Engineering and Manufacturing. Qualification Specification NCFE Level 2 NVQ Diploma in Performing Manufacturing Operations (601/6480/3)

Transcription

1 Engineering and Manufacturing Qualification Specification NCFE Level 2 NVQ Diploma in Performing Manufacturing Operations (601/6480/3)

2 2 Contents Section 1 4 Qualification overview 5 Introduction 5 Things you need to know 6 Total Qualification Time (TQT) 6 Credit 6 About this qualification 7 Aims and objectives of this qualification 7 Achieving this qualification 7 Barred units 10 Qualifications and awards with simulation and assessment in a Realistic Work Environment (RWE) 10 Entry guidance 10 Progression opportunities 11 Recognition of Prior Learning (RPL) 11 Credit transfer 11 Direct Claim Status 11 Qualification dates 12 Staffing requirements 13 Assessors and Internal Quality Assurance 13 Resource requirements 13 Support for learners 14 Support for centres 14 Reasonable Adjustments and Special Considerations Policy 14 Subject maps 14 Fees and Pricing 15 Training and support 15 Mapping to National Occupational Standards 15 Section 2 16 Unit content and assessment guidance 17 Unit Unit Unit Unit Unit Unit Unit Unit Unit Unit Unit Unit Unit Unit Unit Unit 16 80

3 3 Unit Unit Unit Unit Unit Unit Unit Unit Unit Section Assessment and Moderation 121 How the qualification is assessed 121 Internal assessment 121 Moderation 122 Section General information 123 Equal opportunities 124 Diversity, access and inclusion 124 Data protection 124 Feedback 125 Contact us 126

4 4 Section 1 Qualification overview

5 5 Qualification overview Introduction We want to make your experience of working with NCFE as pleasant and easy as possible. This qualification specification contains everything you need to know about this qualification and should be used by everyone involved in the planning, delivery and assessment of the NCFE Level 2 NVQ Diploma in Performing Manufacturing Operations. All information contained in this specification is correct at the time of publishing. To ensure that you re using the most up-to-date version of this qualification specification please check the issue date in the page headers against that of the qualification specification on our website If you advertise this qualification using a different or shortened name you must ensure that learners are aware that their final certificate will state the regulated qualification title of NCFE Level 2 NVQ Diploma in Performing Manufacturing Operations. The NCFE Level 2 NVQ Diploma in Performing Manufacturing Operations is a competence-based qualification. A competence-based qualification is based on National Occupational Standards (NOS) and is a job-ready qualification which requires learners to demonstrate the skills and knowledge required to work in a specific industry. A competence-based qualification must be assessed in the workplace or in a realistic work environment (RWE) in accordance with the relevant assessment strategy. For further information on the assessment strategy please visit the qualifications page on our website

6 6 Things you need to know Qualification number (QN) 601/6480/3 Aim reference Total Qualification Time (TQT): 480 Guided learning hours (GLH): 216 Credit value 48 Level 2 Assessment requirements internally assessed and externally moderated portfolio of evidence Total Qualification Time (TQT) Total Qualification Time is the number of notional hours which represents an estimate of the total amount of time that could reasonably be expected to be required in order for a learner to achieve and demonstrate the achievement of the level of attainment necessary for the award of a qualification. Total Qualification Time comprises: the Guided Learning Hours for the qualification an estimate of the number of hours a learner will reasonably be likely to spend in preparation, study or any other form of participation in education or training, including assessment, which takes place as directed by but not under the immediate guidance or supervision of a lecturer, supervisor, Tutor or other appropriate provider of education or training. Credit The credit value is equal to the Total Qualification Time divided by ten, rounded to the nearest whole number.

7 7 About this qualification This is a regulated qualification. The regulated number for this qualification is 601/6480/3. This qualification forms the CBQ component for Pathway 2: Intermediate Level in Performing Manufacturing Operations for the Apprenticeship in Improving Operational Performance. This qualification may be eligible for funding. For further guidance on funding, please contact your local funding provider. Aims and objectives of this qualification This qualification aims to: provide learners working within a range of manufacturing industries with the skills and knowledge to demonstrate competence in their job roles. The objectives of this qualification are to help learners to: understand and comply with statutory regulations and organisational safety requirements develop and maintain working relationships get ready for, complete and hand over manufacturing operations focus on their area of interest with optional units in producing products including: shaped products; joined products; formed products and moulded products. Achieving this qualification To be awarded the NCFE Level 2 NVQ Diploma in Performing Manufacturing Operations, learners must achieve a minimum of 48 credits: a total of 5 credits from the mandatory units in Group A a minimum of one unit from optional Group B a minimum of 3 units from optional Group C a minimum of one unit from optional Group D. Units H/601/3014 and Y/601/3012 are barred against each other in optional Group C. Unit Y/601/3009 and J/601/3099 are listed in optional Group C and D, but they cannot be achieved twice.

