Rita Charitable Trust

Free Layout Engineer Level 5 Course (6Months)

Layout Engineer Level 5:

Brief Job Description

Individuals at this job need to design, develop and implement the integrated facility layouts for the organization by planning and positioning employees, materials, machines, equipments andother Manufacturing supports and facilities for minimization of waste and material handling cost; thereby providing smooth flow of work, material andinformation throughout the organization.

Personal Attributes

This job requires the individual to work independently and be judicious in making decisions pertaining to his/her area of work. The individual should be result oriented. The individual should also be able to demonstrate skills for information ordering, oral expression, mathematical and deductive reasoning, artistic and spatial skills along with comprehension. The individual should be willing to work at shop floor based job for long hours.

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

GMC 550

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

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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

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Analyze the flow of men, machine, material and information in the process:

Elements and Performance Criteria

Analysis of the machinery and manpower

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

PC1..    study the existing shop floor layout in-depth being used for the manufacturing process and gather inputs pertaining to the floor area, no of workstations, type of machinery used etc.

PC2..    measure the dimensions of the machinery and equipments and calculate the area occupied

PC3..    get similar details in respect of npd (new product development)

PC4..    study the manpower allocation plan thoroughly and collect key insights about the workforce requirements and the nature of work being done by them

PC5..    record the observations for further analysis.

PC6..    participate in the trials with process engineers for validation

Study of the material movement within the process

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

PC7..    understand the complete material flow in the process starting from receipt of raw materials till delivery of finished product

PC8..    analyze the conditions that would be required for storage of various process materials and also study the existing facility being used for it

PC9..    collect all the information related to the material handling facilities that are/would be in use for the process

PC10.. record all these observations for further analysis.

Assessment of information flow

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

PC11.. interact with the shop floor workers and prepare a complete flow chart depicting the flow of information throughout the process and also gain knowledge about the media in use for it.

PC12.. record all these observations for further analysis

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.    company manufacturing processes

KU2.    existing layout for the processes

KU3.    sequence of operations for each process

KU4.    facility planning methodology being followed in the company

KU5.           future capacity expansions plans (if any) of the company

KU6.           complete knowledge of the process in consideration

KU7.    dimensions and type of the existing facility being used for the process

KU8.    engineering drawings of existing layout

KU9.    operation of machinery and equipments being used for the process

KU10. manpower deployment plan for process

KU11. material and information flow of the process

KU12. capacity utilization levels and the cost of manufacturing being incurred

KU13. media of information flow like SAP , ERP etc.

Generic Skills (GS)

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

GS1.   read the information displayed at the workplace

GS2.   draft a pictorial representation of the existing layout for better comprehension

GS3. compile all the data related to study of existing facility in the form of presentations and reports

GS4.    communicate with shop floor workers gathering inputs/requirements

GS5. spell out effectively the findings of the study to the higher management in meetings

GS6. interact with workers and gather all the information related to process requirements

GS7. share operation knowledge with co-workers

GS8.    coordinate with the facility planning department team and ensure timely analysis for layout designing

GS9.    collate data from various third parties involved (if any) in existing facility design and development

GS10. plan the execution of requirements study for layout design in an effective manner and on timely basis

GS11. analyze the way in which the existing facility layout is in operation and think of more economic and feasible measures for existing layout modification/redesigning

Design the model layout for the process and validate:

Elements and Performance Criteria

Preparation of blueprint

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

PC1..    based on the inputs obtained from the study of existing facility layout , contemplate changes for new layout

PC2..    prepare a blueprint of the new layout by measuring and studying available floor space and henceforth drawing plan of floor space to scale, using drafting tools

Development of model layout

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

PC3..    coordinate all available knowledge and information into blueprint, showing most efficient location for each piece of equipment and necessary working area and prepare a master layout

PC4..    draft a production process model ensuring minimization of the distance traveled, backtracking, cross traffic, and production costs

PC5..    build the facility model ensuring addressing of factors like adequate number of workstations, correct work height, appropriate lighting, and enough operator space in co- ordination with process design engineers (NPD)

