Free Plastic Moulding Shop Supervisor Course (6Months)

Plastic Moulding Shop Supervisor:

Brief Job Description

This role is responsible for supervising the PVC moulding and extrusion activities to create well-formed PVC parts for automobile components, maintaining process parameters, conducting quality checks on output product, deploying manpower as per requirement, guiding operatives and technicians to complete the assigned task, maintaining a safe & healthy working environment on the shop floor and maintaining records related to production, rejections, material movement and manpower productivity for a line/shift.

Personal Attributes

Reading, writing and communication skills, ability to plan and prioritize, quality consciousness, analytical thinking, sensitivity to problem solving, quick decision making, safety orientation, dexterity and high precision, ability to use internal ERP systems ( if existing), managing teams, grievance management, listening skills, ability to train team members.

Plastic Moulding Shop Supervisor

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

Understanding process requirements:

Elements and Performance Criteria

Understanding all therequisite processes in detailand ensuringimplementation

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

PC1.     display detailed understanding of all the requisite processes to be adopted for completing the work order through reading the process manuals/ work instructions/standard operating procedures for the production job

PC2..    share knowledge of processes , inputs and outputs with the operators to enhance their skill levels

PC3.     ensure the various SOW/WI created by the master technician are displayed and understood at each and every work station

PC4..    maintain work flow by monitoring steps of the processes, setting variables, observing control points and equipment

PC5.     support in defining detailed processes for each step and line

PC6..    monitor various process parameters on a regular basis and ensure compliance to agreed standards (e.g. ambient air quality, stack monitoring, water quality monitoring etc.)

PC7.     ensuring recording and reporting procedures and systems are in place

PC8.     facilitating corrections to malfunctions within process control points

PC9.     ensure 5s implementation in the production line by analysing possible areas of systems and process improvements and ensure implementation of the recommended measures to address the gaps

PC10.. ensure successful implementation of the completed poka yoke and kaizen on the running line

Data Analysis

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

PC11.   ensure compilation of data of breakdown maintenance and reporting the same to the maintenance team

PC12.. conduct random sampling on the incoming quality of material and provide the relevant feedback on the same to the store

PC13.   conduct random sampling of the process parameters and wip productsand provide necessary feedback to the line leaders

PC14.   conduct random sampling of the finished goods and provide the necessary feedback

PC15.   conduct batch wise product quality check in order to ensure that the quality of the product produced meet customer requirements

Support and provide basiclevel of inputs for processimprovement initiatives

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

PC16.   support in ensuring optimum resource utilization and wastage reduction through process improvements, Kaizens, TQM, Poka Yoke etc.

PC17.. support and provide inputs on analysis of breakdown trends and current maintenance process to identify areas for improvement to achieve costsavings and reduce breakdown timing

PC18.   identify areas of improvement in the existing processes/systems and take counter measures to adhere to the identified kaizens

PC19.. support the master technician in sharing inputs from the line for various poka yoke , kaizen activities

PC20.   encourage team members/ operators to suggest quality improvement measures through suggestion schemes, evaluate feasibility of the ideasand discuss their implementation with seniors

PC21.. support in analysing internal & external rejection data, planning and ensuring implementation of the corrective measures

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.    relevant manufacturing standards and procedures followed in the company in detail

KU2.    different types of products manufactured by the company

KU3.    knowledge of functional processes like Procurement, Store management, inventory management, quality management and key contact points forquery resolution

KU4.    quality norms and standards prescribed in the Quality Manual by the organization for painting

KU5.    5S and Safety norms practiced in the organization

KU6.           different types of manufacturing processes used

KU7.           requirement of raw materials used in the process

KU8.    tools, jigs and fixtures , their usage and maintenance methods

KU9.    how to operate the machine in both, automatic and manual mode

KU10. using engineering drawings, sketches, control plan and work instructions in the plant

KU11. usage of various measurement tools like Vernier Calipers, Micrometres, rulers, scales, weighing machines etc

KU12. different types of defects which may arise due to improper manufacturing and the impact of the defect on product performance

KU13. metallurgical and chemical properties of material involved

KU14. about the hazards involved in the process operations and usage of PPEs

KU15. about handling of electrical equipment and circuits, rectifiers and control panel etc.

KU16. how to measure the correct specifications of the output in the terms of thickness, hardness, durability, tightness, finesse etc.

KU17. various problems solving tools like 7QC, Why Why Analysis, Brain storming etc.

KU18. basic Arithmetic and calculation methods

KU19. key areas of power consumption/ steam consumption, compressed air consumption etc.

KU20. Various data entry tools and formats used in the organization

KU21. ability to visualize the final product output and hence decide on the key steps and parameters to be followed

KU22. about the various hazards related to various chemicals if used in the processes

Generic Skills (GS)

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

GS1.    document information from the manuals,discussion notes, process charts etc.