8 8 Group A mandatory units Unit No Unit title Credit A/601/5013 Complying with statutory regulations and 5 credits organisational safety requirements Group B optional units Unit No Unit title Credit R/601/3008 Promoting effective working relationships 5 credits T/601/3101 Contributing to effective team working 6 credits Group C optional units Unit No Unit title Credit Y/601/3009 Transferring materials 13 credits L/601/3010 Preparing for manufacturing operations 9 credits Y/601/3012 Concluding manufacturing operations 9 credits H/601/3014 Ensuring effective handover of manufacturing 9 credits operations T/601/3017 Receiving and checking incoming materials 9 credits M/601/3095 Controlling manufacturing operations 19 credits A/601/3097 Contributing to improving effectiveness in the 8 credits workplace J/601/3099 Analysing the results of inspection and confirming quality of production 14 credits K/601/3113 Recording and reporting inspection and test results 8 credits Group D optional units Unit No Unit title Credit Y/601/3009 Transferring materials 13 credits R/601/3025 Producing shaped products 18 credits A/601/3035 Producing products by assembly operations 18 credits R/601/3039 Producing joined products 17 credits F/601/3067 Producing products by processing 17 credits

9 9 Unit No Unit title Credit T/601/3079 Producing formed products 18 credits M/601/3081 Finishing products 17 credits J/601/3085 Producing moulded products 18 credits D/601/3089 Producing packaged products 15 credits R/601/3090 Making products using computer controlled equipment 18 credits H/601/3093 Manufacturing products using combined manufacturing operations 18 credits J/601/3099 Analysing the results of inspection and confirming quality of production 14 credits H/601/3112 Carrying out inspection and testing activities 16 credits Units H/601/3014 and Y/601/3012 are barred against each other in optional Group C. Unit Y/601/3009 and J/601/3099 are listed in optional Group C and D, but they cannot be achieved twice. The learning outcomes and assessment criteria for each unit are provided in Section 2 (page 16). The units above may be available as stand-alone unit programmes. Please visit for further information. To achieve the NCFE Level 2 NVQ Diploma in Performing Manufacturing Operations, learners must successfully demonstrate their achievement of all learning outcomes and assessment criteria of the units as detailed in this qualification specification. Grades are not awarded. Learners who aren t successful can resubmit work within the registration period; however, a charge may apply. A Credit Certificate can be requested for learners who don t achieve their full qualification but who have achieved at least one whole unit.

10 10 Barred units This qualification contains barred units. Barred units are identified below. Ensuring effective handover of manufacturing operations (H/601/3014) Concluding manufacturing operations (Y/601/3012) Qualifications and awards with simulation and assessment in a Realistic Work Environment (RWE) Where the assessment strategy for a qualification allows, it is essential that organisations wishing to operate an RWE do so in an environment which reflects a real work setting and replicates the key characteristics of the workplace in which the skill to be assessed is normally employed. This will ensure that any competence achieved in this way will be sustained in real employment. Entry guidance This qualification is designed for learners working within a range of manufacturing industries and will enable them to demonstrate competence in their job role. There are no specific recommended prior learning requirements for this qualification. Entry is at the discretion of the centre. However, learners should be aged 16 or above to undertake this qualification. Centres are responsible for ensuring that this qualification is appropriate for the age and ability of learners. They need to make sure that learners can fulfil the requirements of the assessment criteria and comply with the relevant literacy, numeracy and health and safety aspects of this qualification. Learners registered on this qualification shouldn t undertake another qualification at the same level with the same or a similar title, as duplication of learning may affect funding eligibility.

11 11 Progression opportunities Learners who achieve this qualification could progress to: NCFE Level 2 Certificate in Lean Organisation Management Techniques NCFE Level 2 NVQ Diploma in Business-Improvement Techniques Level 3 Qualifications in Business Improvement Techniques They may also go on to study qualifications in a related area depending on current skills and role within their organisation. Recognition of Prior Learning (RPL) Centres may recognise prior learning at their discretion if they are satisfied that the evidence provided meets the requirements of a qualification. Where RPL is to be used extensively (for a whole unit or more), advice must be given by a qualified RPL Advisor. Credit transfer Where a learner has already achieved a unit with credit, NCFE will recognise that prior learning and will allow the credit to be transferred onto a new qualification, provided that the units have the same Ofqual reference number. Direct Claim Status For more information about Direct Claim Status, please contact our Customer Support team on

12 12 Qualification dates Regulated qualifications have operational end dates and certification end dates. We review qualifications regularly, working with sector representatives, vocational experts and stakeholders to make any changes necessary to meet sector needs and to reflect recent developments. If a decision is made to withdraw a qualification, we will set an operational end date and provide reasonable notice to our centres. We will also take all reasonable steps to protect the interest of learners. An operational end date will only show on the Ofqual Register of Regulated Qualifications register.ofqual.gov.uk and on our website if a decision has been made to withdraw a qualification. After this date we can no longer accept learner registrations. However, certification is allowed until the certification end date so that learners have time to complete any programmes of study. The certification end date will only show on the Ofqual Register once an operational end date has been set. After this date we can no longer process certification claims.

