Contents QUALIFICATIONS PACK - OCCUPATIONAL STANDARDS FOR FOOD PROCESSING. Introduction. Qualifications Pack Corn Starch Manufacturing Technician

Transcription

1 QUALIFICATIONS PACK - OCCUPATIONAL STANDARDS FOR FOOD PROCESSING 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 Food Industry Capacity & Skill Initiative FICCI office 1, Federation House Tansen Marg New Delhi E mail: ceo.ficsi@ficci.com Contents 1. Introduction and Contacts [1] 2. Qualifications Pack..[2] 3. Glossary of Key Terms [3] 4. OS Units [5] 5. Annexure: Nomenclature for QP and NOS [30] 6. Assessment Criteria [32] Qualifications Pack Corn Starch Manufacturing Technician SECTOR: FOOD PROCESSING SUB-SECTOR: FOOD GRAIN MILLING (OILSEEDS) OCCUPATION: Processing REFERENCE ID: FIC/Q1007 ALIGNED TO: NCO-2004/NIL Introduction A Corn Starch Manufacturing Technician is responsible for separating corn starch, bran, and gluten through wet milling process. S/he operates roller mill to grind corn into meal and corn flour through the dry milling process. Brief Job Description: A Corn Starch Manufacturing Technician is responsible for separating corn starch, bran, and gluten through the process of cleaning, steeping, grinding, germ separation, washing, fiber removal, centrifugation, gluten separation, starch washing, dewatering and drying through the in wet milling process and then operating roller mill to grind corn into meal and flour. Personal Attributes: A Corn Starch Manufacturing Technician must be able to read, write, communicate, must have mathematical ability to calculate, plan, organize and prioritize. S/he must be able to concentre, handle pressure, possess physical stamina, mechanical aptitude and trouble shooting skills. Page 1

2 Job Details Qualifications Pack For Corn Starch Manufacturing Technician Qualifications Pack Code FIC/Q1007 Job Role Corn Starch Manufacturing Technician Credits (NSQF) TBD Version number 1.0 Sector Food Processing Drafted on 26/11/2015 Sub-sector Food grain milling (Oilseeds) Last reviewed on 30/03/2016 Occupation Processing Next review date 30/03/2019 NSQC clearance date N/A Job Role Role Description NSQF level Minimum Educational Qualifications Maximum Educational Qualifications Corn Starch Manufacturing Technician A Corn Starch Manufacturing Technician is responsible for operating and maintaining process parameters of all process machineries to produce corn starch through wet and dry milling. 4 Preferably Class 10 Not applicable Training (Suggested but not mandatory) N/A Experience Applicable National Occupational Standards (NOS) Performance Criteria 0-1 years in a food processing unit Compulsory: 1. FIC/N0123 Prepare and maintain work area and process machineries for production of corn starch 2. FIC/N0124 Carry out production of corn starch 3. FIC/N0125 Complete documentation and record keeping related to production of corn starch 4. FIC/N9001 Ensure food safety, hygiene and sanitation for processing food products Optional: N.A. As described in the relevant OS units Page 2

3 Definitions Qualifications Pack For Corn Starch Manufacturing Technician Keywords /Terms Sector Sub-sector Occupation Function Job Role OS Performance Criteria NOS Qualifications Pack Code Qualifications Pack Unit Code Unit Title Description Knowledge and Understanding Organizational Context Technical Knowledge Core Skills or Generic Skills Description Sector is a conglomeration of different business operations having similar businesses 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 area of work, which can be carried out by a person or a group of persons. Functions are identified through analysis and form the basis of OS. 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. Qualifications Pack Code is a unique reference code that identifies a qualifications pack. Qualifications Pack comprises the set of OS, together with the educational, training and other criteria required to perform a job role. A Qualifications Pack is assigned a unique qualification 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. 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 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 key to learning and working 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. Page 3

4 Acronyms Qualifications Pack For Corn Starch Manufacturing Technician Keywords /Terms CIP COP ERP FIFO FEFO FSSAI GMP GHP HACCP NOS NSQF OS PC QP SSC SOP QMS Description Clean In Place Clean Out Of Place Enterprise Resource Planning First In First Out First Expiry First Out Food Safety and Standards Authority of India Good Manufacturing Practice Good Hygiene Practices Hazard Analysis and Critical Control Point National Occupational Standard National Skill Qualification Framework Occupational Standard Performance Criteria Qualification Pack Sector Skill Council Standard Operating Procedure Quality Management System Page 4

5 FIC/N1023 Prepare and maintain work area and process machineries for production of corn starch Overview This OS unit is about preparing work area for hygiene and safety, and ensuring performance, efficiency and maintenance of process machineries and tools for production of corn starch, as per the specifications and standards of the organization. Page 5

