Automotive Skills Development Council

Transcription

1 Automotive Skills Development Council QUALIFICATIONS PACK - OCCUPATIONAL STANDARDS FOR AUTOMOTIVE INDUSTRY What are Occupational Standards(OS)? OS describe what individuals need to do, know and understand in order to carry out a particular job role or function OS are performance standards that individuals must achieve when carrying out functions in the workplace, together with specifications of the underpinning knowledge and understanding Contact Us: ASDC, NEW DELHI SKC.ASDC@gmail.com Contents: Introduction 1. Introduction and Contacts.... P1 2. Qualifications Pack....P2 3. Glossary of Key terms... P3 4. OS Units P5 Qualifications Pack- Manager-Stores Operation Level 5 SECTOR: AUTOMOTIVE SUB-SECTOR: SUPPLY CHAIN MANAGEMENT OCCUPATION: LOGISTICS JOB ROLE : MANAGER STORES OPERATION REFERENCE ID: ASC/Q 6104 ALIGNED TO: NCO-2004/ ,~.20, ~.30 Brief Job Description: Individuals at this job need to manage all aspects of material viz. safe receipt, storage-stock, retrieval and issue/ dispatch for the manufacturing or Logistics processes of an organization adhering to the laid down SOP and schedule requirements. Personal Attributes: This job requires the individual to work on a shop floor based job for long hours. The individual should be result oriented. The individual should also be able to demonstrate skills for information ordering, organization, analytical reasoning, problem solving, time management, interpersonal, oral expression and comprehension.

2 Job Details Qualifications Pack For Manager-Stores Operation Qualifications Pack Code Job Role ASC/Q6104 Manager-Stores Operation Credits(NSQF) [OPTIONAL] TBD Version number 1.1 Sector Automotive Drafted on 14/05/13 Sub-sector Supply Chain Management Last reviewed on 14/06/13 Occupation Store/warehouse Management Next review date 30/07/15 Job Role Manager-Stores operation Role Description NSQF level Minimum Educational Qualifications* Maximum Educational Qualifications* 5 Diploma in Mechanical/Electrical/Electronics Engineering Not Applicable Compulsory: Inventory Management Systems like Training FIFO,LIFO (Suggested but not mandatory) Voluntary: Enterprise Resource systems like SAP depending on applicability in organization Experience 0 years if ASDC Level 4 Certificate or minimum 3-4 years in Stores/Warehouse department Applicable National Occupational Standards (NOS) Compulsory: ASC/N6104. Work on the parts/ materials requirement plan from Materials department ASC/N6105. Arrange for materials procurement in coordination with Materials department in case of shortages ASC/N6106. Receive the ordered materials as per plan and place in the respective storage locations of warehouse/stores ASC/N6107. Issue the materials from warehouse/ Stores in coordination with Materials department ASC/N0006. Maintain a healthy, safe and secure working environment ASC/N0022 Optional: N.A. Ensure implementation of 5S activities at the shop floor & the office area 2

