Free Manager Process Engineering Course (6Months)
Manager Process Engineering:
Brief Job Description
Individuals at this job need to develop and implement Manufacturing processes by planning, conducting techno commercial feasibility analysis and procuring the facilities, tools, gauges and equipments required. They are also responsible for process review for the new process & suggest modifications in order to improve the QCT targets.
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 coordinating & leading the whole gamut of activities in theoretical & practical aspects of the process, information ordering, planning mathematical and deductive reasoning, oral expression and comprehension.
Work effectively in a team:
Elements and Performance Criteria
Effective communication
To be competent, the user/individual on the job must be able to:
PC1. maintain clear communication with colleagues
PC2. work with colleagues
PC3. pass on information to colleagues in line with organisational requirements
PC4.. work in ways that show respect for colleagues
PC5. carry out commitments made to colleagues
PC6. let colleagues know in good time if cannot carry out commitments, explaining the reasons
PC7. identify problems in working with colleagues and take the initiative to solve these problems
PC8. follow the organisations policies and procedures for working with colleagues
PC9. ability to share resources with other members as per priority of tasks
Knowledge and Understanding (KU)
The individual on the job needs to know and understand:
KU1. the organisations policies and procedures for working withcolleagues, role and responsibilities in relation to this
KU2. the importance of effective communication and establishing goodworking relationships with colleagues
KU3. different methods of communication and the circumstances inwhich it is appropriate to use these
KU4. benefits of developing productive working relationships withcolleagues
KU5. the importance of creating an environment of trust and mutualrespect
KU6. whether not meeting commitments, will have implications onindividuals and the organisation
KU7. different types of information that colleagues might need and theimportance of providing this information when it is required
KU8. the importance of problems, from colleagues perspective andhow to provide support, where necessary, to resolve these
Generic Skills (GS)
User/individual on the job needs to know how to:
GS1. complete well written work with attention to detail
GS2. read instructions, guidelines/procedures
GS3. listen effectively and orally communicate information
GS4. make decisions on a suitable course of action or response
GS5. plan and organise work to achieve targets and deadlines
GS6. check that the work meets customer requirements
GS7. deliver consistent and reliable service to customers
GS8. apply problem solving approaches in different situations
GS9. apply balanced judgements to different situations
GS10. apply good attention to detail
GS11. check that the work is complete and free from errors
GS12. get work checked by peers
GS13. work effectively in a team environment
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
Finalize the facilities and equipments required for the new process:
Elements and Performance Criteria
Reviewing Analysis of existing tools and equipments
To be competent, the user/individual on the job must be able to:
PC1.. review the analysis to study /compare for the proposed options 3 D Space utilization, profiles, Cost vis–vis budgets : total & per piece Time required for implementation Capability to achieve product specifications & features
Decide & finalize the process
To be competent, the user/individual on the job must be able to:
PC2.. in the NPD-CFT finalize the proposal based on the feasibility & best balance of QCT vis–vis organizations budgeted targets
Knowledge and Understanding (KU)
The individual on the job needs to know and understand:
KU1. product line expansion plans for the company
KU2. company plant and process layout
KU3. manufacturing processes being followed in the company
KU4. sequence of operations for each process
KU5. in-house and third parties involved in process design for the company
KU6. complete knowledge of the new product usage and application
KU7. product conformance requirements
KU8. product engineering drawings and dimensional tolerances
KU9. knowledge of CAD software and 3D modeling techniques ( to be able to review)
KU10. complete layout for the process in consideration
KU11. material and information flow of the process
KU12. knowledge of decision matrix techniques required for new process approval
Generic Skills (GS)
User/individual on the job needs to know how to:
GS1. read the engineering drawings of the new product
GS2. read the FTG drawings for the new equipments and facilities
GS3. prepare the process approval documents like PFMEA and Control plan
GS4. compile all the data in forms of reports and presentations as per requirement
GS5. communicate the new equipments and facilities design activities to the higher management in meetings for their support
GS6. coordinate with various departments for gathering all the information related to the process
GS7. allocate and monitor the equipment designing activity team member wise to ensure efficient and smooth execution of the activity
GS8. communicate with other departments like for coordinating and executing the process and equipments design activity
GS9. spell out effectively the findings of the proceedings to the higher management in meetings
GS10. Organize expert support from within/ outside professional environment for new technology, feasibility studies, decision matrix
GS11. analyze the way in which the existing process is in operation and think of more economic and feasible measures for process improvement
Prepare the capital budgets, timelines,& procurement plans for the projects:
Elements and Performance Criteria
Preparation of FTGs
To be competent, the user/individual on the job must be able to:
PC1.. collate all the FTGs for the new equipments and facilities
PC2.. compile a comprehensive list of FTGs
Floatation of budgetary quotes
To be competent, the user/individual on the job must be able to:
PC3.. invite budgetary quotes for the finalized equipments from list of approved suppliers capital budget for the investments
PC4.. also ask each supplier to give justification for the quote proposed by the supplier
PC5.. record the budgetary quote along with the justification for each equipment in form of a list
Compiling & monitoring the budget/ timeline
To be competent, the user/individual on the job must be able to:
PC6.. prepare a comprehensive capital budget for all the investments along with a detailed justification note for each investment
PC7.. submit the compiled budget to the authority as per organization sop and get it approved with appropriate justifications
PC8.. based on the time required for designing associated equipment, fixtures, tools etc, procurement and downstream activities of integration, tryouts etc timeline should be prepared by respective process engineers & compiled at the apex level of process manager
/ project manager
PC9.. monitor the budgeted costs and time in the entire cycle of NPD development with the team of engineers by setting review meetings etc.