6 National Occupational Standard FIC/N1023 Unit Code Unit Title (Task) Description Scope Prepare and maintain work area and process machineries for production of corn starch FIC/N1023 Prepare and maintain work area and process machineries for production of corn starch This OS unit is about preparing and maintaining work area and process machineries for the production of corn starch. This unit/task covers the following: Prepare and maintain work area for production of corn starch Prepare and maintain process machineries and tools for production of corn starch Performance Criteria(PC) w.r.t. the Scope Element Prepare and maintain work area for production of corn starch Performance Criteria PC1. clean and maintain the cleanliness of the work area using approved sanitizers and keep it free from dust, waste and pests PC2. ensure that the work area is safe and hygienic for food processing PC3. dispose waste materials as per defined SOPs and industry requirements Prepare and maintain process machineries and tools for production of corn starch PC4. check the working and performance of all machineries and tools used for production of corn starch such as cleaning machines, grinding machines, hydrocyclones, centrifuge, filters, roller mill, sieving machines, drying machine, packaging machines, etc. PC5. clean machineries and tools used, with recommended sanitizers following the SOP PC6. place the necessary tools required for process PC7. attend to the minor repairs/ faults of all machines, if required Knowledge and Understanding (K) A. Organizational Context (Knowledge of the company / organization and its processes) The user/individual on the job needs to know and understand: KA1. hygeine requirements and standards relavnat to food processing unit KA2. standards and procedures followed in the organisation for cleaning process and to disinfect equipment/ tools KA3. job responsibilities/duties to maintian hygiene standards KA4. dress code to be followed KA5. whom to approach for support in order to obtain work related instructions, clarifications and support KA6. relevant people and their responsibilities within the work area KA7. importance of following hygiene, safety and quality standards and the impact of not following the standards Page 6

7 FIC/N1023 Prepare and maintain work area and process machineries for production of corn starch B. Technical Knowledge Skills (S) [Optional] A. Core Skills/ Generic Skills The user/individual on the job needs to know and understand: KB1. types of chemicals, materials and equipment required for cleaning and maintenance KB2. cleaning process to disinfect equipment/ tools KB3. supplier/manufacturers instructions related to cleaning and maintenance KB4. knowledge of Food Safety Standards and Regulations (as per FSSAI) KB5. knowledge of legal regulations pertaining to work place like health and safety, recommended dosage for use of sanitizers, control of substances hazardous to health, handling/storage/ disposal/ cautions of use of sanitizers and disinfectants, fire precautions, occurrences, hygiene practice, disposal of waste, environmental protection, etc. Writing Skills The user/ individual on the job needs to know and understand how to: SA1. note the information communicated SA2. note the raw materials used for production and the finished products produced SA3. note the readings of the process parameters and provide necessary information to fill the process chart SA4. note down observations (if any) related to the process SA5. write information documents to internal departments/ internal teams SA6. note down the data for online ERP or as per applicability in the organization Reading Skills B. Professional Skills Decision Making SA7. read and interpret the process required for producing various types of products SA8. read and interpret and process flowchart for all products produced SA9. read equipment manuals and process documents to understand the equipments operation and process requirement SA10. read internal information documents sent by internal teams Oral Communication (Listening and Speaking skills) SA11. discuss task lists, schedules and activities SA12. effectively communicate with team members SA13. question in order to understand the nature of the problem and to clarify queries SA14. attentively listen and comprehend the information given by the speaker SA15. communicate clearly on the issues being faced Page 7

8 FIC/N1023 Prepare and maintain work area and process machineries for production of corn starch SB1. analyse critical points in day to day tasks through experience and observation and identify control measures to solve the issue SB2. handle issues in case the manager is not available (as per the authority matrix defined by the organization) Plan and Organize SB3. plan and organize the work order and jobs received SB4. organize raw materials and packaging materials required for all products SB5. plan and prioritize the work based on the instructions received SB6. plan to utilise time and equipment's effectively SB7. organize all process/ equipment manuals so as to access information easily SB8. support the manager in scheduling tasks for helper(s) Customer Centricity SB9. understand customer requirements and their priority and respond as per their needs Problem Solving SB10. support manager in solving problems by detailing out problems SB11. discuss the possible solutions with the manager for problem solving Analytical Thinking SB12. apply domain information about maintenance processes and technical knowledge about tools and equipment Critical Thinking SB13. use common sense and make judgments on day to day basis SB14. use reasoning skills to identify and resolve basic problems SB15. use intuition to detect any potential problems which could arise during operations SB16. use acquired knowledge of the process for identifying and handling issues Page 8

9 FIC/N1023 Prepare and maintain work area and process machineries for production of corn starch NOS Version Control NOS Code FIC/N1023 Credits (NSQF) TBD Version number 1.0 Industry Food Processing Drafted on 26/11/2015 Industry Sub-sector Food grain milling (Oilseeds) Last reviewed on 30/03/2016 Occupation Processing Next review date 30/03/2019 Back to Top Page 9