3 Qualifications Pack For Manager-Stores Operation Performance Criteria As described in the relevant OS units Keywords /Terms Sector Sub-sector Occupation Function Sub-function Job role Occupational Standards (OS) Performance Criteria National Occupational Standards (OS) Qualifications Pack (QP) Unit Code Unit Title Description Scope Knowledge and Understanding Organizational Context Description Sector is a conglomeration of different business operations having similar business and interests. It may also be defined as a distinct subset of the economy whose components share similar characteristics and interests. Sub-sector is derived from a further breakdown based on the characteristics and interests of its components. Occupation is a set of job roles, which perform similar/ related set of functions in an industry. Function is an activity necessary for achieving the key purpose of the sector, occupation, or an area of work, which can be carried out by a person or a group of persons. Functions are identified through functional analysis and form the basis of OS. Sub-functions are sub-activities essential to fulfill the achieving the objectives of the function. Job role defines a unique set of functions that together form a unique employment opportunity in an organization. OS specify the standards of performance an individual must achieve when carrying out a function in the workplace, together with the knowledge and understanding they need to meet that standard consistently. Occupational Standards are applicable both in the Indian and global contexts. Performance criteria are statements that together specify the standard of performance required when carrying out a task. NOS are occupational standards which apply uniquely in the Indian context. QP comprises the set of OS, together with the educational, training and other criteria required to perform a job role. A QP is assigned a unique qualifications pack code. Unit code is a unique identifier for an Occupational Standard, which is denoted by an N Unit title gives a clear overall statement about what the incumbent should be able to do. Description gives a short summary of the unit content. This would be helpful to anyone searching on a database to verify that this is the appropriate OS they are looking for. Scope is a set of statements specifying the range of variables that an individual may have to deal with in carrying out the function which have a critical impact on quality of performance required. Knowledge and understanding are statements which together specify the technical, generic, professional and organizational specific knowledge that an individual needs in order to perform to the required standard. Organizational context includes the way the organization is structured and how it operates, including the extent of operative knowledge 3

4 Acronyms Technical Knowledge Core Skills/ Generic Skills Keywords /Terms NOS NVQF NSQF NVEQF QP GRN SAP MSDS Qualifications Pack For Manager-Stores Operation managers have of their relevant areas of responsibility. Technical knowledge is the specific knowledge needed to accomplish specific designated responsibilities. Core skills or generic skills are a group of skills that are the key to learning and working in today s world. These skills are typically needed in any work environment in today s world. These skills are typically needed in any work environment. In the context of the OS, these include communication related skills that are applicable to most job roles. Description National Occupational Standard(s) National Vocational Qualifications Framework National Qualifications Framework National Vocational Education Qualifications Framework Qualifications Pack Goods Receipt Note System Application and Products Material Safety Data Sheet 4

5 ASC/N6104 Work on the Requirement plan from Materials department National Occupational Standards Overview This unit is about working on the material requirement plan based on plant schedules & customer orders and assessment of the physical availability of the materials for the fulfilment of customer orders.

6 National Occupational Standard ASC/N6104 Work on the Requirement plan from Materials /Planning department Unit Code Unit Title (Task) Description Scope ASC/N6104 Receive the materials requirement plan from Materials department and work towards materials supply to meet the Production schedules This OS unit is about the stores manager receiving the material requirement plan from the Materials/ Marketing department and assessing the physical availability of materials vis-a- vis the requirement The unit/ task covers the following: receiving the material requirement schedule assessing the physical availability of raw materials actions to meet shortages/ gaps Performance Criteria(PC) w.r.t. the Scope Element Receipt of material schedule/ PO/WO Assessing the availability, documentation Actions to meet the gaps, overall responsibility Performance Criteria To be competent, the user/individual on the job must be able to: PC1. coordinate with the Materials department for acquiring the raw material requirement plan on monthly, quarterly and annual basis PC2. Co-ordinate with PPC/ marketing department for dispatch schedules to various customers/ locations etc. To be competent, the user/individual on the job must be able to: PC3. assess the physical quantity for each material present in the warehouse vis-àvis the requirement and prepare the list of materials that are in sufficient quantity PC4. in case of sufficient material availability in stores, issue the materials from SAP using FIFO system and coordinate with material handling team / equipment for sending it to the shop floor PC5. complete the documentation, entries in the system. Manage data storage related to MSDS, Traceability,material testing etc.corresponding to received and issued material. PC6. work with materials planning & co-ordination team members for day-to day as well as short/ long term planning activities. PC7. plan for material handling & transport vehicles based on the day s load for receipt and dispatch. PC8. decide on hiring external facilities with due approvals of seniors & or freight budget provisions. PC9. work on fall back action plan in case of failures of quantity, timeliness in materials. 6