13 13 Staffing requirements Centres delivering any of NCFE s qualifications must: have a sufficient number of appropriately qualified/experienced Assessors to assess the volume of learners they intend to register have a sufficient number of appropriately qualified/experienced Internal Quality Assurers to internally quality assure the anticipated number of Assessors and learners ensure that all staff involved in assessment and internal quality assurance are provided with appropriate training and undertake meaningful and relevant continuing professional development implement effective internal quality assurance systems and processes to ensure all assessment decisions are reliable, valid, authentic, sufficient and current. This should include standardisation to ensure consistency of assessment provide all staff involved in the assessment process with sufficient time and resources to carry out their roles effectively. Assessors and Internal Quality Assurance Staff involved in the Assessment and Internal Quality Assurance of this qualification must be able to demonstrate that they have (or are working towards) the relevant occupational knowledge and/or occupational competence, at the same level or higher as the units being assessed and internally quality assured. This may be gained through experience and/or qualifications. Resource requirements The following documents are essential reading for any centre involved in the delivery, assessment and administration of this qualification and is available from the NCFE website: SEMTA Unit Assessment Strategy for Performing Manufacturing Operations Qualifications and Awards with Simulation and Assessment in a Realistic Work Environment (RWE) - Guidance for Centres (and Moderators). These documents can be downloaded from the qualifications page on our website

14 14 Support for learners Learner s Evidence Tracking Log (LETL) The LETL covers the mandatory units in this qualification and it can help learners keep track of their work. This document can be downloaded free of charge from the qualification page on our website You don t have to use the LETL you can devise your own evidence-tracking document instead. Any documents you produce should allow learners to track their achievement against each required learning outcome and assessment criterion and include: information on the content, availability and location of NCFE s procedures and policies advice on support mechanisms for learners who are experiencing difficulties with their studies a mechanism for Assessors and Internal Moderators to authenticate evidence and achievement for each unit. Support for centres There are a number of documents available on our website that centres might find useful. These are linked below: Reasonable Adjustments and Special Considerations Policy This policy is aimed at customers - including learners - who use our products and services and who submit requests for reasonable adjustments and special considerations. The policy can be found on our website here: Subject maps Our suite of subject maps showcase the qualifications we have available within each specialist sector and how they connect to each other. They demonstrate how you can plot routes for your learners at different levels from entry level right through to higher education or the workforce, with supporting qualifications along the way.

15 15 Fees and Pricing The current fees and pricing guide is available on our website at Training and support We can provide training sessions for Assessors and Internal Moderators. Bespoke subject-specific training is also available. For further information please contact our Quality Assurance team on Mapping to National Occupational Standards National Occupational Standards (NOS) are owned by a Sector Skills Council (SSC) or Standard Setting Body (SSB) and describe the skills, knowledge and understanding needed to undertake a particular task or job at different levels of competence. The units and structure of this qualification are based on the Semta NOS for Engineering. Further information on the NOS used in this qualification can be found on the Semta website (

16 16 Section 2 Unit content and assessment guidance

17 17 Unit content and assessment guidance This section provides details of the structure and content of this qualification. The unit summary provides an overview of each unit including: unit title unit overview guided learning hours credit value level an indication of whether a unit is mandatory or optional. Following the unit summary there s detailed information for each unit containing: unit title and number learning outcomes (the learner will) and assessment criteria (the learner can) assessment guidance. The regulators unit number is indicated in brackets for each unit (eg M/100/7116). However, to make cross-referencing assessment and moderation easier, we ve used a sequential numbering system in this document for each unit. The types of evidence listed are for guidance purposes only. Within learners portfolios, other types of evidence are acceptable if all learning outcomes and assessment criteria are covered and if the evidence generated can be internally and externally moderated. For approval of methods of internal assessment other than portfolio building, please contact the Quality Assurance team at NCFE. For further information or guidance about this qualification please contact our Research and Product Development team on

18 18 Unit 01 Complying with statutory regulations and organisational safety requirements (A/601/5013) Unit summary In this unit learners will comply with statutory regulations and organisational safety requirements, demonstrating their understanding of their duties and obligations to health and safety. They ll also apply safe working practices and procedures, identify, recognise and control hazards in the workplace and use and demonstrate correct manual lifting and carrying techniques. Guided learning hours 35 Credit value 5 Level 2 Mandatory/optional Mandatory 1 Comply with statutory regulations and organisational safety requirements 1.1 Comply with their duties and obligations as defined in the Health and Safety at Work Act 1.2 Demonstrate their understanding of their duties and obligations to health and safety by: applying in principle their duties and responsibilities as an individual under the Health and Safety at Work Act identifying, within their organisation, appropriate sources of information and guidance on health and safety issues, such as: - eye protection and personal protective equipment (PPE) - COSHH regulations - risk assessments identifying the warning signs and labels of the main groups of hazardous or dangerous substances complying with the appropriate statutory regulations at all times 1.3 Present themselves in the workplace suitably prepared for the activities to be undertaken 1.4 Follow organisational accident and emergency procedures