10 FIC/N1024 Carry out production of corn starch Overview This OS unit is about producing various corn starch through wet and dry milling process using machineries as per the specifications and standards of the organization. Page 10

11 National Occupational Standard FIC/N1024 Carry out production of corn starch Unit Code Unit Title (Task) Description Scope FIC/N1024 Production of corn starch This unit is about producing corn starch through wet and dry milling process using various machineries as per the specifications and standards of the organization. Prepare machineries for production Wet milling of corn Dry milling of corn Carry out post production cleaning and regular maintenance of equipment Performance Criteria(PC) w.r.t. the Scope Element Prepare machineries for production Performance Criteria PC1. check if all process machineries are clean and in good mechanical condition PC2. select and fit machine components and related attachments to meet operating requirements PC3. check the performance of required machineries and adjust settings as required PC4. carry out pre-start checks to ensure working and performance Wet milling of corn PC5. refer to the work order from the supervisor and refer process chart for products produced PC6. receive raw materials (corn), check weight and visually check for any impurities and transfer to the cleaning area PC7. fix/change screens and set controls parameters of the cleaning machines, dump raw material into feed hopper of the cleaning machineries or cleaning line conveyor PC8. start cleaning machines, open chute to allow corn into machine, monitor cleaning process, monitor material flowing in and out of cleaning machine to remove dust, cobs, sticks, stone, metal, foreign materials etc and adjust controls when required PC9. set controls such as speed of conveyor and start conveyor to transfer weighed quantity of corn into steeping tank PC10. start pump or open valves to fill water into steeping liquid tank, weigh measured quantity of sulphur di-oxide and add into water to prepare steeping liquid, adjust controls to set temperature to heat steeping water to specified temperature following sop PC11. start pump or open valves to fill steeping liquid into corn in steeping tank to soak for specified time following SOP PC12. set controls such as speed of attrition mill, open valves to transfer steeped Page 11

12 FIC/N1024 Carry out production of corn starch corn to attrition mill to break corn kernels to loosen germ PC13. start pump to add water to the mill to prepare mixture of corn slurry and whole germ PC14. set control such as speed of hydrocyclone separator machine, start pump to transfer mixture of corn slurry (containing starch-gluten-fiber) and whole germ to machine to remove lighter germ from corn slurry PC15. set controls such as speed of grinding mills, open feed inlets to feed slurry into mill to grind slurry to break starch from fiber and reduce the size of starch PC16. set controls such as speed, pressure, etc. of washing screens, start pump to allow starch slurry to pass through screens to separate fiber from starchgluten suspension PC17. set controls such as speed of centrifuge/disc separators, start pump transfer starch slurry into centrifuge and start machine to separate gluten from corn starch PC18. set controls of starch washing filter, start pump or open chute to allow starch slurry to pass through filters to remove residual gluten from starch PC19. set controls such as temperature, pressure, etc. of dewatering and drying machines like vacuum filters or basket centrifuge, and air flash dryers, start pump to pass starch slurry through vacuum filters/centrifuge to remove moisture and flash dryers to dry to desired moisture content to produce starch (unmodified starch) PC20. transfer unmodified starch to co-products processing area for production of modified starches such as dextrins, glucose, corn syrup, corn sugar, industrial starches etc (or) transfer to the packaging area for packing as unmodified starch Page 12

13 FIC/N1024 Dry milling of corn Carry out production of corn starch PC21. refer to the work order, organize for transfer of raw material (corn) to the dumping area and dump into feed hopper of the cleaning machineries or cleaning line conveyor PC22. start conveyor to transfer corn to cleaning machines, set controls like speed, vibration, air flow of the aspirator etc of cleaning machines, start and operate and adjust machines as required to remove dust, sticks, stone, metal, foreign materials etc PC23. conduct visual inspection and regular checking of collection points (filters and screens), monitor flow of corn out of grain cleaning machines and ensure it meets organisation standards PC24. calculate water addition required for conditioning/tempering of corn, adjust controls to set water quantity, temperature, conditioning time, moisture content etc of conditioning/tempering machine, start and operate machine, monitor flow of corn in and out of machine and adjust conditioning equipment to achieve required moisture content PC25. sample conditioned corn and check moisture content to confirm it meets organisation standards PC26. set controls such as speed of degerminator machine, start machine, open chute to allow corn to flow into machine, monitor flow of corn on and out of machine adjust process equipment to remove germ and bran from corn PC27. set controls of gravity tables, start, operate, monitor flow of corn in and out of machine and adjust controls to completely remove corn germ from the endosperm PC28. adjust clearance between reduction rolls of roller mills, set controls like speed, start machine, open chute to feed degermed corn, monitor, operate and adjust controls to break and reduce size of corn to required fineness PC29. set controls like speed of sifter, start machine, open valves to allow corn grits/flour from reduction rollers to pass through series of sieves to obtain corn products like corn grits, corn flour etc of required fineness PC30. check the quality of finished products passing out of machines to ensure its specification to organisation standards PC31. start conveyor to transfer product(s) into the feed hopper of packaging machine PC32. load packaging materials and labels in packaging machine, set filling quantity and labeling details, start machine to pack finished products PC33. sample products produced from production line and packed product, and transfer to quality lab for analysis PC34. report discrepancies/concerns to department supervisor for immediate action and implement the suggested corrective action Page 13