PC10.. ensure placing orders for main , auxiliary equipment as per the lists prepared for all projects as per organizational SOP and review progress periodically to monitor the timelines
Knowledge and Understanding (KU)
The individual on the job needs to know and understand:
KU1. product line expansion plans for the company
KU2. company plant and process layout
KU3. manufacturing processes being followed in the company
KU4. sequence of operations for each process
KU5. in-house and third parties involved in process and facilities design for the company
KU6. Process of budgets, approvals , Review meetings
KU7. knowledge of documents required for vendor approval like RFPs , RFQs etc.
KU8. tools and equipments functioning for the new process
KU9. facilities requirement and operation knowledge
KU10. complete layout for the process in consideration
KU11. material and information flow of the process
KU12. knowledge of APQP, PPAP ,
KU13. Preparation of timeline in MS Project / excel
KU14. Decision making matrix
Generic Skills (GS)
User/individual on the job needs to know how to:
GS1. read FTG drawings of the new equipments
GS2. prepare the capital budget in the prescribed format
GS3. compile all the data in forms of reports and presentations as per requirement
GS4. communicate the capital budget requirements to the higher management in meetings for their support
GS5. coordinate with all suppliers and Finance department for compilation and approval of the capital budget for the investments
GS6. Co-ordinate with various Process engineers for the tasks allocated
GS7. plan the capital budget preparation activity and ensure approval of the same in the stipulated time
GS8. Plan stage milestone Reviews for the Projects
GS9. think of alternate economic sources for procurement of finalized equipments
GS10. Think of fall-back action plans in the environment to meet the final goals of QCT for multiple projects being executed simultaneously.
Release the new process and sign off the PPAP document:
Elements and Performance Criteria
Conducting Pre-PPAP Audit
To be competent, the user/individual on the job must be able to:
PC1.. after successful completion of the process trials and error resolution , collate all the process layouts , product drawings and equipment drawings and ftgs
PC2.. attach one copy of each excluding the process in the ppap document the individual handling this function shall be competent to be able to
PC3.. organize an audit with a checklist with support from QA for qualitative and quantitative completion of all the Phase III/IV activities such as completion of all auxiliary activities e.g. material feeding , pokayoke, on the Workstation validation of Process parameters in the Try- out validation of gauges dimensional / material Inspection of samples from the pilot batch performance validation of samples from the Pilot Batch master/ limit samples wherever necessary documentation : PF, FMEA, CP & WI, documentation : Check sheets (e.g. First off
/Stage Inspection plan PDI) documentation in ERP /PLM action Plan from previous reviews completed (Customer/ Internal) training of each WS Technician as per CP/WI review if mix-up of similar parts, orientation etc can occur
PPAP document compilation
To be competent, the user/individual on the job must be able to:
PC4.. compile all the process documents , PFDs , PFMEAs , Pre-launch Control plans , MSA and SPC reports , supplier PPAPs for raw materials , trial run reports , equipment commissioning , process validation reports etc. in one single PPAP document
PC5.. submit the ppap document to the concerned team in higher management and at the customers take their signoff within the stipulated time
PC6.. after the signoff , submit the ppap document to the shop floor quality department for their records
PC7.. send a process development completion status to all the concerned departments and grant the permission to use the process for daily production requirements
Granting access to drawings
To be competent, the user/individual on the job must be able to:
PC8.. after successful signoff of ppap , grant restricted access to all the drawings and FTGS related to process , product and equipments for better comprehension of the concerned departments like production , quality , maintenance etc.
PC9.. ensure that the team member from each department is assigned for accessing all the drawings and other process related data
Knowledge and Understanding (KU)
The individual on the job needs to know and understand:
KU1. manufacturing processes being followed in the company
KU2. sequence of operations for the new process
KU3. approved vendors for equipments procurement for the company
KU4. systems followed for PPAP approval in company
KU5. systems followed for information security in company
KU6. product conformance requirements
KU7. tools and equipments functioning for the new process
KU8. facilities requirement and operation knowledge
KU9. complete layout for the process in consideration
KU10. material and information flow of the process
KU11. knowledge of all the documents required for the PPAP submission
Generic Skills (GS)
User/individual on the job needs to know how to:
GS1. compile all the data in forms of PPAP document
GS2. communicate with concerned departments and explain the method of opening the restricted access to the
GS3. spell out the complete new process development activity execution to the higher management
GS4. coordinate with all the team members and compile the PPAP document
GS5. coordinate with R&D department and compile all the drawings and FTGs
GS6. plan the PPAP submission and drawings release activity in a timely and effective manner
GS7. think of all the alternate solutions for the problems arising in successful PPAP submission
GS8. imagine and visualize possibilities of an error in the environment and draw preventive actions
for these.
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.
