Free Manager Testing Facility Level 6 Course (6Months)

Manager Testing Facility Level 6:

Brief Job Description

Individuals at this job need to manage requirements identification, development and installation of testing facilities in R&D for validating the specifications of the product.

Personal Attributes

This job requires the individual to work for long hours in a laboratory environment. The individual should be result oriented. The individual should also be able to demonstrate skills for information ordering, analytical reasoning, problem solving, time management, interpersonal, oral expression and comprehension.

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

Identify gaps in the existing testing facility:

Elements and Performance Criteria

Identifying the testing requirements

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

PC1..    co-ordinate with marketing/quality / R & D to gather inputs for modifying/developing new technical specifications viz . warranty failures, new sor/ national/ international specifications etc.

PC2..    coordinate with marketing & R & D department and interact with customer to understand their pain points or new requirements with respect to technical specifications in the final product

PC3..    discuss with team and analyze the method for performing testing and validation of the new requirements

PC4..    prioritize the requirements based on the immediate and future basis

PC5..    based on the analysis , evaluate the existing testing facility Analyzing the competency of the existing facility

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

PC6..    analyze the existing facility for requirements for new equipments, product specific fixtures etc. Electro-mechanical systems for performance in NTP/ special conditions/ abuse conditions/ endurance evaluations Standard machines for evaluation e.g. environmental chambers Instrumentation or measurement systems etc. Special equipments e.g. vibration, Stress , impact ,NVH evaluations, NDT etc. Dynamic evaluations, vehicle testing systems etc. Infrastructural back up required for all the above e.g. power, compressed air, IT systems

,floor space etc

PC7..    estimate its feasibility for performing the testing for validation of new specifications

PC8.. if feasible , then in coordination with team update the data for customer specifications in information systems like sap/plm and perform the testing and validation as per standard operating procedures

PC9..    if not feasible , then discuss with team and analyze whether the test can be performed after modification of the existing testing facility or there is a requirement for a new testing facility

PC10.. in case modifications in existing testing facility found to be feasible , then float the test requirements in SAP/PLMwith the approved existing testing facility manufacturer

PC11.. convene a meeting with the testing facility manufacturer and explain in detail about the requirements and finalize the timelines for existing testing facility modification.

PC12.. coordinate with the manufacturer and ensure the development of the modified testing facility as per requirement in compliance to the standard hse regulations

PC13.. inform the r&d testing for performing the validation of the new facility

PC14.. monitor the validation results given by R&D testing and in coordination with manufacturer finalize the modified testing facility

Finalizing the requirements for the new testing facility

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

PC15.. discuss with team and analyze the infrastructure requirements for the new testing facility

PC16.. based on the analysis , prepare a rough estimate of the cost involved and time required for completion

PC17.. present the details for new testing facility requirements including the cost to the senior management and seek their approval

PC18.. once approved , inform the sourcing department to facilitate development of new testing facility from the existing/new manufacturer

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.    protocol for gathering customer requirements from concerned departments

KU2.    product portfolio of organization

KU3.    the manufacturing processes of organization

KU4.    protocol for testing facility development among the R&D department of the organization

KU5.    standards and procedures related to HSE compliances

KU6.    list of approved testing facility manufacturers

KU7.    manufacturing process being followed for each product

KU8.           components being fitted in the final product assembly

KU9.           testing facility standard operating procedures

KU10. testing and validation activities performed using testing facility

KU11. usage knowledge of information systems like SAP , ERP,PLM etc

Generic Skills (GS)

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

GS1.    interpret the customer requirements from the data collected from concerned departments

GS2.    document the requirements for the testing facility for communicating to the testing facility manufacturers

GS3.    prepare the long term and short term plans for testing facility requirements

GS4.    document all the testing facility related data in form of 2D drawings, spreadsheets using MS Excel

GS5.    testing facility manufacturer and ensure interpretation of the testing infrastructure requirements

GS6.    Sourcing department for identification of new testing facility manufacturers

GS7.    distribute workload among team members for acquiring data pertaining to customer requirements

GS8.    share operation knowledge with colleagues and co-workers

GS9.    organize as team and execute the testing facility requirements capturing activity in an efficient and timely manner

GS10. Take external support/ help for technological upgrades ,special evaluations etc.

GS11. identification of problems (technical and non-technical), disruptions and delays

GS12. escalation procedures

GS13. short term / long term planning strategy for testing facility development

Select and approve the testing facility manufacturer:

Elements and Performance Criteria

Interaction with manufacturers & Selection based on feasibility

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

PC1..    coordinate with sourcing department and identify the list of testing facility manufacturers who can develop required testing facility, individually or by integrating multiple sub-systems from various sources/ specialists

PC2..    float a rfq to the identified/existing testing facility manufacturers

PC3..    based on the quote received from manufacturers , select the testing facility manufacturers with appropriate value e.g. cost and specifications balance

PC4..    convene meetings with all the selected manufacturers one-on-one and brief them about the technical and commercial requirements

PC5..    based on the discussions , prepare a timeline for validation of sample test facilities developed at the manufacturers premises

PC6..    communicate the schedule to the r&d testing team for validation of sample testing facility

Development , validation

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

PC7..    ensure development of the facility as per the timeline ; as applicable ensure integration of various systems if ordered from different sources.

PC8..    plan for the installation from civil, mechanical, electrical, electronic & product aspects taking support from others viz. maintenance, R& D / NPD teams .& ensure timelines are as per expectations

PC9..    plan for validation of the testing facility by coordinating with R& D testing team

PC10.. analyze the validation results with the R& D / testing team and in coordination with the testing facility manufacturer, resolve the discrepancies observed

PC11.. repeat steps pc. 7 to pc10. for all the sample test facility manufacturers

Approval of test facility manufacturer

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

PC12.. based on the approval of R& D testing team, , select the most conforming testing facility manufacturers

PC13.. in coordination with sourcing department, negotiate the commercial terms for testing facility installation and commissioning

PC14.. based on the negotiations , identify the most cost effective/ value based manufacturer and signoff the contract along with sourcing department after the approval from senior management

PC15.. communicate the manufacturer for installation and commissioning of testing facility in organization R& D department premises

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1. the manufacturing processes of organization

KU2. protocol for testing facility development among the R&D department of the organization

KU3. standards and procedures related to HSE compliances

KU4. list of approved testing facility manufacturers

KU5. components being fitted in the final product assembly

KU6. testing facility standard operating procedures

KU7. testing and validation activities performed using testing facility

Generic Skills (GS)

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

GS1.    document the requirements for the testing facility for communicating to the testing facility manufacturers

GS2.    prepare the long term and short term plans for testing facility requirements

GS3.    document all the testing facility related data in form of 2D drawings, spreadsheets using MS Excel

GS4.    communicate with the testing facility manufacturer for sample facility validation activity

GS5.    communicate with Sourcing department for finalizing the contract with the technically conforming manufacturer

GS6.    distribute workload among team members for ensuring smooth testing facility manufacturer approval activity

GS7.    share operation knowledge with colleagues and co-workers

GS8.    identification of problems (technical and non-technical), disruptions and delays

GS9.    the fall back action plan in event of any issue

GS10. evaluate and decide the most commercially and technically viable testing facility manufacturer

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.