14 FIC/N1024 Carry out post production cleaning and regular maintenance of equipment Carry out production of corn starch PC35. clean the work area, equipments and tools using recommended cleaning agents and sanitizers PC36. attend minor repairs/faults (if any) of all components and machines PC37. ensure periodic (daily/weekly/monthly/quarterly/half yearly/annual) maintenance of all machines and equipment following the SOP or following suppliers instructions/manuals Knowledge and Understanding (K) A. Organizational Context (Knowledge of the company / organization and its processes) B. Technical Knowledge The user/individual on the job needs to know and understand: KA1. organization standards, process standards and procedures followed in the organisation KA2. products and by-products produced, and production method followed by the organisation KA3. code of business conduct KA4. dress code to be followed KA5. job responsibilities/duties and standard operating procedures relavant to prodution process KA6. internal processes like procurement, store management, inventory management, quality management and key contact points for query resolution KA7. provision of wages, working hours, accident compensation as per organisation policy KA8. food safety and hygiene standards followed The user/individual on the job needs to know and understand: KB1. types and varieties of raw materials (corn) for producing various products and co-products KB2. types of corn milling process, their methods, techniques and machineries KB3. production process, process parameters for various types of corn processing KB4. types of machineries used in various types of corn processing and machineries used in the organisation KB5. operating and handling processing machineries KB6. maintenance of machineries, equipments and tools KB7. basic mathematics KB8. quality parameters, basic food microbiology and quality assessment based on physical parameters KB9. procedure for disposal of waste KB10. types and category of packaging materials, packaging machineries KB11. storage procedures for raw materials, packaging materials and finished goods KB12. cleaning procedures like CIP and COP KB13. knowledge on sanitizers and disinfectants and its handling and storing methods KB14. food laws and regulations on product, packaging and labelling KB15. GMP KB16. HACCP Page 14

15 FIC/N1024 Skills (S) [Optional] A. Core Skills/ Generic Skills Writing Skills Carry out production of corn starch The user/ individual on the job needs to know and understand how to: SA1. note the information communicated SA2. note the raw materials used for production and the finished products produced SA3. note the readings of the process parameters and provide necessary information to fill the process chart SA4. note down observations (if any) related to the process SA5. write information documents to internal departments/ internal teams SA6. note down the data for online ERP or as per applicability in the organization Reading Skills SA7. read and interpret the process required for producing various types of products SA8. read and interpret and process flowchart for all products produced SA9. read equipment manuals and process documents to understand the equipments operation and process requirement SA10. read internal information documents sent by internal teams Oral Communication (Listening and Speaking skills) SA11. discuss task lists, schedules and activities SA12. effectively communicate with team members SA13. question in order to understand the nature of the problem and to clarify queries SA14. attentively listen and comprehend the information given by the speaker SA15. communicate clearly on the issues being faced B. Professional Skills Decision Making SB1. analyse critical points in day to day tasks through experience and observation and identify control measures to solve the issue SB2. handle issues in case the manager is not available (as per the authority matrix defined by the organization) Plan and Organize SB3. plan and organize the work order and jobs received SB4. organize raw materials and packaging materials required for all products SB5. plan and prioritize the work based on the instructions received SB6. plan to utilise time and equipment's effectively SB7. organize all process/ equipment manuals so as to access information easily SB8. support the manager in scheduling tasks for helper(s) Customer Centricity SB9. understand customer requirements and their priority and respond as per their needs Page 15

16 FIC/N1024 Carry out production of corn starch Problem Solving SB10. support manager in solving problems by detailing out problems SB11. discuss the possible solutions with the manager for problem solving Analytical Thinking SB12. apply domain information about maintenance processes and technical knowledge about tools and equipment Critical Thinking SB13. use common sense and make judgments on day to day basis SB14. use reasoning skills to identify and resolve basic problems SB15. use intuition to detect any potential problems which could arise during operations SB16. use acquired knowledge of the process for identifying and handling issues Page 16

