Free Method Study Executive Course (6Months)

Method Study Executive:

Brief Job Description

Individuals at this job need to design, develop, test andevaluate integrated systems for managing industrial production processes including human work factors, quality control, inventory control, logistics and material flow, cost analysis andproduction coordination.

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 information ordering, oral expression, mathematical and deductive reasoning and comprehension. The individual should be willing to work at shop floor based job for long hours.

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

Maintain 5S at the work premises:

Elements and Performance Criteria

Ensure sorting

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

PC1..    follow the sorting process and check that the tools, fixtures & jigs that are lying on workstations are the ones in use and unnecessary items are not cluttering the workbenches or work surfaces.

PC2..    ensure segregation of waste in hazardous/ non hazardous waste as per the sorting work instructions

PC3..    follow the technique of waste disposal and waste storage in the proper bins as per sop

PC4..    segregate the items which are labelled as red tag items for the process area and keep them in the correct places

PC5.     sort the tools/ equipment/ fasteners/ spare parts as per specifications/ utility into proper trays, cabinets, lockers as mentioned in the 5s guidelines/ work instructions

PC6. .  ensure that areas of material storage areas are not overflowing

PC7.     properly stack 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

PC8.     return the extra material and tools to the designated sections and make sure that no additional material/ tool is lying near the work area

PC9.     follow the floor markings/ area markings used for demarcating the various sections in the plant as per the prescribed instructions and standards

PC10.   follow the proper labeling mechanism of instruments/ boxes/ containers and maintaining reference files/ documents with the codes and the lists

Ensure proper documentation and storage ( organizing , streamlining)

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

PC11.   check that the items in the respective areas have been identified as broken or damaged

PC12.   follow the given instructions and check for labelling of fluids, oils. lubricants, solvents, chemicals etc. and proper storage of the same to avoid spillage, leakage, fire etc

PC13.   make sure that all material and tools are stored in the designated places and in the manner indicated in the 5s instructions

Ensure cleaning of self and the work place

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

PC14.   check whether safety glasses are clean and in good condition

PC15.   keep all outside surfaces of recycling containers are clean

PC16.. ensure that the area has floors swept, machinery clean and generally clean. in case of cleaning, ensure that proper displays are maintained on the floor which indicate potential safety hazards

PC17.. check whether all hoses, cabling & wires are clean, in goodcondition and clamped to avoid any mishap or mix up

PC18.. ensure workbenches and work surfaces are clean and in good condition

PC19.   follow the cleaning schedule for the lighting system to ensure proper illumination

PC20.   store the cleaning material and equipment in the correct location and in good condition

PC21.   ensure self-cleanliness – clean uniform, clean shoes, clean gloves, clean helmets, personal hygiene

Ensure sustenance

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

PC22.   follow the daily cleaning standards and schedules to create a clean working environment

PC23.   attend all training programs for employees on 5 s

PC24.   support the team during the audit of 5 s

PC25.   participate actively in employee work groups on 5s and encourage team members for active participation

PC26.   follow the guidelines for what to do and what not to do to build sustainability in 5s as mentioned in the 5s check lists/ work instructions

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.    relevant standards, procedures and policies related to 5S followed 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.    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/unwanted substances on the process/ environment/ machinery/ human body

KU10. have knowledge of best ways of cleaning & 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.

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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.    read 5S instructions put up across the plant premises

GS4.    effectively communicate information to team members inform employees in the plant and concerned functions about 5S

GS5.    question the process head in order to understand the 5S related issues

GS6.    attentively listen with full attention and comprehend the information given by the speaker during 5S training programs

GS7.    use common sense and make judgments during day to day basis

GS8.           use reasoning skills to identify and resolve basic problems using 5S

GS9.           persuade co team members to follow 5 S

GS10. ensure that the co team members understand the importance of using 5 S tool

GS11. use innovative skills to perform and manage 5 S activities at the work desk and the shop floor

GS12. exhibit inquisitive behaviour to seek feedback and question on the existing set patterns of work

GS13. do what is right, not what is a popular practices

GS14. follow shop floor rules& regulations and avoid deviations; make 5S an integral way of life

GS15. ensure self-cleanliness on a daily basis

GS16. demonstrate the will to keep the work area in a clean and orderly manner

Method Study Executive

Analyze the work movement of operator for each shop floor activity:

Elements and Performance Criteria

Analyzing the motion of operator

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

PC1..     select the shop floor activity for motion study

PC2..     study all the movements of the operator while doing the work like motion of hand , type of movement involved and henceforth the accuracy of the work done by the operator

PC3..     also observe the eye movements being done by the operator

PC4..     record the observations in the prescribed format for further analysis

Studying the work related movements

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

PC5..     study the arrangements of the workplace like number of workstations, the position of tools and materials and the work environment.

PC6..     also analyze the design of the tools and equipments in order to estimate the human effort involved in job performance for the activity.

PC7..     record all these observations in the prescribed format for further analysis.

Establishment of work standards, deployment

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

PC8..     based on the observations for both motion and work movements, develop the most practical and convenient work method.

PC9..     also establish the procedure for execution of the work in co-ordination with the process engineer

PC10..   incorporate the method in process documentation ( PF, CP , WI etc. ) ensuring clarity.

PC11..   verify the implementation of the work method on a periodic basis.

PC 12.. co-ordinate with production for problem solving , improvements of cycle time ergonomics etc.