7 ASC/N6104 Work on the Requirement plan from Materials /Planning department PC10. draw & modify Short term / long term action plans for storage,mh, preservation methods, equipment & facilities,manpower etc. PC11. work on continuous improvement projects in one s own area. PC12. work for physical stock taking, inventory verification, PC13. work for KANBAN, JIT, Milk-run requirements in case adopted by the organizations concerned etc. PC14. work for preservation of material, actions on material disposal, rejected material, production scrap etc. Knowledge and Understanding (K) A. Organizational Context (Knowledge of the company / organization and its processes) B. Technical Knowledge Skills (S) [Optional] A. Core Skills/ Generic Skills The user/individual on the job needs to know and understand: KA1. product portfolio of organization KA2. the manufacturing processes of organization KA3. layout for identification of material storage locations in each plant KA4. protocol for communication regarding materials requirement among the various departments of the organization KA5. agencies on contract for material handling equipment, casual manpower KA6. protocol for periodic activities such as budget planning, Inventory stock taking, disposal of rejection/ scrap generated in production process, stock preservation etc. The individual on the job needs to have knowledge of: KB1. manufacturing process being followed for each product KB2. raw materials being used for manufacturing of each product KB3. physical and chemical properties of each material KB4. storage conditions required for each material KB5. packing and transportation methods for each material KB6. usage knowledge of information systems like SAP, ERP etc. KB7. knowledge of inventory management systems like FIFO, LIFO etc. KB8. KANBAN card details updation in SAP system (if applicable) Basic reading and writing skills The user/ individual on the job needs to know and understand how to: SA1. interpret the material requirement plan SA2. document all the material inventory related data in ERP or SAP / form of spreadsheets using MS Excel Communication skills SA3. communicate with the Materials department & other interfaces in the organization. Teamwork and multitasking SA4. distribute workload for acquiring inventory information for all the materials present in warehouse among workers SA5. share operation knowledge with colleagues and co-workers 7

8 ASC/N6104 Work on the Requirement plan from Materials /Planning department B. Professional Skills Plan and Organize The user/individual on the job needs to know and understand : SB1. to organize the material inventory capturing activity in an efficient and timely manner SB2. to take steps continuously to address the gaps Critical thinking SB3. identification of problems (technical and non-technical), disruptions and delays SB4. escalation procedures SB5. Short term / long term planning strategy in the vendor-organization environment. 8

9 ASC/N6104 Work on the Requirement plan from Materials /Planning department NOS Version Control NOS Code Credits(NSQF) [OPTIONAL] NOS Code ASC/N6104 TBD Version number 1.0 ASC/N6104 9

10 ASC/N/6105 Organize & Plan the procurement & address the shortages National Occupational Standards Overview This unit is about arranging the shortage raw materials for shop floor in coordination with Materials department based on the immediate and future requirements for timely fulfillment of customer orders

11 National Occupational Standard ASC/N6105 Organize & Plan the procurement & address the shortages Unit Code Unit Title (Task) Description Scope ASC/N6105 Arrange for materials procurement in coordination with Materials department in case of shortages This OS unit is about the store deputy manager coordinating with Materials department and ensuring that the shortage raw materials are procured on immediate basis This unit/ task covers the following for material requirement for Production as well as despatches.: prioritising the list of shortage materials based on the immediate requirements informing the Materials department about the list of shortage raw materials specifying the priorities for each follow up with Materials department for the procurement status of the shortage materials make adjustments in the working methodology for improvement based on the experience. Performance Criteria(PC) w.r.t. the Scope Element Prioritization of materials Information of shortages Follow up with Materials department Working methodology Performance Criteria To be competent, the user/individual on the job must be able to: PC1. prioritize the materials based on the immediate and future requirements of the shop floor PC2. Co-ordinate with Planning department for finalizing the priorities for each shortage material PC3. dynamically update the lists based on suitable, agreed frequency with the user interface in the organization To be competent, the user/individual on the job must be able to: PC4. Submit the finalized list of shortage raw materials to the Materials department PC5. update the list of shortages in SAP PC6. Coordinate with the Materials department to get a rough estimate of the expected delivery lead time for all these materials PC7. inform the Production/ Marketing department about expected period of availability in warehouse for each of the shortage raw material PC8. Take a daily follow up with Materials department about the material procurement/shipment status PC9. inform about the shipment status also to Production department on daily basis PC10. make changes in the working methodology in consultation with the interfacing departments in the organization.