19 19 Unit 01 Complying with statutory regulations and organisational safety requirements (A/601/5013) (cont d) 1.5 Comply with emergency requirements, to include: identifying the appropriate qualified first aiders and the location of first aid facilities identifying the procedures to be followed in the event of injury to themselves or others following organisational procedures in the event of fire and the evacuation of premises identifying the procedures to be followed in the event of dangerous occurrences or hazardous malfunctions of equipment 1.6 Recognise and control hazards in the workplace 1.7 Identify the hazards and risks that are associated with the following: their working environment the equipment that they use materials and substances (where appropriate) that they use working practices that do not follow laid-down procedures 1.8 Use correct manual lifting and carrying techniques 1.9 Demonstrate one of the following methods of manual lifting and carrying: lifting alone with assistance of others with mechanical assistance 1.10 Apply safe working practices and procedures to include: maintaining a tidy workplace, with exits and gangways free from obstruction using equipment safely and only for the purpose intended observing organisational safety rules, signs and hazard warnings taking measures to protect others from any harm resulting from the work that they are carrying out

20 20 Unit 01 Complying with statutory regulations and organisational safety requirements (A/601/5013) (cont d) 2 Know how to comply with statutory regulations and organisational safety requirements 2.1 Describe the roles and responsibilities of themselves and others under the Health and Safety at Work Act, and other current legislation (such as The Management of Health and Safety at Work Regulations, Workplace Health and Safety and Welfare Regulations, Personal Protective Equipment at Work Regulations, Manual Handling Operations Regulations, Provision and Use of Work Equipment Regulations, Display Screen at Work Regulations, Reporting of Injuries, Diseases and Dangerous Occurrences Regulations) 2.2 Describe the specific regulations and safe working practices and procedures that apply to their work activities 2.3 Describe the warning signs for the 7 main groups of hazardous substances defined by Classification, Packaging and Labelling of Dangerous Substances Regulations 2.4 Explain how to locate relevant health and safety information for their tasks, and the sources of expert assistance when help is needed 2.5 Explain what constitutes a hazard in the workplace (such as moving parts of machinery, electricity, slippery and uneven surfaces, poorly placed equipment, dust and fumes, handling and transporting, contaminants and irritants, material ejection, fire, working at height, environment, pressure/stored energy systems, volatile, flammable or toxic materials, unshielded processes, working in confined spaces) 2.6 Describe their responsibilities for identifying and dealing with hazards and reducing risks in the workplace 2.7 Describe the risks associated with their working environment (such as the tools, materials and equipment that they use, spillages of oil, chemicals and other substances, not reporting accidental breakages of tools or equipment and not following laid-down working practices and procedures) 2.8 Describe the processes and procedures that are used to identify and rate the level of risk (such as safety inspections, the use of hazard checklists, carrying out risk assessments, COSHH assessments) 2.9 Describe the first aid facilities that exist within their work area and within the organisation in general; the procedures to be followed in the case of accidents involving injury 2.10 Explain what constitutes dangerous occurrences and hazardous malfunctions, and why these must be reported even if no-one is injured

21 21 Unit 01 Complying with statutory regulations and organisational safety requirements (A/601/5013) (cont d) 2.11 Describe the procedures for sounding the emergency alarms, evacuation procedures and escape routes to be used, and the need to report their presence at the appropriate assembly point 2.12 Describe the organisational policy with regard to fire fighting procedures; the common causes of fire and what they can do to help prevent them 2.13 Describe the protective clothing and equipment that is available for their areas of activity 2.14 Explain how to safely lift and carry loads, and the manual and mechanical aids available 2.15 Explain how to prepare and maintain safe working areas; the standards and procedures to ensure good housekeeping 2.16 Describe the importance of safe storage of tools, equipment, materials and products 2.17 Describe the extent of their own authority, and to whom they should report in the event of problems that they cannot resolve Assessment guidance This unit must be assessed in a work environment and must be assessed in accordance with the Common Requirements for National Vocational Qualifications (NVQ). Additional assessment requirements have been published by Semta. These additional assessment requirements are set down in Semta s Unit Assessment Strategies. These documents can be downloaded from the qualification page on our website

22 22 Unit 02 Promoting effective working relationships (R/601/3008) Unit summary In this unit learners will promote effective working relationships. They ll also communicate in a manner which promotes understanding, goodwill and trust. Guided learning hours 30 Credit value 5 Level 2 Mandatory/optional Optional 1 Promote effective working relationships 1.1 Present themselves in the workplace on time and in a way that does not cause concern to others 1.2 Promote and maintain working relationships with 3 of the following: immediate supervision/line management colleagues in same work group colleagues in other work groups personnel in other departments (such as those supplying inputs or receiving outputs) managers and supervisors in other departments external contacts (such as customers, clients) 1.3 Ask for information, advice and/or help politely, without causing disruption to their own or other s work 1.4 Offer help and information to others promptly and willingly 1.5 Respect the views, rights and property of others 1.6 Identify problems in working relationships 1.7 Discuss problems which may affect working relationships with the appropriate person to include 2 of the following: work colleagues supervisor line manager team leader personnel or welfare officer