17 FIC/N1024 Carry out production of corn starch NOS Version Control NOS Code FIC/N1024 Credits (NSQF) TBD Version number 1.0 Industry Food Processing Drafted on 26/11/2015 Industry Sub-sector Food grain milling (Oilseeds) Last reviewed on 30/03/2016 Occupation Processing Next review date 30/03/2019 Back to Top Page 17

18 FIC/N1025 Complete documentation and record keeping related to production of corn starch Overview This OS unit is about documenting and maintaining records of raw materials, process and finished products related to production of corn starch. Page 18

19 National Occupational Standard FIC/N1025 Complete documentation and record keeping related to production of corn starch Unit Code Unit Title (Task) Description Scope FIC/N1025 Performance Criteria(PC) w.r.t. the Scope Element Document and maintain records of raw materials for production of corn starch Complete documentation and record keeping related to production of corn starch This unit is about documenting and maintaining records of raw materials, process and finished products related to production of corn starch. Document and maintain records of raw materials for production of corn starch Document and maintain records of production schedule and process parameters for production of corn starch Document and maintain records of finished products for production of corn starch Performance Criteria PC1. document and maintain record of details on raw materials and packaging materials such as variety of raw material, grown area, grown season, vendor/supplier details, receiving date, expiry date, quality parameters, supplier quality document, internal quality analysis report, etc. as per organisation standards PC2. document and maintain record on observations (if any) related to raw materials and packaging materials PC3. load the raw materials details in ERP for future reference PC4. verify the documents and track from finished product to raw materials, in case of quality concerns and during quality management system audits Document and maintain records of production schedule and process parameters for production of corn starch PC5. document and maintain records of production plan with details such as product details, equipments and machinery details, efficiency and capacity utilization of equipment PC6. document and maintain records of process details such as variety of raw material used, process parameters (temperature, pressure, time, speed etc. as applicable) for entire production and packaging in process chart or production log for products produced PC7. document and maintain records of batch size, production yield, wastage of raw materials, energy utilization and final products produced PC8. document and maintain record of observations (if any) or deviations related to process and production PC9. load the production plan and process details in ERP for future reference PC10. verify documents and track from finished product to process details and raw materials, in case of quality concerns and for quality management system audits Page 19

20 FIC/N1025 Document and maintain records of finished products for production of corn starch Complete documentation and record keeping related to production of corn starch PC11. document and maintain records of the type of products produced like unmodified starch, corn meal, corn flour etc PC12. document and maintain records of the finished products details such as batch number, time of packing, date of manufacture, date of expiry, other label details, primary, secondary and tertiary packaging materials for all finished products, storage conditions, etc. as per organisation standards PC13. document and maintain record of observations or deviations (if any) related to finished products PC14. load the finished product details in ERP for future reference PC15. verify the documents and track from finished product to ingredients, in case of quality concerns and for quality management system audits Knowledge and Understanding (K) A. Organizational Context (Knowledge of the company / organization and its processes) The user/individual on the job needs to know and understand: KB1. organization standards and procedures followed for documentation and record keeping KB2. marks and accreditations of the organisation KB3. job responsibilities/duties for documentaion and records management in the organisation KB4. ERP (Enterprise Resource Planning) software system used/followed in the organisation B. Technical Knowledge Skills (S) [Optional] A. Core Skills/ Generic Skills The user/individual on the job needs to know and understand: KB5. documentation system followed in the organization like, production chart, process chart and finished goods chart KB6. details to be recorded on raw materials and finished products KB7. details to be recorded and maintained on production plan and process parameters KB8. methods to record and maintain records on observations (if any) related to raw materials, process and finished products KB9. tracking back the record from finished product to raw material KB10. entering details in the ERP system followed by the organisation Writing Skills The user/ individual on the job needs to know and understand how to: SA1. note the information communicated SA2. note the raw materials used for production and the finished products produced SA3. note the readings of the process parameters and provide necessary information to fill the process chart SA4. note down observations (if any) related to the process SA5. write information documents to internal departments/ internal teams SA6. note down the data for online ERP or as per applicability in the organization Reading Skills Page 20

21 FIC/N1025 Complete documentation and record keeping related to production of corn starch SA7. read and interpret the process required for producing various types of products SA8. read and interpret and process flowchart for all products produced SA9. read equipment manuals and process documents to understand the equipments operation and process requirement SA10. read internal information documents sent by internal teams Oral Communication (Listening and Speaking skills) SA11. discuss task lists, schedules and activities SA12. effectively communicate with team members SA13. question in order to understand the nature of the problem and to clarify queries SA14. attentively listen and comprehend the information given by the speaker SA15. communicate clearly on the issues being faced B. Professional Skills Decision Making SB1. analyse critical points in day to day tasks through experience and observation and identify control measures to solve the issue SB2. handle issues in case the manager is not available (as per the authority matrix defined by the organization) Plan and Organize SB3. plan and organize the work order and jobs received SB4. organize raw materials and packaging materials required for all products SB5. plan and prioritize the work based on the instructions received SB6. plan to utilise time and equipment's effectively SB7. organize all process/ equipment manuals so as to access information easily SB8. support the manager in scheduling tasks for helper(s) Customer Centricity SB9. understand customer requirements and their priority and respond as per their needs Problem Solving SB10. support manager in solving problems by detailing out problems SB11. discuss the possible solutions with the manager for problem solving Analytical Thinking SB12. apply domain information about maintenance processes and technical knowledge about tools and equipment Critical Thinking SB13. use common sense and make judgments on day to day basis SB14. use reasoning skills to identify and resolve basic problems SB15. use intuition to detect any potential problems which could arise during Page 21

