Free Supervisor Manufacturing and R&D Quality Level 7 Course (6Months)

Supervisor Manufacturing and R&D Quality Level 7:

Brief Job Description

Individuals at this job need to be responsible for the quality inspection, performance and improvement of in process products and their Manufacturing and R&D processes in order to deliver high quality to customers

Personal Attributes

This job requires the individual to be able to coordinate internally and externally within the organization. The individual should be result oriented andpossess strong quality management skills. The individual should also be able to demonstrate skills for mathematical reasoning, problem solving, relationship building and leadership

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 process and product quality:

Elements and Performance Criteria

Inspection of final products

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

PC1..     prepare a quality plan for product and process audit on annual basis and further bifurcate month wise after discussion with the qc inspectors

PC2..     distribute the roles and responsibilities among the qc inspectors and ensure the strict implementation of the plan

PC3..     ensure that the respective QC inspectors prepare the checklist for product audit including the following checkpoints : product dimensions functionality including Performance validation packaging & labeling

PC4..     ensure that the frequency of the product audit is mentioned in the quality plan at npd stage and is strictly adhered to

PC5..     coordinate with qc inspector and monitor the product audit activity. layout inspection / re- validation results are tallied with the design/development records

PC6..     based on the results obtained , discuss with the manufacturing process owners for countermeasures required to resolve the non-conformities in the product audit and the expected timeline for same

PC7..     ensure that all the findings of the product audit is documented & communicated to customer as per sop .ensure the discrepancies observed are co-related with 0-km / warranty performance and appropriate action plans are drawn with functional stake holders viz. production, process engg., r & d etc. & findings are reflected in the process documentation : PFMEA/CP as applicable

Audit and validation of processes

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

PC8..     based on the quality plan , prepare a comprehensive manufacturing process audit checklist including the following checkpoints : raw material purchase from an approved supplier material inspection as per the requirements calibration of gauges used material in storage with labeling and preservation proper instructions followed for withdrawing from inventory (rotation, handling, )etc. part made on machine per the control plan SPC done as defined on the control plan process rate per requirements TPM followed for equipments quality data analysis for rejections, COPQ, NCs status etc. quality levels meet requirements (scrap, etc.) all steps / sequence on the control plan followed inspection requirements followed skill levels of shop floor workforce

PC9..     frequency of the process audit

PC10..   repeat the steps from pc5. to 8; only instead of product audit , the qc inspector should be conducting the process audit activity

PC11..   based on the requirements of the process, ensure that the validation of manufacturing processes is being carried out by respective QC inspectors covering the following checkpoints: defined criteria for review and approval of the processes, approval of equipment and qualification of personnel, use of specific methods and procedures, requirements for records revalidation

PC12..   ensure that the process validation non-conformities are resolved by discussion with manufacturing process owners and the processes are revalidated.

PC13..   give feedback to npd- cft for implementation in subsequent projects. if required, seek support/feedback from senior management as per requirement

QMS Audit

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

PC14..   be a certified internal auditor for qms/ts16949 system by undergoing the training for internal audit

PC15..   internally audit the processes and the corresponding products as per the central internal audit plan

PC16..   discuss with process owners and explain the reasons for giving ncs in the audit. be judicious about the ncs to be customer/ quality /improvement centric

PC17..   ensure that the process team has mentioned suggested effective countermeasures for the root cause ( usage of 5 why etc.)

PC18..   based on the implementation date , re-audit the non-conforming process and ensure that the ncs are closed and closure report is also prepared as per the prescribed format

PC19..   submit the internal auditors report to the process owners for their records

PC 20.. if required , be an auditee for the same process for the external audit by certification agency

PC21..   ensure the smooth conduct of external audit and ensure the identified ncs are closed and signed off as per the timelines

Process capability studies

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

PC22..   coordinate with team and ensure that the specifications are clearly understood and maintained throughout the process

PC23..   ensure that the team has prioritized the process activities based on criticality and identified the same in the pfmeas and control plans

PC24..   ensure that the team has prepared a comprehensive spc schedule for carrying out the process capability studies and is strictly adhering to it

PC25..   monitor the spc activity and review the cp and cpk for the critical processes- as indicated in cp

PC26..   in case of Cp and Cpk for any of the processes less than 1.33 , ensure that the team had identified the abnormal process points (special causes) and devised the countermeasures for their rectification

PC27..   ensure that the team had completely documented the process capability report and the charts for process variation depiction like x bar , range chart etc. are mapped and documented for recording purposes

Standards & measuring instruments & Equipments

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

PC28..   strategize & co-ordinate the activities for quality assurance of the product , quality and measurement standards and link with the working of relevant functions