12 ASC/N6105 Organize & Plan the procurement & address the shortages Knowledge and Understanding (K) A. Organizational Context (Knowledge of the company / organization and its processes) B. Technical Knowledge Skills (S) [Optional] A. Core Skills/ Generic Skills The user/individual on the job needs to know and understand: KA1. the manufacturing processes of organization KA2. classification of materials based on the criticality and quality KA3. storage and transportation media for materials from vendors warehouse to the organization KA4. protocol for communication regarding materials requirement among the various departments of the organization KB1. raw materials/ BOF parts being used for manufacturing of each product KB2. physical and chemical properties of each material KB3. methodology followed for classification of materials based on criticality and quality KB4. the complete knowledge of information flow for material tracking and dispatch KB5. usage knowledge of information systems like SAP, ERP etc. Basic reading and writing skills The user/ individual on the job needs to know and understand how to: SA1. read the delivery schedule of materials/ WO/PO in SAP SA2. document all the material classification related data in form of spreadsheets using MS Excel Communication skills The user/individual on the job needs to know and understand how to: SA3. communicate with the Materials department for gathering data about material delivery / shipment status SA4. coordinate with executives in Production department for gathering material requirements priorities Teamwork and multitasking The user/individual on the job needs to know and understand how to: SA5. distribute workload for acquiring material classification information for all the materials present in warehouse among workers SA6. share operation knowledge with colleagues and co-workers B. Professional Skills Critical thinking The user/individual on the job needs to know and understand: SB1. identification of problems (technical and non-technical), disruptions and delays SB2. escalation procedures SB3. working to develop the Fall back action plan in the organization- vendor base environment. Decision Making The user/individual on the job needs to know and understand how to: SB4. decide and prioritize material based on criticality in case of shortages of 12

13 ASC/N6105 Organize & Plan the procurement & address the shortages materials NOS Code ASC/N6105 Credits(NSQF/NSQF) [OPTIONAL] TBD Version number 1.0 Industry Automotive Drafted on 24/05/13 Industry Sub-sector Supply Chain Management Last reviewed on 14/06/13 Occupation Store/warehouse Management Next review date 30/07/15 NOS Version Control 13

14 ASC/N6106. Receive the materials as per plan and place it in the respective storage locations of warehouse National Occupational Standards Overview This unit about the receipt and safe storage of the Quality certified OK shortage raw materials at the designated locations in warehouse in coordination with Materials department

15 National Occupational Standard ASC/N6106. Receive the materials as per plan and place it in the respective storage locations of warehouse Unit Code Unit Title (Task) Description Scope ASC/N6106 Receive the shipped materials as per plan and place it in the respective storage locations of warehouse This OS unit is about the store deputy manager receiving the shipped shortage raw materials certified OK by Quality department and placing it in the respective storage locations of the warehouse This unit/ task covers the following: Performance Criteria(PC) w.r.t. the Scope Element Receipt of materials Storage of the materials Long term & periodic actions Knowledge and Understanding (K) receiving the materials in the warehouse after Quality inspection storing the materials in the designated locations in warehouse and updating the KANBAN card accordingly Performance Criteria To be competent, the user/individual on the job must be able to: PC1. Coordinate with the Materials department and receive the shipped shortage raw materials in the warehouse only after being certified OK during incoming inspection by Quality department PC2. Unload the material safely in warehouse using material handling equipments To be competent, the user/individual on the job must be able to: PC3. After unloading the material, move the material from the unloading point to the respective storage location of the material in warehouse PC4. Place the material in the shelf/bin based on the FIFO sequence and update the KANBAN card accordingly PC5. Ensure that the material has been placed safely in the shelf/bin PC6. Update the respective material quantity in SAP PC7. Prepare MIS on inventory,improvement actions & corresponding budgets. PC8. Ensure material preservation at all times & establish frequency for review PC9. Work with material planning on non-moving materials. A. Organizational The user/individual on the job needs to know and understand: Context (Knowledge of KA1. layout for identification of material storage locations in each plant the company / KA2. safety policies and procedures to be followed for material unloading and storage in stores organization and its KA3. the individual storage layout for all the warehouses along with the designated processes) locations earmarked for respective materials KA4. escalation procedure in case of crisis and emergency situations B. Technical Knowledge The individual on the job needs to know and understand: KB1. physical and chemical properties of each material KB2. Storage, preservation conditions required for each material KB3. packing and transportation methods for each material KB4. usage knowledge of information systems like SAP, ERP etc. 15