22 FIC/N1025 Complete documentation and record keeping related to production of corn starch operations SB16. use acquired knowledge of the process for identifying and handling issues Page 22

23 FIC/N1025 Complete documentation and record keeping related to production of corn starch NOS Version Control NOS Code FIC/N1025 Credits (NSQF) TBD Version number 1.0 Industry Food Processing Drafted on 26/11/2015 Industry Sub-sector Food grain milling (Oilseeds) Last reviewed on 30/03/2016 Occupation Processing Next review date 30/03/2019 Back to Top Page 23

24 Qualifications Pack for Corn Starch Manufacturing Technician Overview This OS unit is about maintaining food safety, hygiene and sanitation in work area and processing unit for processing food products. Page 24

25 National Occupational Standard Unit Code Unit Title (Task) Description Scope Qualifications Pack for Corn Starch Manufacturing Technician FIC/N9001 Ensure food safety, hygiene and sanitation for processing food products This OS unit is about maintaining food safety, hygiene and sanitation in work area and processing unit for processing food products Perform safety and sanitation related functions Apply food safety practices Performance Criteria(PC) w.r.t. the Scope Element Perform safety and sanitation related functions Performance Criteria PC1. comply with food safety and hygiene procedures followed in the organisation PC2. ensure personal hygiene by use of gloves, hairnets, masks, ear plugs, goggles, shoes, etc. PC3. ensure hygienic production of food by inspecting raw materials, ingredients, finished products, etc. for compliance to physical, chemical and microbiological parameters PC4. pack products in appropriate packaging materials, label and store them in designated area, free from pests, flies and infestations PC5. clean, maintain and monitor food processing equipment periodically, using it only for the specified purpose PC6. use safety equipment such as fire extinguisher, first aid kit and eye-wash station when required PC7. follow housekeeping practices by having designated area for materials/tools PC8. follow industry standards like GMP and HACCP and product recall process PC9. attend training on hazard management to understand types of hazards such as physical, chemical and biological hazards and measures to control and prevent them PC10. identify, document and report problems such as rodents and pests to management PC11. conduct workplace checklist audits before and after work to ensure safety and hygiene PC12. document and maintain raw material, packaging material, process and finished products for the credibility and effectiveness of the food safety control system Apply food safety practices PC13. determine the quality of food using criteria such as odour, appearance, taste and best before date, and take immediate measures to prevent spoilage PC14. store raw materials, finished products, allergens separately to prevent crosscontamination PC15. label raw materials and finished products and store them in designated storage areas according to safe food practices Page 25

26 Qualifications Pack for Corn Starch Manufacturing Technician PC16. follow stock rotation based on FEFO/ FIFO 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. organization standards and procedures followed for food safety, hygeine and sanitation KA2. food safety and hygiene standards followed KA3. personal hygiene and fitness requirements KA4. job responsibilities/duties for following food safety, hygeine and sanitation KA5. personal protective equipment and clothing to be used KA6. safe methods to use materials and equipment KA7. housekeeping methods and importance KA8. safe disposal methods for waste KA9. methods for minimizing environmental damage KA10. accident compensation as per organisation policy KA11. importance of following health, hygiene and safety standards and the impact of not following the standards The user/individual on the job needs to know and understand: KB1. possible physical, chemical and biological hazards and methods of prevention of various hazards KB2. personal hygiene requirement KB3. different types of sanitizers used for process area, equipment and the procedure to use them KB4. knowledge on Food Safety Standards and Regulations (as per FSSAI) KB5. quality parameters and quality assessment based on physical parameters, basic food microbiology KB6. labelling/marking requirements for raw materials, finished goods, stored materials, packaging materials and their designated storage area KB7. cleaning and sanitation of equipment and work area KB8. CIP and COP methods and procedures KB9. storage norms for raw materials, packaging material and finished products KB10. stock rotation of ingredients and finished products based on FEFO/FIFO KB11. method of maintaining safety check lists for all machineries KB12. GHP KB13. GMP KB14. HACCP Writing Skills The user/ individual on the job needs to know and understand how to: SA1. note the information communicated SA2. note the raw materials used for production and the finished products Page 26