Fixtures and equipments inspection

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

PC29..   prepare a plan for quality inspection of tools/fixtures/gauges covering the following checkpoints : dimensions, profiles, GD&T aspects etc. tools properties like surface finish, hardness, geometric parameters e.g. roundness, concentricity etc. precision and accuracy of usage on CMM , gauges like bore/air, slip , roundness tester etc. MSA study results for gauges and R&R as defined in SOP calibration in the Standards Room/ Lab wear and tear, damages/breakages etc

PC30..   based on the inspection results/defects observed , analyze and discuss with the process owners countermeasures for rectification of defects and re- inspect

PC31..   also in discussion with quality manager , inspect the fixtures used in manufacturing process in coordination with Maintenance and Process Engineering department for following checkpoints & co-relate results with the trends for the parameters in the product : fixtures profiles , dimensions wear and tear damages/breakages

PC32..   analyze the defects observed and discuss with the concerned departments for countermeasures to be implemented for defect rectification re-inspect the defective fixtures after the implementation

Problem Solving

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

PC33..   rejection and apply suitable prioritization and quality tools to find solutions , lead the problem solving teams.

PC34..   pfmea /cp and update the occurrence and detection related entries suitably.

PC35..   need for experts from pe, engineering/ r & d , maintenance to solve the problems and get these co-opted in the team

Documentation and reports

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

PC36.. ensure that the team records all the data and reports related to quality like the rejection trends , copq, no. of ncs, no. of internal customer complaints, process validation, product and process audit reports etc.

PC37..   coordinate with the qc inspectors and review the defect trends (pareto charts, histograms, capability index etc.) and ensure that the countermeasures for defect prevention have been implemented

PC38..   ensure that all the pfds, pfmeas, control plans, calibration records etc. are well documented, updated and reviewed as per schedule

PC39..   ensure that all the msa and process control studies are regularly being conducted by the respective qc inspectors and well documented

PC40..   prepare the mis for process quality and share it with senior management once a month for the review

PC41..   all the reports/ppap documents pertaining to new process/product development are recorded and well documented

PC42..   ensure that the team updates all the data related to quality in the information system followed in organization like sap/erp etc. (if applicable)

Resource management

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

PC43..   provide approval for recruitment of sufficient amount of staff in coordination with hr department for carrying out the various activities in different departments of customer quality assurance

PC44..   ensure that the new joinees are given proper training by the existing staff members in an efficient and timely manner

PC45..   prepare the annual budget for the customer quality assurance activities and seek approval from senior management

PC46..   provide inputs for mis report for quality assurance on monthly basis

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.    TS-16949/any other QMS system guidelines followed in the organization

KU7.    New Process/Product development protocol and methodology

KU8.    third party agencies for calibration of equipments

KU9.           manufacturing process being followed for each product

KU10. inspection checkpoints for product and process audits

KU11. tests performed for product and process parameters maintenance

KU12. process validation methodology followed

KU13. R&R gauge study procedures

KU14. calibration certificate contents

KU15. QC tools like MSA , SPC , Pareto analysis , Fishbone diagram etc.

KU16. APQP procedures

KU17. data analysis tools like TOPS-8Ds , five why analysis etc.

KU18. documentation requirements for PPAP

KU19. documentation requirements for TS-16949/QMS system followed KU20. laboratory and testing guidelines mentioned in ISO/IEC17025 standard KU21. standard room parameters and requirements

KU22. dimension validation and testing methods for product

KU23. testing equipments operational knowledge

KU24. information systems like SAP, ERP etc

Generic Skills (GS)

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

GS1.    the supplier quality and the concerned departments for discrepancies observed in new parts/tool development

GS2.    senior management for updating the progress and seeking their support

GS3.    team members for reviewing the progress of day to day activities

GS4.    distribute workload among team members ensuring smooth progress of material inspection activity and within the desired timelines

GS5.    coordinate with various departments like Metallurgy , Vendor Development, Manufacturing, R&D, process Quality etc. based on the requirement /subassembly validation

GS6.    share operation knowledge with colleagues

GS7.    understand the drawings for part/tool and interpret the key characteristics like dimensions, profile, material etc

GS8.    prepare the dimension testing reports for the parts/sub-assemblies using precise terminology for acceptance, defects , actions to be taken etc

GS9.    understand the inspection reports of the Metallurgy /Materials department

GS10. prepare the inspection reports and maintain records

GS11. think through and devise the countermeasure for resolution for any quality related issue observed in the manufacturing process

GS12. work on actions to be taken on immediate basis in case of frequent rejections during the manufacturing processes

GS13. resolve issues related to process control and MSA studies implementation

GS14. devise and implement interim/permanent countermeasures for the nonconformities observed during the product and the process audit based on the severity

GS15. brainstorm the reasons for abnormal special causes identified in SPC analysis for the unstable processes and devise their countermeasures

GS16. identify problems (technical and non-technical), disruptions and delays

GS17. analyze the interim countermeasures taken for the resolution of nonconformities observed in the product & process audit and accordingly devise the permanent countermeasures for prevention from re-occurrence

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.