Masking Machine Operator (6 Month Diploma)

Masking Machine Operator

Masking Machine Operator: The Masking Machine Operator is responsible
for wrapping capacitors in Kraft-paper-tape for further processing.
Brief Job Description: The individual at work sets up and operate masking
machine for covering capacitors with Kraft paper tape for further processing.
Personal Attributes: The job requires the individual to have: steady hands
and ability to work in a standing position for long hours.

Set up and operate masking machine

Description

This OS unit is about setting up the masking machine and operating as per capacitor
size and standard operating procedure
Scope

This unit/task covers the following:
 Set up the masking machine
 Apply outer masking tape
 Maintain masking machine
 Achieve productivity and quality of standards

Performance Criteria
Setting up masking machine

To be competent, the user/individual on the job must be able to:
receive capacitors from Hot Pressing operator along with Lot Paper
read the Lot Paper for capacitor type and size
set Hopper unit, Bowl feeder, Vibrations of bowl feeder, Liner feeder,Piece
feeder and Punch unit in the masking machine as per the capacitor size
select Kraft paper tape according to the capacitor size and SOP
position Kraft paper tape on the masking machine and set up Tape guider
Apply masking tape

To be competent, the user/individual on the job must be able to:
load few capacitors on the masking machine for sample processing
operate masking machine as per the SOP
check that capacitor packing method is ‘Ω’ type
check that capacitor should be at centre of the tape, there is no loose tape,
no hole in the tape and no space between every packed capacitor,
. in case the packing is not proper adjust the setting of Tape guider, Piece
feeder and again operate the machine and check packed capacitors
operate masking machine and process the whole lot of capacitors when
packing is happening as per the SOP stop masking machine when masked roll
reaches to specified height
unload the masking roll and take out rolled Kraft paper containing capacitors
cover rolled Kraft paper containing capacitors with outer masking tape as per
SOP to keep it intact
make entries in the Lot Paper
send rolled Kraft paper containing capacitors along with Lot Paper to Spray
Operator for further processing
Maintain masking machine

To be competent, the user/individual on the job must be able to:
clean masking machine and nearby area at the start of the shift as per the
SOP
inform maintenance department in case of machine breakdown after
completing the necessary documentation
receive the machine in functional condition from the maintenance

department after the repair work
Achieving productivity and quality standards

To be competent, the user/individual on the job must be able to:
achieve 100% target number of masked capacitors
ensure capacitor packing method is ‘Ω’ type without any hole or space
document as per SOP
report to shift in-charge when required
Knowledge and Understanding (K)
Organizational Context

The individual on the job needs to know and understand:
company’s policies on: incentives, delivery standards and personnel
management
work flow involved in production process of the company
importance of the individual’s role in the workflow
reporting structure
profile of clients
raw material stocking standards
safety and quality standards followed in the organization
Technical Knowledge
The user/individual on the job needs to know and understand:
different types of capacitors
related SOPs and work instructions
special safety precautions to be taken during the processing of capacitors
quality standards
FIFO system ofinventory control
handling of raw materials
traceability back to original materials
routine maintenance of machines and basic repairs
5S standards (sorting, setting, standardise, sustain, shining) + safety, security
commonly occurring machine and component defects
Skills (S) [Optional] Core Skills/ Generic Skills
Reading and Writing Skills
The user/individual on the job needs to know and understand how:

to read production schedules, SOPs and work instructions
to read Lot Paper and special work instructions
to maintain Lot Paper
to write break down slip
to document the activities as per the SOP
Communication Skills
The user/individual on the job needs to know and understand how:
to effectively communicate with the shift in-charge on the process issues
to effectively communicate maintenance issues to the maintenance personnel
Team work and Multitasking
The user/individual on the job needs to know and understand how:
to be able to work on multiple masking machines at a time, as instructed
to work as a team and deliver on time to next work process

Set up and operate masking machine

Professional Skills Reflective Thinking
The user/individual on the job needs to know and understand how:
to reduce repetitive errors
to improve work process
Analytical Thinking
The user/individual on the job needs to know and understand how:
to enhance machine performance
Using Test instruments and Machines
The user/individual on the job needs to know and understand how:
to operate the Allen keys
Problem solving and Troubleshooting
The user/individual on the job needs to know and understand how:
to troubleshoot and rectify when capacitor gets stuck in the masking machine

Work with superiors and colleagues
Description

This OS unit is about communicating, coordinating and maintaining proper
relationship with colleagues and seniors in order to achieve smooth work flow
Scope

