned in the work instructions

PC17. . ensure that the components are picked up and placed in the proper trolley and are ready to be heat treated

Check furnace auxiliaries for operations

To be competent, the user/individual on the job must be able to:

PC18..    ensure that the gas flow and water flow valves are operating without any hindrances and the pipes carrying gas and water are free from any roadblocks

PC19..    ensure that the furnace cover can be opened and closed whenever required

PC20. . ensure that the furnace loading and unloading mechanism is in order and working properly

Escalations of queries on the given job

To be competent, the user/individual on the job must be able to:

PC21..    refer the queries to supervisor/ metallurgist if they cannot be resolved by the operator

PC22. . confirm self – understanding to the supervisor/ metallurgist 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 heat treatment processes and associated equipment

KU5.     different types of furnaces and process nuances for each type of heat treatment process

KU6.     basic knowledge of the metallurgical properties of the material

KU7.     relationship between various process parameters like furnace temperature, pressure, carbon potential, gas flow for endothermic process, Cycle time for heating during the heat treatment process

KU8.     how to handle solvents and anti-carburizing paste

KU9.     basic principles of geometry and drawing

KU10. safety aspects associated with furnace operations and heat treatment process and use of relevant PPEs for each process

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1.     note down observations (if any) related to heat treatment process and share the same with the supervisor/ metallurgist

GS2.     note down the production data for the respective shifts in the log sheets/ online ERP as per applicability in the organization

GS3.     read and interpret engineering drawing and sketches

GS4.     read and interpret symbols and measurements instruments

GS5.     read equipment manuals and process documents to understand the equipment and processes better

GS6.     read internal information documents send by internal customers ( other functions within the organization)

GS7.     discuss task lists, schedules and activities with the supervisor

GS8.     effectively communicate with the team members

GS9.     question the supervisor/ metallurgist in order to understand the nature of the problem and to clarify queries

GS10. attentively listen with full attention and comprehend the information given by the speaker

GS11. plan and organize the work order and jobs received from the supervisor

GS12. organize all process/ equipment manuals so that sorting/ accessing information is easy

GS13. support the supervisor in scheduling tasks for helper grade

GS14. ability to visualize the final job product after understanding the given drawing/ sketches

GS15. co relate the type of job output required ability to identify the strengths and weakness of various heat treatment related process

GS16. use common sense and make judgments during day to day basis

GS17. use reasoning skills to identify and resolve basic problems

GS18. use intuition to detect any potential problems which could arise during operations

GS19. follow instructions and work on areas of improvement identified

GS20. complete the assigned tasks with minimum supervision

GS21. complete the job defined by the supervisor within the timelines and quality norms

GS22. detect problems in day to day tasks

GS23. support supervisor in using specific problem solving techniques and detailing out the problems

GS24. discuss possible solution with the supervisor for problem solving

GS25. make decisions in emergency conditions in case the supervisor is not available( as per the authority matrix defined by the organization)

Operate different furnaces and conduct the heat treatment process:

Elements and Performance Criteria

Load the Charge into the Furnace

To be competent, the user/individual on the job must be able to:

PC1. .     open the furnace cover and check the furnace internally for any impurities/ material from the previous heat treatment process

PC2. .     ensure that the furnace checking is done using a torch and not using any combustible material like match stick, fire etc.

PC3. .     once the furnace is inspected, load the furnace with the charge material ( components to be heat treated) using hoists, conveyors etc.

Carburise the charge loaded in the furnace

To be competent, the user/individual on the job must be able to:

PC4. .     once the loading is completed and the furnace thoroughly checked, close the door of the furnace

PC5..      select the right program from the list for the carburizing process/ tempering process as per the instructions given in the sop manual/ work instructions

PC6. .     switch on the furnace and ensure that the furnace temperature reaches the desired temperature as per the sops/ work instructions

PC7. .     ensure that the cycle time for furnace temperature is maintained throughout the process. the cycle time for each process is mentioned in the process work instructions

PC8..      ensure that the furnace fan operations is in the on mode and air circulation is as per requirement

PC9. .     once the temperature in the furnace reaches the desired value, switch on the carburising valve and ensure the flow of the carburizing fluid within the furnace

PC10..    regularly monitor the temperature of the furnace and the gas composition

PC11..    once the cycle time is completed, ensure that the carburising valve of the furnace is closed

PC12. . ensure that the material is carefully removed from the furnace and unload the material in the tray for the quenching process

Temper the charge in the tempering furnace

To be competent, the user/individual on the job must be able to:

PC13..    once the loading is completed and the furnace thoroughly checked, close the door of the furnace

PC14. . switch on the furnace and ensure that the furnace temperature reaches the desired temperature as per the sops/ work instructions

PC15..    maintain the furnace temperature and the furnace cycle time as per the process chart/ work instructions/ sops

Monitor the Heat Treatment process

To be competent, the user/individual on the job must be able to:

PC16. . ensure constant monitoring of temperature indicators, flow meters, heat exchangers, display panels for process operations

PC17. . periodically monitor the flame pipe, gas outlets, water inlets and water outlets for proper operations

PC18. . periodically monitor the carbon potential % during the heat treatment process

PC19. . periodically take readings at various intervals ( as per the cycle time) in the format as mentioned in the work instructions/ internal guidelines

PC20..    periodically monitor the furnace of any vibrations during operations

PC21..    inform the maintenance team of any issues observed in the furnace operations

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 heat treatment processes and associated equipment

KU5.     different types of furnaces and process nuances for each type of heat treatment process

KU6.     basic knowledge of the metallurgical properties of the material

KU7.     relationship between various process parameters like furnace temperature, pressure, carbon potential, gas flow for endothermic process, Cycle time for heating during the heat treatment process

KU8.     how to read displays on the computer monitor and understand the information being displayed

KU9.     understand various alarms and signals in the furnace and the action required for each type of alarm

KU10. methods for lifting and loading/unloading the metal components in the furnace

KU11. basic troubleshooting techniques for the furnaces

KU12. basic principles of geometry and drawing

KU13. safety aspects associated with furnace operations and heat treatment process and use of relevant PPEs for each process

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1.     document information from the sketches and engineering drawings

GS2.     prepare draft drawings for the final output product

GS3.     note down observations (if any) related to the heat treatment process

GS4.     write information documents to internal departments/ internal teams or enter the information in online ERP systems under guidance of the supervisor

GS5.     read and interpret engineering drawing and sketches

GS6.     read and interpret symbols and measurements used in the drawings

GS7.     read equipment manuals and process documents to understand the equipment and processes better

GS8.     read internal information documents sent by internal teams

GS9.             discuss task lists, schedules and activities with the supervisor

GS10. effectively communicate with the team members

GS11. question the supervisor in order to understand the nature of the problem and to clarify queries

GS12. attentively listen with full attention and comprehend the information given by the speaker

GS13. plan and organize the work order and jobs received from the operator

GS14. organize all process/ equipment manuals so that sorting/ accessing information is easy

GS15. support the supervisor in scheduling tasks for helper and assistant operator

GS16. use common sense and make judgments during day to day basis

GS17. use reasoning skills to identify and resolve basic problems

GS18. use intuition to detect any potential problems which could arise during operations

GS19. follow instructions and work on areas of improvement identified

GS20. complete the assigned tasks with minimum supervision

GS21. complete the job defined by the supervisor within timelines and quality norms

GS22. detect problems in day to day tasks

GS23. support supervisor in using specific problem solving techniques and detailing out the problems

GS24. discuss possible solution with the supervisor for problem solving

GS25. 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.