23 23 Unit 02 Promoting effective working relationships (R/601/3008) (cont d) 2 Promote effective working relationships (cont d) 2.1 Deal with problems in working relationships in ways which minimise offence and maintain the mutual respect of others to include 2 of the following; work related issues personal issues communication problems 2.2 Make sure that any actions that they take are within the limits of their own responsibility and authority 2.3 Refer requests for information and/or assistance that are outside their authority/responsibility to the appropriate person 2.4 Resolve disagreements and difficulties in working relationships with the appropriate person 2.5 Communicate in a manner which promotes understanding, goodwill and trust 2.6 Maintain effective communication using 2 of the following methods: in writing electronically orally 3 Know how to promote effective working relationships 3.1 Describe the statutory regulations that can affect working relationships ie, Disability, Equal Opportunities, Discrimination, Harassment 3.2 Explain why it is important to present themselves in the workplace on time and ready for work 3.3 Explain the methods in their organisation that can be used to gain information, advice and help 3.4 Explain the methods that can be used to establish and maintain good working relationships 3.5 Explain what might affect good working relationships 3.6 Explain how to identify problems in working relationships 3.7 Explain the methods of handling and resolving problems in working relationships

24 24 Unit 02 Promoting effective working relationships (R/601/3008) (cont d) 3.8 Explain why it is important to resolve difficulties or misunderstandings quickly and not let them develop into more serious problems 4 Know how to promote effective working relationships (cont d) 4.1 Explain how to identify and use different methods and styles of communication 4.2 Explain why it is important to avoid disruption in the workplace, and methods of avoiding it 4.3 Explain why it is important to request help from others in a polite and timely manner and to offer assistance to others when help is needed 4.4 Explain why it is important to show respect for the views, rights and property of others 4.5 Explain who to refer to with requests that are not within the limits of their responsibility 4.6 Explain who to refer to if they have problems with working relationships that they cannot resolve 4.7 Explain what their responsibilities are with regard to the reporting lines and procedures in their working area 4.8 Explain what are the responsibilities are of the people identified in assessment criteria 4.5 and 4.6 above

25 25 Unit 02 Promoting effective working relationships (R/601/3008) (cont d) Assessment guidance AC 1.6, 1.7, 2.1, 2.3, 2.4 Assessment guidance The use of simulation within a realistic working environment is acceptable. This unit must be assessed in a work environment and must be assessed in accordance with the Common Requirements for National Vocational Qualifications (NVQ). Additional assessment requirements have been published by Semta. These additional assessment requirements are set down in Semta s Unit Assessment Strategies. These documents can be downloaded from the qualification page on our website

26 26 Unit 03 Contributing to effective team working (T/601/3101) Unit summary In this unit learners will contribute to effective team working. They ll develop and maintain team working relationships and work in accordance with the roles and responsibilities identified for their individual and team activities. Guided learning hours 30 Credit value 6 Level 2 Mandatory/optional Optional 1 Contribute to effective team working 1.1 Present themselves in the workplace on time and in a way that does not cause concern to other team members 1.2 Develop and maintain team working relationships with 2 of the following: immediate supervision/line management colleagues in same work group colleagues in other work groups those for whom they have responsibility personnel in other departments external contacts 1.3 Work in accordance with the roles and responsibilities identified for their individual and team activities 1.4 Make sure that any actions that they take are within the limits of their own responsibility and authority 1.5 Ask for information, advice and/or help politely, without causing disruption to their own or other team members work 1.6 Offer help to others promptly and willingly in order to ensure team objectives are met 1.7 Contribute to team discussion/briefing sessions in a positive manner that shows respect for the views and rights of others

27 27 Unit 03 Contributing to effective team working (T/601/3101) (cont d) 2 Contribute to effective team working (cont d) 2.1 Deal with problems in team relationships in ways which minimise offence and maintain mutual respect 2.2 Discuss problems which may affect team relationships with the appropriate person to include 2 of the following: other team members team leader immediate line manager personnel or welfare officer 2.3 Refer requests for information and/or assistance that are outside their authority/responsibility to the appropriate people 2.4 Work together to resolve disagreements and difficulties in team relationships 2.5 Communicate orally with team members by 2 of the following methods: team briefings question and answer sessions group discussions problem resolution processes 2.6 Communicate in writing or electronically to include using one of the following methods: adding ideas and actions to team boards maintaining up to date key performance/production indicators processing information communicating via /internal network services 2.7 Communicate in a manner which promotes understanding, goodwill and trust