GS2.    create small notes/ work documents/ diagrams for operators and helpers to help them understand the process

GS3.    write inter departmental notes/ memos or make suitable entries in the online system

GS4.    read equipment manuals and process documents to understand theequipment and processes better

GS5.    read internal information memos send by internal customers ( otherfunctions within the organization)

GS6.    discuss task lists, schedules, and work-loads with the operative teammembers

GS7.    answer the queries raised by the operative team as well asintercompany departments

GS8.    effectively communicate with the operators and helpers and make them aware of work expectations, targets, policies, processes etc

GS9.    attentively listen with full attention the queries and grievances raised by the operative team and comprehend the information given by the speaker

GS10. communicate effectively to the team members

GS11. identify conflicts in the team and try to resolve them at the earliest GS12. interact and engage with the team members on a day to day basis GS13. counsel and coach the operators and help them resolve issues

GS14. timely highlight to the management about any good work/ achievement

GS15. break the problem into smaller issues and tasks to arrive at a solution by the operators and helpers

GS16. understand inter process relationship and establish relationship between various parts of the problem

GS17. leverage experience to find effective solutions to problems

GS18. use basic analytical tools to arrive at solutions

GS19. plan, organize and prioritize the work order and jobs received from the production manager

GS20. manage the schedule plan for the operators and helpers on the line/shift

GS21. validate all process/ equipment manuals so that the final process selected is correct

GS22. organize information, tools, manuals etc. on the shop floor so that sorting becomes easy

GS23. reorganize resources on the line/ shift in case of change of plans

GS24. use common sense and make judgments during day to day basis

GS25. use reasoning skills to identify and resolve problems

GS26. use intuition to detect any potential problems which could arise during operations

GS27. accept additional responsibility for self and the team

GS28. encourage self and other to take greater responsibilities

GS29. ensure that the work allocated to the team is completed as per timelines and quality norms

GS30. identify obstacles and bottlenecks in the process and on own find basiclevel solutions for removing these obstacles

GS31. motivate and provide support for the team on the shop floor

GS32. encourage collaboration between team members

GS33. resolve team issues and grievances to manage conflicts within the team

GS34. create an environment of approachability, trust and openness withinthe team

GS35. ensure role clarity for all operators and helpers on the line/ shift

GS36. escalate any team related issues to the concerned person at the righttime

GS37. identify defective parts in the manufacturing line by comparing

GS38. manufactured pieces with the work standard

GS39. link the defect observed with the overall impact on the performance of the component/ automobile

GS40. support and contribute in monitoring and delivering high quality output from self and others

GS41. train team members on maintaining quality standards set by the organization

GS42. use previous experience in resolving problems and taking decisions

GS43. make timely and independent decisions on the line/ shift within the boundaries of the delegation matrix of the organization

Injection Molding Job Works, Delhi, Plastick | ID: 22329113097

Manage production related operations of the a shift/line on a day to day basis:

Elements and Performance Criteria

Manpower Management

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

PC1..     undertake effective shift planning based on manpower allocation and shift handling of place right manpower on the right workstation in coordination with Production In-charge to achieve production targets

PC2..     support Shift In Charge/ Process head/ Shop head is finalizing the shift rosters for the week and month based on the production plan available

Material Management

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

PC3.      send inventory requirements to Stores and Purchase department and follow up with stores and purchase to ensure timely receipt of material (Spares, Consumables)

PC4..     ensure that the material and work piece movement on the shop floor conforms to the TAT time prescribed in the sop/ work plans so that production targets are met for the line/ shift

Supervise ProductionOperations

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

PC5.      support the in charge/ shop head in fulfilment of the production plan for the shop in a given line/ shift

PC6.      coordinate with various functions like material management, stores, paint shop, assembly line, quality, safety, production planning etc to ensure communication of required information and resolution of queries

PC7.      responsible for end of line inspection under supervision

PC8.      ensure that the operators and helpers have the required tools and equipment at the start of the process

PC9.      facilitate the production runs along with engineering and quality function

PC10..   ensure optimal resource utilization(man , machine and material) and streamlining of activities within the shift

PC11.    identify & implement action steps to reduce losses and wastages during shift operation and ensure minimum rejection of components

PC12..   prepare daily and monthly production mis reports to match actual performance vis–vis the targets and report the same to production in-chart

PC13..   verify the production and material movement related data entries in the system ( manual/ erp) for the line/ shift and ensure correctness of the data

PC14.    support the in charge/ engineer/ shop head in analysing the various data sheets related to production, maintenance, manpower deployment etc

PC15.    support the maintenance team in finalizing the preventive maintenance schedule for the shop/ line

PC16. . support the maintenance function to ensure execution of the maintenance schedules

PC17.    ensure shift handover to the next shift supervisor

PC18.    Observe and note the consumption of energy, fuel, steam on the production line and support the engineer in optimization of utilization of factors of production

PC19..   ensure that the operator and helper are using the required personal protective equipment like goggles, masks, gloves and other ppes at the time of conducting the painting operation