16 ASC/N6106. Receive the materials as per plan and place it in the respective storage locations of warehouse KB5. working knowledge of material handling equipments for unloading of materials Skills (S) [Optional] A. Core Skills/ Generic Skills Basic reading and writing skills The user/individual on the job needs to know and understand how: SA1. read the packaging instructions and safety warnings printed on labels of packaged materials SA2. read the information mentioned on the KANBAN card SA3. document all the received material related data in form of spreadsheets using MS Excel Communication skills The user/individual on the job needs to know and understand how: SA4. coordinate with workers for material movement within the warehouse SA5. coordinating with Quality department for getting the inspection report of the received material Team work and multi tasking The user/individual on the job needs to know and understand how to: SA6. coordinate with workers and arrange all the received materials safely and at the designated locations in warehouse SA7. share operation knowledge with colleagues and co-workers B. Professional Skills Plan and Organize The user/individual on the job needs to know and understand how to: SB1. organize the material unloading and storage in a safe, efficient and timely manner Problem Solving The user/individual on the job needs to know and understand how to: SB2. assess the problem, evaluate the possible solution(s) and use an optimum /best possible solution(s) SB3. identify immediate or temporary solutions to resolve delays and crisis situations 16

17 ASC/N6106. Receive the materials as per plan and place it in the respective storage locations of warehouse NOS Version Control NOS Code ASC/N6106 Credits(NSQF/NSQF) [OPTIONAL] TBD Version number 1.0 Industry Automotive Drafted on 24/05/13 Industry Sub-sector Supply Chain Management Last reviewed on 15/06/13 Occupation Store/warehouse Management Next review date 30/07/15 17

18 ASC/N6107. Issue the materials from warehouse/ Stores in coordination with Materials department National Occupational Standards Overview This unit is about issuance of the received raw materials on shop floor as per requirement in coordination with Materials department and maintenance of a safe and clean working environment in warehouse. 18

19 National Occupational Standard ASC/N6107. Issue the materials from warehouse/ Stores in coordination with Materials department Unit Code Unit Title (Task) Description Scope ASC/N6107 Issue the materials from warehouse in coordination with Materials department This OS unit is about store manager issuing the received raw materials to shop floor in coordination with Materials/Planning department; thereby ensuring optimal schedule adherence for the various products This unit/ task covers the following: Performance Criteria(PC) w.r.t. the Scope Element Issuance of material on shop floor/ for despatch Monitoring the stock of material in warehouse issuing the materials based on the requisitions raised by Production department on shop floor & WO by Planning for dispatch goods. monitoring the quality of the material while in storage in warehouse Performance Criteria To be competent, the user/individual on the job must be able to: PC1. based on the material requisitions/wo raised by the Production department or Planning department through SAP, issue the material for usage as per the FIFO system PC2. coordinate with the Materials department for safe movement of materials from warehouse to shop floor process storage location using material handling equipments PC3. ensure all the documentation related for dispatch is in order and accompanying the shipment in the packing box/ with the driver of the transport vehicle. PC4. update the KANBAN card accordingly based on the remaining physical quantity of material available in stores/ warehouse PC5. update the current stock of the issued material in SAP To be competent, the user/individual on the job must be able to: PC6. keep a track of the physical quantity of various materials available in the warehouse on daily basis PC7. ensure that the quantity of respective material mentioned in physical inventory and system inventory are matching PC8. monitor the status of KANBAN cards for individual materials and ensure that the card replacement while issuance of material is being strictly adhered on daily basis. PC9. in case of any damage to the material kept while movement within the 19