27 Qualifications Pack for Corn Starch Manufacturing Technician produced SA3. note the readings of the process parameters and provide necessary information to fill the process chart SA4. note down observations (if any) related to the process SA5. write information documents to internal departments/ internal teams SA6. note down the data for online ERP or as per applicability in the organization Reading Skills B. sprofessional Skills SA7. read and interpret the process required for producing various types of products SA8. read and interpret and process flowchart for all products produced SA9. read equipment manuals and process documents to understand the equipments operation and process requirement SA10. read internal information documents sent by internal teams Oral Communication (Listening and Speaking skills) SA11. discuss task lists, schedules and activities SA12. effectively communicate with team members SA13. question in order to understand the nature of the problem and to clarify queries SA14. attentively listen and comprehend the information given by the speaker SA15. communicate clearly on the issues being faced Decision Making SB1. analyse critical points in day to day tasks through experience and observation and identify control measures to solve the issue SB2. handle issues in case the manager is not available (as per the authority matrix defined by the organization) Plan and Organize SB3. plan and organize the work order and jobs received SB4. organize raw materials and packaging materials required for all products SB5. plan and prioritize the work based on the instructions received SB6. plan to utilise time and equipment's effectively SB7. organize all process/ equipment manuals so as to access information easily SB8. support the manager in scheduling tasks for helper(s) Customer Centricity SB9. understand customer requirements and their priority and respond as per their needs Problem Solving Page 27

28 Qualifications Pack for Corn Starch Manufacturing Technician SB9. support manager in solving problems by detailing out problems SB10. discuss the possible solutions with the manager for problem solving Analytical Thinking SB11. apply domain information about maintenance processes and technical knowledge about tools and equipment Critical Thinking SB12. use common sense and make judgments on day to day basis SB13. use reasoning skills to identify and resolve basic problems SB14. use intuition to detect any potential problems which could arise during operations SB15. use acquired knowledge of the process for identifying and handling issues NOS Version Control Page 28

29 Qualifications Pack for Corn Starch Manufacturing Technician Back to Top NOS Code FIC/N9001 Credits (NSQF) TBD Version number 1.0 Industry Food Processing Drafted on 26/11/2015 Industry Sub-sector Food grain milling (Oilseeds) Last reviewed on 30/03/2016 Occupation Processing Next review date 30/03/2019 Page 29

30 Qualifications Pack for Corn Starch Manufacturing Technician Annexure Nomenclature for QP and NOS Qualifications Pack 9 characters [ABC]/ Q 0101 [Insert 3 letter code for SSC] Q denoting Qualifications Pack QP number (2 numbers) Occupation (2 numbers) Occupational Standard An example of NOS with N 9 characters [ABC] / N 0101 [Insert 3 letter code for SSC] N denoting National Occupational Standard OS number (2 numbers) Occupation (2 numbers) Back to top Page 30

31 Qualifications Pack for Corn Starch Manufacturing Technician The following acronyms/codes have been used in the nomenclature above: Sub-sector Range of Occupation numbers Fruit and Vegetable Food Grain Milling (including Oilseeds) Dairy products Meat and Poultry Fish and Sea Food Bread and Bakery Alcoholic Beverages Aerated water/ soft drinks Quality Analysis (involving physical and chemical lab analysis) Packaging, Refrigeration and Procurement Soya Food Packaged Foods Miscellaneous Sequence Description Example Three letters Industry name FIC Slash / / Next letter Whether QP or NOS Q or N Next two numbers Occupation code 01 Next two numbers OS number 01 Note: The range of occupation numbers have been decided based on the number of existing and future occupations in a segment Page 31

32 CRITERIA FOR ASSESSMENT OF TRAINEES Job Role Corn Starch Manufacturing Technician Qualification Pack FIC/Q1007 Sector Skill Council Food Processing Guidelines for Assessment 1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each 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 PC 2. The assessment for the theory part will be based on knowledge bank of questions created by the SSC 3. Individual assessment agencies will create unique question papers for theory part for each candidate at each examination/training center (as per assessment criteria below) 4. Individual assessment agencies will create unique evaulations for skill practical for every student at each examination/training center based on this criteria 5. To pass the Qualification Pack, every trainee should score a minimum of 70% in every NOS 6. In case of successfully passing only certain number of NOS's, the trainee is eligible to take subsequent assessment on the balance NOS's to pass the Qualification Pack Marks Allocation Assessment outcomes Assessment criteria for outcomes Total Marks Out Of Theory Skills Practical 1. FIC/N1023 (Prepare and maintain work area and process machineries for production of corn starch) PC1. Clean and maintain the cleanliness of the work area using approved sanitizers and keep it free from dust, waste and pests PC2. Ensure that the work area is safe and hygienic for food processing PC3. Dispose waste materials as per defined sops and industry requirements PC4. Check the working and performance of all machineries and tools used for production of corn starch such as cleaning machines, grinding machines, hydrocyclones, centrifuge, filters, roller mill, sieving machines, drying machine, packaging machines etc Page 32