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1. company manufacturing processes

KU2. sequence of operations for each shop floor activity

KU3. recording methods prescribed by organization for conducting the motion study

KU4. techniques for doing the motion study

KU5. the standards related to human motion while performing the work

KU6. all the economic factors involved in the activity

Generic Skills (GS)

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

GS1. read the work instructions being displayed at the workplace.

GS2. compile all the data related to motion study for all shop floor activities

GS3. communicate with shop floor workers for motion study at shop floor

GS4. assist workers in doing their job as per the standards

GS5. share operation knowledge with co-workers

GS6. plan the execution of motion study so that he can finish compilation of the data activity wise in the stipulated time at appropriate stage of the development

GS7. analyze the way in which job is being performed and think of some other suitable method in order to minimize the operator movement while performing the work

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Measure the time taken for each activity and compute the TAKT time:

Elements and Performance Criteria

Observation of the shop floor activities

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

PC1..    select the shop floor activity for time study.

PC2..    obtain and record all the information available about the job, the operator and the working conditions likely to affect the time study work

Calculation of time taken activity wise

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

PC3..    breakdown the activity into distinct parts based on convenience of observation and timing

PC4..    measure the time taken by means of a stop watch taken by the operator to perform each element of the operation.

PC5..    at the same time, assess the operators effective speed of work relative to the observers concept of normal speed; known as performance rating

Establishment of work standards

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

PC6..    adjust the observed time by rating factor to obtain normal time for each element

PC7..    add the standard allowances suitably in order to compensate for fatigue, personal needs, contingencies etc. to give standard time for each element

PC8..    compute allowed time using most production study for the entire job by adding elemental standard times considering frequency of occurrence of each part

PC9..    repeat the whole procedure for all the shop floor activities and finally compute the TAKT time of the process

Compliance to allowance allocation standards

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

PC10.. ensure that the allowances added for computation of standard time are as per the norms of time motion study

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1. company manufacturing processes

KU2. sequence of operations for each shop floor activity

KU3. norms established for time study

KU4. most production studies for computation of standard time

KU5. working of various tools , machines and gauges for shop floor activities

KU6. all factors involved in the activity like economic and human apart from technical

Generic Skills (GS)

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

GS1. calculate the time taken for each activity using stopwatch

GS2. compile all the data related to time study for all shop floor activities

GS3. communicate with shop floor workers for time motion study at shop floor

GS4. communicate with process design / validation engineers to share data related to method study for npd/ ci projects.

GS5. assist workers in doing their job as per the standards

GS6. share operation knowledge with co-workers

GS7. plan the execution of time study so that he can finish compilation of the data activity wise in the stipulated time

GS8. analyze the way in which job is being performed and think of some other suitable method in order to minimize the ineffective time taken in each activity

Develop the work standards for each activity and maintain the system:

Elements and Performance Criteria

Improvement of working conditions

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

PC1..    based on time motion study , identify the time consuming and high fatigue operations for the selected shop floor activity

PC2..    arrange the material and tools if applicable to permit the best sequence of operator motions and thereby reduce searching

PC3..    ensure provisions for adequate lightning, and a chair of type and height to permit good posture

PC4..    if necessary, modify the height of workplace and seat to allow alternate standing and seating

Elimination of waste and ineffective operations

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

PC5..    identify the repetitive and non-repetitive type of work for each shop floor activity during time study

PC6..    based on most studies , identify the NVAoperations in each activity

PC7..    evaluate alternatives for removal of NVA operations by developing economic and effective working methods for same

PC8..    implement the best alternative and recalculate the TAKT time for the activity.

PC9..           calculate the cycle time reduction after implementation of the developed method Development of work standards and updating in system

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

PC10.. based on the inputs from time motion study, devise the standard working method and establish the procedure for all the shop floor activities

PC11.. calculate the new takt time for the modified activities and update the same in system in ERP

/SAP and PLM

PC12.. also update the most timings for all activities process wise and link it with ERP/SAP system.

PC13.. link the most timings to sap routings and release the same for production costing and entry in system

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.    company manufacturing processes

KU2.    sequence of operations for each shop floor activity

KU3.    norms established for time motion study

KU4.    method study procedures followed in organization

KU5.    SAP modules being followed in the organization

KU6.    most production studies for computation of standard time

KU7.    working of various tools , machines and gauges for shop floor activities

KU8.    all the factors involved in the activity like economic and human apart from technical

KU9.    work content reduction techniques

KU10. all arithmetic calculations for determining productivity and cost of manufacturing

KU11. proficiency of working with sap module for costing and production entry purposes

Generic Skills (GS)

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

GS1.    record the observations of the time motion study

GS2.    read and understand the work instructions if displayed at shop floor

GS3.    SAP software and its data usability for all production related entry and costing calculations

GS4.    communicate with shop floor workers for time motion study at shop floor

GS5.    communicate with production/ process engineering engineers for work related to NPD / CI projects.

GS6.    assist workers in doing their job as per the standards

GS7.    share operation knowledge with co-workers

GS8.    coordinate and take inputs from the workers for devising alternative methods for work content reduction

GS9.    plan the execution of time study so that he can finish compilation of the data activity wise in the stipulated time & at appropriate stage of the project timeline.

GS10. workplace arrangements for reduction of human effort

GS11. identification of the nva operations

GS12. selection of the best work content reduction technique to be followed

GS13. defining the linkages of work standards to production data in sap system

GS14. assess the problem, evaluate the possible solution(s) and use an optimum /best possible solution(s)

GS15. identify immediate or temporary solutions to resolve delays and crisis situations

GS16. how to learn from past mistakes to resolve technical and nontechnical problems

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.