28 28 Unit 03 Contributing to effective team working (T/601/3101) (cont d) 3 Know how to contribute to effective team working 3.1 Describe the statutory regulations that can affect working relationships ie Disability, Equal Opportunities, Discrimination, Harassment 3.2 Explain why it is important to create and maintain good team working relationships 3.3 Explain what are the sort of things that might affect good team working relationships 3.4 Explain why it is important to present themselves in the workplace on time and ready for work 3.5 Explain the methods that can be used to establish and maintain good team working relationships 3.6 Explain the methods of handling and resolving difficulties in team working relationships 3.7 Explain how to use data and team information to help resolve concerns and disagreements 3.8 Explain why it is important to resolve difficulties or misunderstandings quickly and not let them develop into more serious problems 3.9 Explain why it is important to share their knowledge and information and their performance measures with other people in their team and with other groups 3.10 Explain how to use the data and information available to them to communicate their performances effectively to others 3.11 Explain what types of information and data are available in their area such as key performance measures, production targets, quality, scrap ratios, problem resolution processes, action planning brainstorming and continuous improvement processes

29 29 Unit 03 Contributing to effective team working (T/601/3101) (cont d) 4 Know how to contribute to effective team working (cont d) 4.1 Explain what mixture of skills and experience is available in their team to support them or the manufacturing process when problems occur (such as a team skills matrix) 4.2 Explain why they need to keep other team members involved in or informed of any plans or activities they may be doing 4.3 Explain what type of support or assistance might they need from other team members 4.4 Explain why it is important to request help from other team members in a polite and timely manner and to offer assistance to them when help is needed 4.5 Explain why it is important to show respect for the views, rights and property of other team members 4.6 Explain how asking for help or assistance at inappropriate times can lead to disruption and problems within the team 4.7 Describe the methods used in their area for effective communication (such as team briefings covering team performance, quality, cost and delivery issues, general information, personnel issues and action plans) 4.8 Explain who to refer to with requests that are not within the limits of their responsibility 4.9 Explain who to refer to if they have problems with team relationships that they cannot resolve 4.10 Explain what their responsibilities are with regard to the reporting lines and procedures in their working area 4.11 Explain who are the appropriate people and what are their responsibilities within their working area

30 30 Unit 03 Contributing to effective team working (T/601/3101) (cont d) Assessment guidance AC Assessment guidance The use of simulation within a realistic working environment is acceptable. This unit must be assessed in a work environment and must be assessed in accordance with the Common Requirements for National Vocational Qualifications (NVQ). Additional assessment requirements have been published by Semta. These additional assessment requirements are set down in Semta s Unit Assessment Strategies. These documents can be downloaded from the qualification page on our website

31 31 Unit 04 Transferring materials (Y/601/3009) Unit summary In this unit learners will know and demonstrate how to transfer materials, working safely at all times, complying with health and safety regulations and guidelines. Guided learning hours 53 Credit value 13 Level 2 Mandatory/optional Optional 1 Transfer materials 1.1 Work safely at all times, complying with health and safety, environmental and other relevant regulations and guidelines 1.2 Follow the relevant lifting and moving procedures and safety requirements to include all of the following: health and safety regulations safe working practices job instructions lifting and moving equipment operating instructions company standards and procedures 1.3 Choose the right equipment/techniques to move the materials 1.4 Move materials using one or more of the following types of equipment: hand operated power operated 1.5 Carry out lifting and carrying techniques to include 2 of the following: lifting alone lifting with assistance from others lifting with mechanical assistance 1.6 Carry out safe and correct manual lifting techniques to include 3 of the following: lifting from ground level lifting from an angle lifting from waist high lifting from below ground level lifting from overhead 1.7 Check that the weight of the materials does not exceed the safe lifting capacity of the equipment chosen 1.8 Check that the materials to be moved are correct, safely loaded and secure

32 32 Unit 04 Transferring materials (Y/601/3009) (cont d) 2 Transfer materials (cont d) 2.1 Carry out checks of the materials to be moved to include all of the following: the materials are as specified on the documentation the materials are stacked safely materials are in a suitable condition for the moving operation the load does not exceed the safe lifting capacity of the equipment the load is secure there are no restrictions or obstacles preventing movement of the materials 2.2 Move the materials to their correct location in accordance with instructions to include one of the following: production materials consumable materials finished products or components waste or scrap 2.3 Identify any problems with the material transfer 2.4 Take appropriate action to solve problems which are within their permitted authority/responsibility 2.5 Make permitted adjustments to solve problems related to 2 of the following: equipment condition material weight/suitability for moving securing the load in place 2.6 Report any problems that they cannot solve or are outside their permitted authority to the appropriate person to include one of the following: supervisor team leader quality control 2.7 Return any equipment they have used to its correct location on completion of the activities and leave it in a safe and reusable condition 2.8 Maintain any material(s) movement documentation accurately and legibly