PC6..    integrate the two and prepare the working model for new facility

Simulation of model layout

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

PC7..    validate the model facility layout using the latest simulation techniques

PC8..    identify the mistakes/areas of improvement in the layout and take appropriate rectification measures

PC9..    implement the measures and re-simulate the modified layout

PC10.. repeat the first three steps till the model layout is free from any discrepancies

Compliance to design standards

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

PC11.. ensure that the guidelines mentioned in facility designing standards are strictly adhered to for preparation of the model layout

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.    company manufacturing processes

KU2.    existing layout for the processes

KU3.    facility designing standards followed in the organization

KU4.    third parties (if any) involved in construction of facilities for the organization

KU5.    facility planning methodology being followed in the company

KU6.    complete knowledge of the process in consideration

KU7.    type of the layout to be developed like product, process, U type etc.

KU8.    engineering drawings of existing layout

KU9.    operation of machinery and equipments being used for the process

KU10. complete knowledge of material and information flow for the process

KU11. latest simulation techniques used for validation of model layouts

Generic Skills (GS)

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

GS1.    compile all the data related to layout design and development in form of reports and presentations

GS2.    understand the drawings of layout

GS3.    communicate the new layout design and development to the higher management in meetings for their support

GS4.    interact with workers and gather all the information related to process requirements

GS5.    coordinate with the facility planning, process engineering department team and ensure model layout designing on timely basis

GS6.    collate resources from various third parties involved (if any) for the facility layout implementation

GS7.    plan the execution of layout design and development in an effective manner and on timely basis

GS8.    analyze the results obtained after running simulation and identifying the measures for resolving the discrepancies arising out of it

GS9.    assess the problem, evaluate the possible solution(s) and use an optimum /best possible solution(s)

GS10. identify immediate or temporary solutions to resolve delays and crisis situations

GS11. how to learn from past mistakes to resolve technical and non-technical problems

Plan for shifting of resources and implement the layout for the process:

Elements and Performance Criteria

Arrangement of resources

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

PC1.. as per the finalized model of facility layout for the process in consideration, arrange for shifting and repositioning of workforce , machinery , equipments, materials and other support facilities in consultation with production have a fallback action plan in place.

PC2.. carry out the shifting process as per the plan taking care that adequate safety stock has been built by production for the lines affected by the layout change & timing plan is closely monitored.

PC3.. check risks related to hazards , safety are mitigated adequately in the new layout .

PC4.. in case of any discrepancy/issues arising due to rearrangement , escalate the matter to higher management and ensure addressing of same on timely basis

Implementation of new layout

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

PC5.. after arrangement of resources , implement the new facility layout as per the finalized model

PC6.. monitor the functioning of layout on a periodic basis and sort out the discrepancies arising during same

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.    company manufacturing processes

KU2.    existing layout for the processes

KU3.    facility designing standards followed in the organization

KU4.    third parties (if any) involved in construction of facilities for the organization

KU5.    complete knowledge of the process in consideration

KU6.    type of the layout to be developed like product, process, u type etc.

KU7.    engineering drawings of existing layout

KU8.    operation of machinery and equipments being used for the process

KU9.           complete knowledge of material and information flow for the process

KU10. atest simulation techniques used for validation of model layouts

Generic Skills (GS)

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

GS1.    compile all the data related to layout planning and implementation in form of reports and presentations

GS2.    understand the drawings of layout

GS3.    communicate the layout implementation status to higher management in form of presentations

GS4.    interact with workers and gather all the information related to process requirements

GS5.    coordinate with the facility planning department team and ensure model layout designing on timely basis

GS6.    collate resources from various third parties involved (if any) for the facility layout implementation

GS7.    plan the execution of time study so that he can finish compilation of the data activity wise in the stipulated time

GS8.    analyze the implementation of the finalized layout design and think of measures to resolve the issues arising after same

GS9.    assess the problem, evaluate the possible solution(s) and use an optimum /best possible solution(s)

GS10. identify immediate or temporary solutions to resolve delays and crisis situations

GS11. how to learn from past mistakes to resolve technical and nontechnical problems

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.