SKILL LEVEL CRITERIA FOR MACHINING

Level Parameters

Load / Unload the job

Can start the machine
Identify the model (Product)
1- Can understand the work instructions
Basic
Competence Knowledge of basic machine and operation names
Knowledge of safety devices/aids and safety precautions while operating the
machine.

Can do 1S activity on his/her machine

Understands the Control plan / Process Sheets

Knowledge of inspection gauges and inspection procedure

Can record the quality parameters in self-inspection report (SIR) and Control
2- Charts
Medium
Competence
Can understand and use the autonomous maintenance checksheet

Can do 2S activities on his/her workstations

Can do and monitor the tool changing

Can do the quality correction as per self inspection and/or CMM report

Can do the setting of Variable Inspection Gauges

3- Can understand the status of Measuring instruments and inspection gauges
Advanced (Calibration status)
Competence
 3-
Advanced
Competence
Knowledge of defect-effect on immediate customer, OEM and end user

Can do model-to-model set-up change

Can work on the station as per standard cycle time

Can understand the status of Jigs / Fixtures

Can independently do the Machine, Process and Quality related

troubleshooting

Can work on all the work stations in the cell as per standard cycle time

4- Knowledge of Cp, Cpk of critical machines of the cell

Ability to set the machine for new product

Expert
Can handle the cell shift activity independently
Knowledge of OEE/PPM
Active involvement in SGAs and APS keys for continuous improvements like
5S, TPM, idea implementation.
Can train others
Has good soft skills like team work and initiative
MACHINING CELLS

Trainings Required

1. Process related training through visual aids like

video films and photos

2. Training by senior OE and team leader as a Mentor

3. Safety Training (Visual + Practical)

4. 1 S

1. Training for process sheets

2. Use of Measuring instruments, Inspection Gauges,

recording methods and Control charts.

3. Training for autonomous maintenance (CLIT-

Cleaning, Lubrication, Inspection & Tightening)

4. 2 S

1. Tools, Tool holders, cutting parameters, Tool life and

jigs / fixtures

2. CNC Programing
3. Training for setting of variable inspection gauges,
understanding the gauge status and gauge plan

4. Training for CMM report reading.

1. Basics of Pneumatics, Hydraulics & Electrical

2. APS- 4 Days Regular Training

3. APS- 2 Days Training focused on 20 keys

implementation

4. TPM

5. 5 S
6. SPC
7. OEE and PPM Improvement Actions

8. Problem solving techniques

9. 8D Methodology
 Rev: # 01,25 Nov 2010
Certifying Learning
Training Material Required
Authority Days

1. Standard Video clip of operation

2. Work Standards Cell Co-ordinator 3

3. Safety Training material

4. 1 S Methodology

1. Process Sheets

2. Record Sheet

Quality + Cell Co-

6
ordinator
3. Autonomous Maintenance Check sheet

4. 2 S Methodology

1. Tool Monitoring Chart

2. Gauge Calibration plan

3. Effect-defect Chart TSG + Cell Co-

90
ordinator
 TSG + Cell Co-
90
ordinator
4. Set-up change procedure

5. Set-up approval report

1. Tooling / Fixture Checksheet

2. Guidelines for SGA Working Methodology

Head - Production "

3. APS Keys Audit Methodology

4. 8D Format
 SKILL EVALUATION FORM - MACHINING CELL
Revision # 1, Date - 25 Nov 2010