33 33 Unit 04 Transferring materials (Y/601/3009) (cont d) 3 Know how to transfer materials 3.1 Describe the relevant health and safety requirements of the work area in which they are carrying out the material moving operations 3.2 Explain the specific safe working practices, lifting and moving procedures and regulations that need to be observed 3.3 Explain the hazards associated with carrying out the material moving operations 3.4 Explain how can the specific hazards be minimised 3.5 Explain what personal protective equipment needs to be used during the material movement activities and where can it be obtained 3.6 Explain how to obtain the necessary job instructions, lifting and moving equipment operating procedures and how to interpret them 3.7 Explain what procedures and documentation are required to allow the transfer of materials to take place 3.8 Explain what tools and equipment are used for the material movement operations undertaken and how to check that they are in a safe and usable condition 3.9 Explain how to choose the most suitable equipment for the moving operation being performed 3.10 Explain the lifting and handling procedures, and load bearing capacities of the equipment being used 4 Know how to transfer materials (cont d) 4.1 Explain how to apply manual lifting techniques when lifting alone and with the assistance of others 4.2 Explain what specific moving/transfer operations are being performed 4.3 Explain how to identify problems with the moving/transfer operation 4.4 Explain what action they should take to solve problems that are within the limits of their responsibility 4.5 Explain why it is important to report problems to the appropriate people when they cannot solve them and/or they are not their responsibility 4.6 Explain why is it important to return the equipment to its correct location on completion of the activities, store it correctly, and leave it in a safe and reusable condition

34 34 Unit 04 Transferring materials (Y/601/3009) (cont d) 4.7 Explain what documentation may need to be completed, and why it is important to complete it accurately and legibly 4.8 Explain what their responsibilities are with regard to the reporting lines and procedures in their working area 4.9 Explain who are the appropriate people and what are their responsibilities within their working area If this unit has been completed in optional Group C it cannot be completed again in optional Group D. Assessment guidance AC Assessment guidance 1.1, 1.2 This assessment criteria should be observed over a period of time , 2.8 The use of simulation within a realistic working environment is acceptable. This unit must be assessed in a work environment and must be assessed in accordance with the Common Requirements for National Vocational Qualifications (NVQ). Additional assessment requirements have been published by Semta. These additional assessment requirements are set down in Semta s Unit Assessment Strategies. These documents can be downloaded from the qualification page on our website

35 35 Unit 05 Preparing for manufacturing operations (L/601/3010) Unit summary In this unit learners will prepare for manufacturing operations. They will know and demonstrate how to work safely at all times, complying with health and safety, and following relevant regulations and guidelines. They will carry out work area preparations and prepare the equipment for the manufacturing operations and check that it is in a safe and usable condition. Guided learning hours 42 Credit value 9 Level 2 Mandatory/optional Optional 1 Prepare for manufacturing operations 1.1 Work safely at all times, complying with health and safety, environmental and other relevant regulations and guidelines 1.2 Follow the relevant preparation procedures and safety requirements to include all of the following: health and safety and environmental regulations safe working practices job instructions equipment/tool operating instructions company standards and procedures 1.3 Obtain and follow the correct job instructions and any relevant preparation procedure specifications 1.4 Carry out work area preparations according to procedure specification and take account of any specific safety requirements 1.5 Prepare and maintain the work area to include all of the following: accessibility for receipt and removal of materials freedom from obstructions and hazards correct equipment and material layout 1.6 Prepare the equipment for the manufacturing operations and check that it is in a safe and usable condition to include one of the following: machinery process plant tools - hand held and portable material handling arrangements equipment specific to the operation 1.7 When necessary, request replacement tools and equipment within the limits of their responsibility

36 36 Unit 05 Preparing for manufacturing operations (L/601/3010) (cont d) 2 Prepare for manufacturing operations (cont d) 2.1 Ensure that the materials are available, and they meet the specification for type, quantity and quality 2.2 Make available and check materials for manufacturing operations to include one of the following: production materials consumable materials 2.3 Minimise any waste during preparation activities 2.4 Deal with problems in preparation in 2 of the following areas: raw materials documentation tooling equipment work area 2.5 Resolve any problems with the preparation activity within the limits of their responsibility 2.6 Report any problems that they cannot solve or are outside their permitted authority to the appropriate person to include 2 of the following: supervisor team leader maintenance personnel quality control 2.7 Maintain a safe and organised work area at all times 3 Know how to prepare for manufacturing operations 3.1 Describe the relevant health and safety requirements of the work area in which they are carrying out the preparation activities 3.2 Explain the specific safe working practices that need to be observed whilst carrying out the preparations 3.3 Explain the hazards associated with carrying out the preparation activities and how they can be minimised 3.4 Explain what personal protective equipment needs to be used during the preparation activities and where can it be obtained 3.5 Explain how to obtain the necessary job instructions, equipment preparation procedures and how to interpret them