20 ASC/N6107. Issue the materials from warehouse/ Stores in coordination with Materials department warehouse, immediately inform the Materials department and scrap the material by raising a scrap note in SAP PC10. inform the Materials department about the fresh quantity to be procured for the scrapped material Long Term/ periodic actions Knowledge and Understanding (K) A. Organizational Context (Knowledge of the company / organization and its processes) B. Technical Knowledge Skills (S) [Optional] A. Core Skills/Generic Skills PC11. implement a warehouse improvement plan & ensure its adherence strictly PC12. work towards preparation of annual budgets based on the guidelines. PC13. work for implementation of KRA s. The user/individual on the job needs to know and understand: KA1. the manufacturing processes of organization KA2. layout for identification of material storage locations in each plant KA3. the individual storage layout for all the warehouses along with the designated locations earmarked for respective materials KA4. safety practices and procedure being followed in organization for warehouse management KA5. escalation procedure in case of accident and emergency situations The individual on the job needs to know and understand how to: manufacturing process being followed for each product KB1. raw materials being used for manufacturing of each product KB2. physical and chemical properties of each material KB3. storage conditions required for each material KB4. usage knowledge of information systems like SAP, ERP, KANBAN etc. KB5. working knowledge of material handling equipments for unloading of materials KB6. KANBAN card details updation in SAP system (if applicable) KB7. knowledge of inventory management systems like FIFO, LIFO etc. KB8. complete knowledge of documents received from vendors related to material safety like MSDS, Do s and Dont s etc. Communication skills The user/individual on the job needs to know and understand how to : SA1. communicate with the workers for material movement within the warehouse SA2. communicate with executives of Planning department for movement of issued material from warehouse to the shop floor/ dispatch Teamwork and multitasking The user/ individual on the job needs to know and understand how to: SA3. share operation knowledge with colleagues and co-workers 20

21 ASC/N6107. Issue the materials from warehouse/ Stores in coordination with Materials department B. Professional Skills Decision making The user/ individual on the job needs to make decisions pertaining to: SB1. accident and emergency situations Problem Solving The user/individual on the job needs to know and understand how to: SB2. assess the problem, evaluate the possible solution(s) and use an optimum /best possible solution(s) SB3. identify immediate or temporary solutions to resolve delays and crisis situations Critical thinking The user/individual on the job needs to know and understand how to: SB4. anticipate technical and non-technical problems and resolve proactively 21

22 ASC/N6107. Issue the materials from warehouse/ Stores in coordination with Materials department NOS Version Control NOS Code ASC/N6107 Credits(NSQF/NSQF) [OPTIONAL] TBD Version number 1.0 Industry Automotive Drafted on 24/05/13 Industry Sub-sector Supply Chain Management Last reviewed on 20/06/13 Occupation Store/warehouse Management Next review date 30/07/15 22

23 ASC/N0006. Maintain a safe, clean and secure working environment National Occupational Standards Overview This unit is about establishing a Safe, Healthy and Environment friendly workplace 23