SPICER IND. LTD. OPERATION UNDER SUPERVISION

Date -

SKILL LEVEL - 1:
DATE OF JOINING -

NAME OF O.E:
CELL -

WORK STATION

ON JOB EVALUATION

SR. NO. QUESTIONS MARKS SCORED MAX MARKS REMARKS

1 CAN IDENTIFY THE NAME OF THE PRODUCT.

5
2 UNDERSTANDING OF WORK INSTRUCTION ON MACHINE.
5
3 UNDERSTANDING OF CELL OBJECTIVES
5
4 KNOWLEDGE OF OPERATION NAME AND OPERATING THE MACHINE .
5
5 KNOWLEDGE OF SAFETY DEVICES /AIDS AND SAFETY PRECAUTIONS WHILE OPERATING THE M/C
5
6 KNOWLEDGE OF 2 S IN THE CELL AND IN MACHINE
5
7 KNOWLEDGE OF AUTONOMOUS MAINTENANCE , HOW TO FILL UP AM CHECKSHEET
5
S/N
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
 Requirements
What is the final product of your cell
What is the process flow of the jobs in the cell
What is mean by PCP,WI,PCS, PM Checklist, Safety Checklist & Defect- Effect matrix?
What are the targets of production,rej,rew of your process ?
What are the targets of production,rej,rew of shop floor ?
What is the Quality policy ?
Where do you get Raw material details ?
How many types of tags are there & what are those?
What do operating buttons control panel contain ?
How you are ensuring input material is ok ?
What are customer complaints of your process ?
What are the Poke-Yoke of your process and how they are functioning ?
What are the safety measures we need to take ?
Types of fire exstinguishers available in Plant ?
How many Emergency Exits are there in plant ? Mention Location .Where is the assembly point?
What is 1 'S' and 2 "S" ? Give a brief description on each ?
How can you ensure 2 S in your workstation?
What is Autonomous Maintenance?
What do we check daily in Autonomous Maintenance Checksheet?
TOTAL MARKS
Max Marks
2
5
8
3
3
3
3
2
3
5
5
5
5
3
3
3
3
3
3

70
 1
2
3
5
6
7

Evaluation

Minimum
No.of
working day
after
Induction

Skill Index
 Trainings Needed L1
Training on 'Safety'
Training on Autonomous Maintenance
Training on PCP,DEM,WI,PM Checklist , Safety Checklist & Other documentations
Training on' POKA-YOKE'
"Mockdrill"
Training on 1 'S' and 2"S"

On the Job Evaluation

Total Marks =50
Qualifying Mark =25
Written Examination
Total Marks =70
Qualifying Mark =35

15
SKILL LEVEL - 2 :

NAME OF O.E:

WORK STATION

ON JOB EVALUATION

QUESTIONS
SR. NO.

1 CAN MACHINING THE PART AS PER PROCESS SHEET &CAN EXPLAIN IN DETAIL, WITH REACTION PLAN

2 KNOWLEDGE OF INSPECTION GAUGES & INSPECTION PROCEDURES

3 CAN UNDERSTAND & USE THE AUTONOMOUS MAINT. /SHIFT START UP CHECK SHEET

4 CAN UNDERSTAND THE STATUS OF MEASURING INSTRUMENTS /GAUGES(CALIBRATION STATUS)

5 CAN RECORD THE QUALITY PARAMETERS IN SELF INSPECTION REPORT (SIR)

6 KNOWLEDGE OF N.C. COMPONENTS HANDLING

7 KNOWLEDGE OF CONTROL CHARTS AND CAN USE THE CONTROL CHARTS ON THE WORK INSTRUCTI

*PASSING CRITERIA MIN 50% MARKS

*WRITTEN TEST-PASSING CRITERIA MIN 70 MA

SIGN OF OPERATING ENGINEER SIGN OF CERTIFYING AUTHORIT
 SKILL EVALUATION FORM - MACHINING CELL
OPERATE INDEPENDENTLY

VALUATION

QUESTIONS

NING THE PART AS PER PROCESS SHEET &CAN EXPLAIN IN DETAIL, WITH REACTION PLAN

E OF INSPECTION GAUGES & INSPECTION PROCEDURES

RSTAND & USE THE AUTONOMOUS MAINT. /SHIFT START UP CHECK SHEET

STAND THE STATUS OF MEASURING INSTRUMENTS /GAUGES(CALIBRATION STATUS)

D THE QUALITY PARAMETERS IN SELF INSPECTION REPORT (SIR)

E OF N.C. COMPONENTS HANDLING

E OF CONTROL CHARTS AND CAN USE THE CONTROL CHARTS ON THE WORK INSTRUCTION

*PASSING CRITERIA MIN 50% MARKS

*WRITTEN TEST-PASSING CRITERIA MIN 70 MARKS. ADDITIONAL FOR THIS LEVEL.

GN OF OPERATING ENGINEER SIGN OF CERTIFYING AUTHORITY - (QUALITY ENGINEER )
 Revision # 1, Date - 25 Nov 2010
Date -

DATE OF LAST EVALUATION-

CELL -

ANSWERS MARKS REMARKS

10

15

15

15

15

15

15

100

MARKS. ADDITIONAL FOR THIS LEVEL.