37 37 Unit 05 Preparing for manufacturing operations (L/601/3010) (cont d) 3.6 Explain how the work area needs to be laid out, and where tools and materials need to be positioned 3.7 Explain what material preparations may be required and how they will be carried out 3.8 Explain what preparation checks need to be taken on the tools and/or equipment that they will use 3.9 Explain what to do if their work area, equipment and/or materials are unsuitable for the planned operations 3.10 Explain the arrangements for the receiving and removal of materials and products 3.11 Explain what checks are needed to make sure materials meet the required specification 4 Know how to prepare for manufacturing operations (cont d) 4.1 Explain how to check that preparation is complete and correct 4.2 Explain what methods can be used to minimise waste during preparation activities 4.3 Explain the potential problems with carrying out preparation activities and how they can be avoided 4.4 Explain what problems can occur in preparation activities 4.5 Explain how to identify problems within preparation activities 4.6 Explain what actions they can take within the limits of their responsibility to solve the problems 4.7 Explain who to report unsolvable problems to, or problems that are not within the limits of their responsibility 4.8 Explain what documentation may need to be completed, and why it is important to complete it accurately 4.9 Explain what their personal responsibilities are with regard to health, safety and environmental issues 4.10 Explain who are the appropriate people and what are their responsibilities within their working area

38 38 Unit 05 Preparing for manufacturing operations (L/601/3010) (cont d) Assessment guidance AC Assessment guidance 1.1, 1.2, Assessment criteria should be observed and recorded over a 2.7 period of time The use of simulation within a realistic working environment is acceptable for assessment criteria. This unit must be assessed in a work environment and must be assessed in accordance with the Common Requirements for National Vocational Qualifications (NVQ). Additional assessment requirements have been published by Semta. These additional assessment requirements are set down in Semta s Unit Assessment Strategies. These documents can be downloaded from the qualification page on our website

39 39 Unit 06 Concluding manufacturing operations (Y/601/3012) Unit summary In this unit learners will conclude manufacturing operations, following relevant completion/shutdown procedures and safety requirements. Learners will close down equipment used in the manufacturing operations and ensure equipment is clean for further use. Guided learning hours 42 Credit value 9 Level 2 Mandatory/optional Optional 1 Conclude manufacturing operations 1.1 Work safely at all times, complying with health and safety, environmental and other relevant regulations and guidelines 1.2 Follow relevant shutdown procedures and safety requirements to include all of the following: health and safety regulations safe working practices company procedures job instructions equipment shutdown instructions 1.3 Obtain and follow the correct job instructions and any relevant completion/shutdown procedure instructions 1.4 Stop the operations in accordance with job instructions and specified completion/shutdown procedures, and take account of any specific safety procedures 1.5 Close down equipment used in the manufacturing operations to include one of the following: machinery process plant tools (hand held and portable) material handling arrangements equipment specific to the operation 1.6 Make sure any related equipment is shut down to a safe condition in accordance with completion/shutdown procedures 1.7 Ensure equipment is clean for further use 1.8 Remove and store materials in a correct and safe manner

40 40 Unit 06 Concluding manufacturing operations (Y/601/3012) (cont d) 2 Conclude manufacturing operations (cont d) 2.1 Deal appropriately with materials at completion of the manufacturing operations to include the following: finished products/components and one other type of material from the following: production materials surplus consumable materials waste or scrap materials 2.2 Minimise any waste during completion/shutdown activities 2.3 Resolve any problems with the completion/shutdown activity within the limits of their responsibility 2.4 Report any problems that they cannot solve or are outside their permitted authority to the appropriate person to include 2 of the following: supervisor team leader maintenance personnel quality control 2.5 Maintain a safe and organised work area at all times 2.6 Report on status of completion/shutdown of manufacturing operations 2.7 Use the correct reporting procedure on completion of manufacturing operations for one of the following: output downtime quality maintenance requirements scrap work in progress 2.8 Confirm completion/shutdown is correct and complete according to defined procedures/instructions

41 41 Unit 06 Concluding manufacturing operations (Y/601/3012) (cont d) 3 Know how to conclude manufacturing operations 3.1 Describe the relevant health and safety requirements of the work area in which they are carrying out the activities 3.2 Explain the specific safe working practices that need to be observed whilst carrying out the completion/shut down activities 3.3 Explain the hazards associated with carrying out the completion/shutdown activities and how they can be minimised 3.4 Explain what personal protective equipment needs to be used during the completion/shutdown and cleaning activities and where can it be obtained 3.5 Explain what actions need to be taken in case of emergencies when shutting down machines or fully automated manufacturing operations 3.6 Explain how to obtain the necessary job instructions, equipment shutdown procedures and how to interpret them 3.7 Explain when in the manufacturing operation is it safe to shut down the equipment 3.8 Explain what completion checks need to be made 3.9 Explain the procedures for cleaning the equipment 3.10 Explain the procedures for storing and removing materials and waste 4 Know how to conclude manufacturing operations (cont d) 4.1 Explain what methods can be used to minimise waste during completion activities 4.2 Explain the potential problems with carrying out the completion activities and how they can be avoided 4.3 Explain what problems can occur in completion/shutdown activities 4.4 Explain how to identify problems within completion/shutdown activities 4.5 Explain what actions they can take within the limits of their responsibility to solve the problems 4.6 Explain who to report unsolvable problems to, or problems that are not within the limits of their responsibility 4.7 Explain what documentation needs to be completed and why it is important to complete it accurately and legibly