33 PC5. Clean machineries and tools used, with recommended sanitizers following the SOP PC6. Place the necessary tools required for process PC7. Attend to the minor repairs/ faults of all machines, if required FIC/N1024 (Carry out production of corn starch) PC1. PC2. Check if all process machineries are clean and in good mechanical condition Select and fit machine components and related attachments to meet operating requirements PC3. Check the performance of required machineries and adjust settings as required PC4. Carry out pre-start checks to ensure working and performance PC5. Refer work order from the supervisor and refer process chart for products produced PC6. Receive raw materials (corn), check weight and visually check for any impurities and transfer to the cleaning area PC7. Fix/change screens and set controls parameters of the cleaning machines, dump raw material into feed hopper of the cleaning machineries or cleaning line conveyor PC8. Start cleaning machines, open chute to allow corn into machine, monitor cleaning process, monitor material flowing in and out of cleaning machine to remove dust, cobs, sticks, stone, metal, foreign materials etc and adjust controls when required Page 33

34 PC9. Set controls like speed of conveyor and start conveyor to transfer weighed quantity of corn into steeping tank PC10. Start pump or open valves to fill water into steeping liquid tank, weigh measured quantity of sulphur di-oxide and add into water to prepare steeping liquid, adjust controls to set temperature to heat steeping water to specified temperature following sop PC11. Start pump or open valves to fill steeping liquid into corn in steeping tank to soak for specified time following sop PC12. Set controls like speed of attrition mill, open valves to transfer steeped corn to attrition mill to break corn kernels to loosen germ PC13. Start pump to add water to the mill to prepare mixture of corn slurry and whole germ PC14. Set control like speed of hydrocyclone separator machine, start pump to transfer mixture of corn slurry (containing starchgluten-fiber) and whole germ to machine to remove lighter germ from corn slurry PC15. Set controls like speed of grinding mills, open feed inlets to feed slurry into mill to grind slurry to break starch from fiber and reduce the size of starch PC16. Set controls like speed, pressure etc of washing screens, start pump to allow starch slurry to pass through screens to separate fiber from starch-gluten suspension PC17. Set controls like speed of centrifuge/disc separators, start Page 34

35 pump transfer starch slurry into centrifuge and start machine to separate gluten from corn starch PC18. Set controls of starch washing filter, start pump or open chute to allow starch slurry to pass through filters to remove residual gluten from starch PC19. Set controls like temperature, pressure etc of dewatering and drying machines like vacuum filters or basket centrifuge, and air flash dryers, start pump to pass starch slurry through vacuum filters/centrifuge to remove moisture and flash dryers to dry to desired moisture content to produce starch (unmodified starch) PC20. Transfer unmodified starch to coproducts processing area for production of modified starches like dextrins, glucose, corn syrup, corn sugar, industrial starches etc (or) transfer to the packaging area for packing as unmodified starch PC21. Refer work order, organize for transfer of raw material (corn) to the dumping area and dump into feed hopper of the cleaning machineries or cleaning line conveyor PC22. Start conveyor to transfer corn to cleaning machines, set controls like speed, vibration, air flow of the aspirator etc of cleaning machines, start and operate and adjust machines as required to remove dust, sticks, stone, metal, foreign materials etc PC23. Conduct visual inspection and regular checking of collection points (filters and screens), monitor flow of corn out of grain cleaning machines and ensure it meets Page 35

36 organisation standards PC24. Calculate water addition required for conditioning/tempering of corn, adjust controls to set water quantity, temperature, conditioning time, moisture content etc of conditioning/tempering machine, start and operate machine, monitor flow of corn in and out of machine and adjust conditioning equipment to achieve required moisture content PC25. Sample conditioned corn and check moisture content to confirm it meets organisation standards PC26. Set controls like speed of degerminator machine, start machine, open chute to allow corn to flow into machine, monitor flow of corn on and out of machine adjust process equipment to remove germ and bran from corn PC27. Set controls of gravity tables, start, operate, monitor flow of corn in and out of machine and adjust controls to completely remove corn germ from the endosperm PC28. Adjust clearance between reduction rolls of roller mills, set controls like speed, start machine, open chute to feed degermed corn, monitor, operate and adjust controls to break and reduce size of corn to required fineness PC29. Set controls like speed of sifter, start machine, open valves to allow corn grits/flour from reduction rollers to pass through series of sieves to obtain corn products like corn grits, corn flour etc of required fineness PC30. Check the quality of finished products passing out of machines Page 36