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

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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

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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:

  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.
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