24 National Occupational Standard ASC/N0006. Maintain a safe, clean and secure working environment Unit Code Unit Title (Task) Description Scope ASC/N0006 Maintain a healthy, safe and secure working environment This OS unit is about creating a Safe and Healthy work place, adhering to the safety guidelines in the working area, following practices which are not impacting the environment in a negative manner This unit/task covers the following: Types of support processes: Stores Loading and Unloading Types of products individual child parts part assemblies Performance Criteria (PC) w.r.t. the Scope Element Performance Criteria Identify and report the risks To be competent, the user/individual on the job must be able to : identified Create and sustain a Safe, clean and environment friendly work place 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 damages which can potentially harm man/ machine during operations PC4. create awareness amongst other by sharing information on the identified risks 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 happens in the designated area as 24

25 ASC/N0006. Maintain a safe, clean and secure working environment per organization SOP. PC11. inform appropriately the medical officer/ HR in case of self or an employee s illness of contagious nature so that preventive actions can be planned for others. Knowledge and Understanding (K) w.r.t. the scope Element A. Organizational Context (Knowledge of the company / organization and its processes) Knowledge and Understanding The user/individual on the job needs to know and understand: KA1. relevant standards, procedures and policies related to Health, Safety and Environment followed in the company A. Technical Knowledge The user/individual on the job needs to know and understand: KB1. basic knowledge of Safety procedures( fire fighting, first aid) within the organization KB2. basic knowledge of various types of PPEs and their usage KB3. basic knowledge of risks associated with each occupation in the organization KB4. knowledge of personal hygiene and how an individual an contribute towards creating a highly safe and clean working environment Skills (S) w.r.t. the scope Element Skills A. Core Skills/ Generic Skills Writing Skills The user/ individual on the job needs to know and understand how to: SA1. write basic level notes and observations Reading Skills The user/individual on the job needs to know and understand how to: SA2. read safety instructions put up across the plant premises SA3. read safety precautions mentioned in equipment manuals and panels to understand the potential risks associate with the equipment Oral Communication (Listening and Speaking skills) The user/individual on the job needs to know and understand how to: SA4. effectively communicate information to team members and Inform employees in the plant and concerned functions about potentials Safety, Health and Environment related risks observed SA5. question operator/ supervisor in order to understand the safety related issues SA6. attentively listen with full attention and comprehend the information given by the speaker during safety drills and training programs B. Professional Skills Judgmental Thinking 25

26 ASC/N0006. Maintain a safe, clean and secure working environment The user/individual on the job needs to know and understand how to: SB1. use common sense and make judgments during day to day basis SB2. use reasoning skills to identify and resolve basic problems NOS Version Control NOS Code ASC/N0006 Credits(NSQF/NSQF) TBD Version number 1.0 Industry Automotive Drafted on 14/05/13 Industry Sub-sector Supply Chain Management Last reviewed on 14/06/13 Occupation Store/warehouse Management Next review date 30/07/15 26

27 ASC/N0022. Ensure Implementation of 5 S activities in the workshop and office National Occupational Standard Overview This unit is about the implementing the various principles of 5S and ensure that the given guidelines are followed to ensure a clean and efficient working environment in the organization 27

28 National Occupational Standard ASC/N0022. Ensure Implementation of 5 S activities in the workshop and office Unit Code Unit Title (Task) Description Scope ASC/N0022 Ensure implementation of 5S activities at the shop floor & the office area This NOS is about overseeing the implementation of all 5 S activities both at the shop floor and the office area by the team members and training the team in implementation of the 5S principles The individual needs to Ensure sorting, streamlining/ organizing, storage and documentation, systematic cleaning, standardization and sustenance across the plant and office premises of the organization as given in the organization guidelines Performance Criteria (PC) w.r.t. the Scope Element Performance Criteria Ensure proper sorting of PC1. Ensure all recyclable materials are put in designated containers items at the work place 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/ Ensure proper documentation and storage streamlining & organizing the workplace breakage and also enable easy sorting when required 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 28

29 ASC/N0022. Ensure Implementation of 5 S activities in the workshop and office Ensure cleaning of self and the work place Ensure standardization Ensure sustenance Knowledge and Understanding (K) w.r.t. the scope Element 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. 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 self-cleanliness - clean uniform, clean shoes, clean gloves, clean helmets, personal hygiene PC18. Ensure that daily cleaning standards and schedules to create a clean working environment are followed across the plant PC19. Oversee that various cleaning and organizing tasks have been developed and assigned for the work area 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 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 29