This unit/ task covers the following:
 Interact with supervisor or superior
 Coordinate with colleagues
Performance Criteria(PC) w.r.t. the Scope
Element Performance Criteria Interacting with supervisor
To be competent, the user/ individual must be able to:
understand work requirements by receiving instructions from reporting
supervisor
understand standard operating procedure of the company
escalate problems that cannot be handled including repetitive PCB defects,
machine failures, potential hazards, process disruptions, repairs and
maintenance of machine
report work completed and receive feedback on work done
resolve personnel issues
rectify errors as per feedback and minimize mistakes to zero in future
communicate about process flow improvements, quality of output, product
defects received from previous process, repairs and maintenance of tools and
machinery as required and find technical solutions on specific issues
handover completed work and deliver the work of expected quality despite
constraints Interacting with colleagues
To be competent, the user/ individual must be able to:
collect required spares and raw materials from tool room or stores
deposit unused or faulty materials, parts and tools to stores
assist colleagues where necessary and as per capability
resolve conflicts with colleagues at work to achieve smooth workflow
complete rework in time based on feedback from quality or process
departments
put team over individual goals
Knowledge and Understanding
Organizational Context

The individual on the job needs to know and understand:
company’s policies on: incentives, delivery standards, and personnel
management
work flow involved in company’s process
importance of the individual’s role in the workflow
reporting structure

Work with superiors and colleagues

Technical Knowledge
The individual on the job needs to know and understand:
how to communicate effectively
how to build team coordination Skills (S) [Optional] Core Skills/ Generic Skills
Teamwork and Multitasking
The individual on the job needs to know and understand how:
to deliver product to next work process on time
to share work load as required
Professional Skills Decision Making
The individual on the job needs to know and understand:
how to report potential areas of disruptions to work process
when to report to supervisor and when to deal with a colleague depending on
the type of concern
Reflective Thinking
The individual on the job needs to know and understand:
To reduce repetitive errors and improve work process
Critical Thinking
The individual on the job needs to know and understand:
how to spot process disruptions and delays

Follow safety standards
Description

This OS unit is about following safety procedures, communicating potential hazards
and dangers of accidents on the job
Scope

This unit/ task covers the following:
 Understand potential sources of accidents
 Use safety gear to avoid accidents
 Understand the safety procedures followed by the company
Performance Criteria(PC) w.r.t. the Scope
Element Performance Criteria
Understanding
potential sources of
accidents
To be competent, the user/individual on the job must be able to:
spot and report potential hazards on time
follow company policy and rules regarding hazardous materials
avoid accidents related to use of potentially dangerous chemicals, gases,
sharp tools and hazards from machines which involves exposure to possible
injuries such as cuts, bites, stings, minor burns, etc.
Handle with care when using an electrical drill and sharp cutting objects
Using safety gear To be competent, the user/individual on the job must be able to:
understand which safety gear must be used for a particular task
eye, respiratory and hearing protection as per company policy
use safety gear such as respirator, mask, skull caps, gloves, googles, jacket ,
etc., as prescribed for the job
Understanding of safety procedures
To be competent, the user/individual on the job must be able to:
comply with standard health and safety procedure followed in the company
while handling an equipment and hazardous materials and tools or situations
understand and follow the evacuation procedure properly such as fire drills,
emergency evacuation procedures, first aid to self and others, etc., which
help in case of an emergency Following daily safety measure
To be competent, the user/ individual must be able to:
take adequate safety measures while on work to prevent accidents
ensure zero accidents in work
avoid damage of components due to negligence in ESD procedures
ensure no loss for company due to safety negligence
ensure proper machine maintenance, work process achieving quality outputs
as per the company standard Communicating to supervisor
To be competent, the user/ individual must be able to:
improve process flow to reduce anticipated or repetitive hazards
report on mishandling of tools, machines or hazardous materials and on
electrical problems that could result in accident
escalate about any hazardous materials or things found in the premises
report about any breach of safety procedure in the company
follow electrostatic discharge (ESD) measures for electronic component
safety

Organizational Context

The individual on the job needs to know and understand:
company’s policies on handling: harmful chemicals and sharp tools, safety
and hazards of machines, fire safety/drill, first aid and, disposal of harmful
chemicals and materials, quality standards
company occupational safety and health policy followed
company emergency evacuation procedure
company’s medical policy
Technical Knowledge
The individual on the job needs to know and understand:
how to maintain the work area safe and secureKB2. how to handle hazardous material
how to follow safety procedures while operating hazardous tools and
equipment
emergency procedures to be followed such as fire accidents and fire safety
education
how to use machines and tools without causing bodily harm
first aid execution
disposal of hazardous chemicals, tools and materials by following prescribed
environmental norms or as per company policy
Skills (S) [Optional] Core Skills/ Generic Skills Communication Skills
The individual on the job needs to know and understand how:
to effectively communicate the danger
to understand the quality standard of the company
Professional Skills Reflective Thinking
The individual on the job needs to know and understand how:
to learn from past mistakes regarding use of hazardous machines, tools or
chemicals critical Thinking
The individual on the job needs to know and understand:
how to spot danger
procedure to follow in the event of a fire or other hazard
Handling Safety Equipment
The individual on the job needs to know and understand:
towear gloves, goggles, masks, caps, shoes, coats, etc.
to use safety equipment such as fire extinguisher during fire accidents
Decision Making
The individual on the job needs to know and understand:
importance of reporting potential sources of danger
appropriate actions to be taken in the event of an accident
procedure for disposing of hazardous materials, safely and following
environmental guidelines