Free Manager Supplier Quality Level 6 Course (6Months)

Manager Supplier Quality Level 6:

Brief Job Description

Individuals at this job need to be responsible for overall supplier quality assurance functions for all facilities including incoming inspection, issue containment and supplier corrective actions.

Personal Attributes

Individuals at this job need to be responsible for overall supplier quality assurance functions for all facilities including incoming inspection, issue containment and supplier corrective actions.

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

Monitor the quality of incoming materials:

Elements and Performance Criteria

Material inspection

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

PC1..    ensure the inspection of the incoming parts/subassemblies/materials/tools/gauges received by Stores department for following checkpoints by team members responsible for quality : items received as per the drawing no items are missing quantity of items received matches quantity indicated on invoice quantity of items received matches quantity requested by laboratory manufacturers expiry date is acceptable shelf life (in case of perishable goods) items transported in the suitable ambient environment items are not crushed, broken or leaking any broken or leaking item has been handled and disposed of as per the requirements of the SOP on HSE any manufacturers alerts or changes to the package insert are noted norms for Inspection & Report are followed for the shipment inventory records are updated copy of the invoice and order request is retained in the laboratory shipment is unpacked and properly integrated with existing inventory

PC2..    co-ordinate the preparation of inspection report with support from materials lab and inspection team members and recording in the system ; and appropriately for traceability / batch control.

PC3..    if the incoming material is not OK, then raise a rejection note and inform the supplier quarantine the material and its invoice documents till the replacement material is received from supplier once received, re- inspect the material repeat PC2 submit the invoice and other documents to Stores

PC4..    remotely monitor the quality of the material in coordination with process quality team while usage at shop floor

PC5..    in case of any rejections/deviations reported by downstream process quality,or field failures reported by customer quality team ensure that the interim / permanent corrective actions are taken after investigation at the supplier end thro 8d etc.

PC6..    review periodically impact on suppliers rating (QCD ) as per sop and decide follow through actions for communication, business impact, payments etc.

PC7..    convene meetings with suppliers in case of frequent rejections and understand their point of concern; brainstorm and devise countermeasures

PC8..    support the supplier in implementing the continuous improvement projects (C.I.) at their manufacturing facility processes

New material quality validation

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

PC9..    receive the drawings/specifications, and ECN/ PCN of the new material from R&D/NPD department

PC10.. develop an insight into the process to derive an effective audit check list

PC11.. audit the sample part/sub-assembly manufacturing process and ensure that the guidelines of APQP, PFMEA, CP are understood & adhered to by the supplier

PC12.. check the dimensions of the representative part/new part/sub-assembly, and identify the best supplier meeting the quality requirements for the new part/sub-assembly

PC13.. co-ordinate specific milestones on the timeline and review the qualitative meeting of the targets for part & process.

PC14.. co-ordinate the participation in ppap at the vendor end to ensure the process meets the requirements/ targets of QCT

PC15.. countermeasures for the deviations, re-review of the quality

PC16.. signoff the ppap / record along with the concerned departments and supplier representative; flag off the process for bulk.

PC17.. prepare a periodic audit schedule and accordingly inspect the new part/subassembly for quality and performance

PC18.. present the findings of the new material validation to the senior management and seek their inputs and support

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.    product portfolio of organization

KU2.    the manufacturing processes of organization

KU3.    material classification criteria followed by organization

KU4.    policies and procedures for storage and preservation of materials

KU5.    policies , compliances and systems followed for HSE

KU6.    list of approved suppliers for each material

KU7.    auditing and certification methodology followed for suppliers

KU8.           manufacturing process being followed for each product

KU9.           incoming inspection checkpoints

KU10. tests performed by Metallurgy department for inspection

KU11. QC tools like MSA , SPC , Pareto analysis , Fishbone diagram etc.

KU12. Special Purpose machines(SPM) used by manufacturing processes (if any)

KU13. supplier environment : capacity, capability, cost structures, delivery time, reliability factors

KU14. packaging and transportation methods for each part and sub-assembly

KU15. APQP procedures

KU16. requirements for PPAP

KU17. dimension validation and performance testing methods

KU18. information systems like SAP, ERP etc.

KU19. type of P.O.s raised in SAP

Generic Skills (GS)

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

GS1.    the suppliers for discrepancies observed in new parts/tool development

GS2.    metallurgy department for new parts material dimension validation and quality testing

GS3.    vendor development department for procurement of approved new parts

GS4.    conduct telecon / video conferences for long distance co-ordination with suppliers (if required)of day to day activities

GS5.    senior management for updating the progress and seeking their support

GS6.    team members for reviewing the progress of day to day activities

GS7.    process Quality team for performing the MSA analysis in case of new par

GS8.    distribute workload among team members ensuring smooth progress of material inspection activity and within the desired timelines

GS9.    coordinate with various departments like Metallurgy , Vendor Development, Manufacturing, R&D, process Quality etc. based on the requirement /subassembly validation

GS10. share operation knowledge with colleagues

GS11. understand the drawings for part/tool and interpret the key characteristics like dimensions, profile, material etc

GS12. prepare the dimension testing reports for the parts/sub-assemblies

GS13. understand the inspection reports of the Metallurgy departments

GS14. prepare the inspection reports and maintain records

GS15. think through and devise the countermeasure for resolution for any quality related issue observed in the received suppliers parts or the manufacturing process followed by the supplier

GS16. prepare the fall back action plan in the environment of vendors, transport mechanisms and organizations capacity/ capability

GS17. work on actions to be taken on immediate basis in case of part rejections during trials

GS18. use escalation procedures

GS19. identify problems (technical and non-technical), disruptions and delays

GS20. keep abreast of special events such as holidays/ work calendars / maintenance shutdowns of vendors & organization and plan accordingly so that the final schedules are adhered to

GS21. plan and monitor the ambient conditions for storage and preservation of perishable goods as per the supplier requirements in coordination with Stores department

GS22. in consultation with Metallurgy department , inform the suppliers for fabrication of parts with cost effective and durable alternate material

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.