30 ASC/N0022. Ensure Implementation of 5 S activities in the workshop and office A. Organizational Context (Knowledge of the company / organization and its processes) The user/individual on the job needs to know and understand: KA1. relevant standards, procedures and policies related to 5S followed in the company B. Technical Knowledge The user/individual on the job needs to : KB5. have basic knowledge of 5S procedures KB6. know various types 5s practices followed in various areas KB7. understand the 5S checklists provided in the department/ team KB8. have skills to identify useful & non useful items KB9. have knowledge of labels, signs & colours used as indicators KB10. Have knowledge on how to sort and store various types of tools, equipment, material etc. KB11. know, how to identify various types of waste products KB12. understand the impact of waste/ dirt/ dust/unwanted substances on the process/ environment/ machinery/ human body KB13. have knowledge of best and environment protective ways of cleaning & waste disposal KB14. understand the importance of standardization in processes KB15. understand the importance of sustainability in 5S KB16. have knowledge of TQM process KB17. have knowledge of various materials and storage norms KB18. understand visual controls, symbols, graphs etc. Skills (S)w.r.t. the scope Element Skills A. Core Skills/ Generic Skills Writing Skills The user/ individual on the job needs to know and understand how to: SA7. write basic level notes and observations SA8. note down observations (if any) related to the process SA9. write information documents to internal departments/ internal teams Reading Skills The user/individual on the job needs to know and understand how to: SA10. read 5S instructions put up across the plant premises Oral Communication (Listening and Speaking skills) 30

31 ASC/N0022. Ensure Implementation of 5 S activities in the workshop and office The user/individual on the job needs to know and understand how to: SA11. effectively communicate information to team members inform employees in the plant and concerned functions about 5S SA12. question the process head in order to understand the 5S related issues SA13. attentively listen with full attention and comprehend the information given by the speaker during 5S training programs B. Professional Skills Judgmental Thinking The user/individual on the job needs to know and understand how to: SB3. use common sense and make judgments during day to day basis SB4. use reasoning skills to identify and resolve basic problems using 5S Persuasion The user/ individual on the jobs needs to know and understand how to: SB5. persuade team members to follow 5 S SB6. ensure that the team members understand the importance of using 5 S tool Creativity The user/individual on the job needs to know and understand how to : SB7. use innovative skills to perform and manage 5 S activities at the work desk and the shop floor SB8. 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 Self -Discipline The user/individual on the job needs to know and understand how to: SB9. do what is right, not what is a popular practice SB10. follow shop floor rules& regulations and avoid deviations SB11. lead by example in the plant premises while performing activities related to 5S SB12. ensure self-cleanliness on a daily basis SB13. demonstrate the will to keep the work area in a clean and orderly manner Ownership The user/individual on the job needs to know and understand how to: SB14. accept additional responsibility for self and the team SB15. encourage self and other to take greater responsibilities for managing 5S SB16. identify obstacles and bottlenecks in the process and find basic level solutions for removing these obstacles Decision making 31

32 ASC/N0022. Ensure Implementation of 5 S activities in the workshop and office The user/individual on the job needs to know and understand how to: SB17. use previous experience in resolving problems and taking decisions SB18. make timely and independent decisions on the line/ shift within the boundaries of the delegation matrix of the organization NOS Version Control 32

33 ASC/N0022. Ensure Implementation of 5 S activities in the workshop and office NOS Code ASC/N0022 Credits(NSQF) TBD Version number 1 Industry Automotive Drafted on 1/03/2014 Industry Sub-sector Manufacturing/ R&D Last reviewed on 15/03/2014 Occupation All Next review date 15/03/

34 ASC/N0022. Ensure Implementation of 5 S activities in the workshop and office 34