Conformance To Product AndProcess Quality

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

PC20..   conduct incoming quality inspection of material and provide the relevant feedback on the same to the store

PC21.    conduct quality inspection of the process parameters, lab parameters and wip products and provide necessary feedback to the line leaders

PC22.    conduct quality inspection of the finished goods and provide the necessary feedback

PC23.    conduct quality inspection of the first sample/batch to ensure that the quality of the product produced meet customer requirements

PC24.    conduct inspection and analysis of the defects observed in the process and products

Implementation OfInitiatives

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

PC25.    take overall responsibility to ensure adherence to safety standards by all employees and establish zero accident practice in the section

PC26..   implement various business excellence techniques like kaizen, 5s initiatives

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.    relevant manufacturing standards and procedures followed in the company in detail

KU2.    different types of products manufactured by the company

KU3.    knowledge of functional processes like Procurement, Store management, inventory management, quality management and key contact points for query resolution

KU4.    quality norms and standards prescribed in the Quality Manual by the organization for painting

KU5.    5S and Safety norms practiced in the organization

KU6.    different types of manufacturing processes

KU7.    requirement of raw materials used in the process

KU8.    about tools, jigs and fixtures , their usage and maintenance

KU9.    how to operate both in automatic and manual mode

KU10. about the various hazards related to various chemicals if used in the processes

KU11. different types of defects which may arise due to improper manufacturing

KU12. basic Arithmetic and calculation methods

KU13. ability to visualize the final product output and hence decide on the key steps to be followed

KU14. about the hazards involved in the process operations

KU15. about handling of electrical equipment and circuits, rectifiers and control panel etc

KU16. metallurgical and chemical properties of the material under usage

KU17. how to measure the correct specifications of the output in the terms of thickness, hardness, durability, tightness etc

KU18. how to visualize the final product output and hence decide on the parameters of temperature, pressure, current and voltage

KU19. various problems solving tools like 7QC, Why Why Analysis, Brainstorming

Injection Moulding Machine 100 ton, Injection Moulding Machines, इंजेक्शन  मोल्डिंग मशीन in Peenya, Bengaluru , Prashanthi Polymers (India) Private  Limited | ID: 15060483730

Generic Skills (GS)

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

GS1.    document information from the manuals,discussion notes, process charts etc

GS2.    create small notes/ work documents/ diagrams for operators and helpers to help them understand the process

GS3.    write inter departmental notes/ memos or make suitable entries in the online system

GS4.    read equipment manuals and process documents to understand the equipment and processes better

GS5.    read internal information memos send by internal customers ( other functions within the organization)

GS6.    discuss task lists, schedules, and work-loads with the operative team members

GS7.    answer the queries raised by the operative team as well as intercompany departments

GS8.    effectively communicate with the operators and helpers and make them aware of work expectations, targets, policies, processes etc

GS9.    attentively listen with full attention the queries and grievances raised by the operative team and comprehend the information given by the speaker

GS10. communicate effectively to the team members

GS11. identify conflicts in the team and try to resolve them at the earliest

GS12. interact and engage with the team members on a day to day basis

GS13. counsel and coach the operators and help them resolve issues

GS14. timely highlight to the management about any good work/ achievement by the operators and helpers

GS15. break the problem into smaller issues and tasks to arrive at a solution

GS16. understand inter process relationship and establish relationship between various parts of the problem

GS17. leverage experience to find effective solutions to problems

GS18. use basic analytical tools to arrive at solutions

GS19. plan, organize and prioritize the work order and jobs received from the production manager

GS20. manage the schedule plan for the operators and helpers on the line/shift

GS21. validate all process/ equipment manuals so that the final process selected is correct

GS22. organize information, tools, manuals etc on the shop floor so that sorting becomes easy

GS23. reorganize resources on the line/ shift in case of change of plans

GS24. use common sense and make judgments during day to day basis

GS25. use reasoning skills to identify and resolve problems

GS26. use intuition to detect any potential problems which could arise during operations

GS27. accept additional responsibility for self and the team

GS28. encourage self and other to take greater responsibilities

GS29. ensure that the work allocated to the team is completed as per timelines and quality norms

GS30. identify obstacles and bottlenecks in the process and on own find basic level solutions for removing these obstacles

GS31. motivate and provide support for the team on the shop floor

GS32. encourage collaboration between team members

GS33. resolve team issues and grievances to manage conflicts within the team

GS34. create an environment of approachability, trust and openness within the team

GS35. ensure role clarity for all operators and helpers on the line/ shift

GS36. escalate any team related issues to the concerned person at the right time

GS37. identify defective parts in the manufacturing line by comparing

GS38. manufactured pieces with the work standard

GS39. link the defect observed with the overall impact on the performance of the component/ automobile

GS40. support and contribute in monitoring and delivering high quality output from self and others

GS41. train team members on maintaining quality standards set by the organization

GS42. use previous experience in resolving problems and taking decisions

GS43. make timely and independent decisions on the line/ shift within the boundaries of the delegation matrix of the organization

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

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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