RITY - (QUALITY ENGINEER ) CELL , CO-ORDINATOR
S/N
1
2
3
4
5
6
7
8
9
10
 Requirements
What are the activity involved in set-up change part to part and series to series ?
What are the tools specification ?
How Poka-Yokes are working in your process ?
List out all the defects occurring in your process ?
What are the reasons for getting defects ?
What are the activity you are doing in CLIT and how?
What is mean by reaction plan ?
What are the Critical parameters in your process ?
List out gauges, tools ,fixture using on your work station ?
What is mean by calibration and how you are ensuring ?
Pertaining to Scoring Point Number
10
10
10
10
10
10
10
10
10
10
100
 1
2
3
4
5
6
7
8

Evaluation

Minimum No.of
working days after
L1

Skill Index
 Trainings Needed
Awareness on gauge handling & calibration
Training on Problem Solving
Training on Autonomous Maintenance
Training on' POKA-YOKE'
Training on 5 'S'
Use of Measuring instruments, Inspection Gauges, recording methods and Control charts.
Training for process sheets
Training on TS 16949 Awareness

On the Job Evaluation

Total Marks =100
Qualifying Mark =50
Written Examination
Total Marks =100
Qualifying Mark =50

15
SKILL LEVEL - 3:
NAME OF O.E:

WORK STATION

ON JOB EVALUATION

SR. NO. QUESTIONS

1 KNOWLEDGE OF TOOLINGS ,FIXTURES& MONITOR THE TOOL CHANGING

2 KNOWLEDGE OF DEFECT-EFECT ON IMMEDIATE CUSTOMER, OEM & EN

3 CAN DO MODEL -TO-MODEL SET -UP CHANGE

4 CAN WORK ON ALL WORK STATIONS AS PER STANDARD CYCLE TIME

5 CAN DO THE QUALITY CORRECTION AS PER SELF INSPECTION AND /OR

 6 IS ABLE TO TAKE DISPOSAL/CORRECTIVE ACTION & DO THE REWORK

*PASSING CRITERIA MIN 50%

SIGN OF OPERATING ENGINEER SIGN OF CERTIFYING AUTHO

 SKILL EVALUATION FORM
OPERATE & ABLE TO DO SET UP

QUESTIONS

OF TOOLINGS ,FIXTURES& MONITOR THE TOOL CHANGING FOR TOOL LIFE MONITORING

OF DEFECT-EFECT ON IMMEDIATE CUSTOMER, OEM & END CUSTOMER

DEL -TO-MODEL SET -UP CHANGE

N ALL WORK STATIONS AS PER STANDARD CYCLE TIME IN THE CELL

QUALITY CORRECTION AS PER SELF INSPECTION AND /OR CMM REPORT

TAKE DISPOSAL/CORRECTIVE ACTION & DO THE REWORK FOR NON CONF. PARTS

*PASSING CRITERIA MIN 50% MARKS

ENGINEER SIGN OF CERTIFYING AUTHORITY - T.S.G ENGINEER

Revision # 1, Date - 25 NOV 2010
Date -
DATE OF LAST EVALUATION -
CELL -

ANSWERS MARKS

15

20

20

15

15
 15

100

CO-ORDINATOR
- 25 NOV 2010

ALUATION -

REMARKS
S/N
1
2
3
4
5
6
7
8
9
10
 Requirements
What are the activity involved in new product set-up change ?
What are the systems implemented and how these systems are helping the organization ?
What are the raw material specification ?
What are the points need to considered during your fixture modification ?
What are the QC tools you are using when you want to analyze the problem ?
Operation Specific Questions to come here
Operation Specific Questions to come here
Operation Specific Questions to come here
Operation Specific Questions to come here
Operation Specific Questions to come here
Pertaining to Scoring Point Number
10
10
10
10
10
10
10
10
10
10
100
 1
2
3
4
5
6
7
8
9

Evaluation

Minimum
No.of
working days
after L2

Skill Index
 Trainings Needed L3
Training on 'Quick Change Over'
Training on' POKA-YOKE'
Training on AM Atep 1 & 2
Training on 'Cutting Tools'
Tools, Tool holders, cutting parameters, Tool life and jigs / fixtures
CNC Programing
Training for setting of variable inspection gauges, understanding the gauge status and gauge plan
Training for CMM report reading.
Operation Specific Trainings if any to come here

On the Job Evaluation

Total Marks =100
Qualifying Mark =50
Written Examination
Total Marks =100
Qualifying Mark =50

45
SPICER IND. LTD

SKILL LEVEL - 4 :

NAME OF O.E:

WORK STATION

ON JOB EVALUATION

QUESTIONS
SR. NO.

1 CAN DO THE TROUBLE SHOOTING FOR MACHINE PROCESS & QUALITY ISSUES

2 CAN UNDERSTAND THE STATUS OF JIGS /FIXTURES

3 ABILITY TO SET THE MACHINE FOR NEW PRODUCT.

4 CAN HANDLE THE CELL SHIFT ACTIVITY INDEPENDENTLY

5 CAN LEAD IMPROVEMENT ACTIONS RELATED TO OEE & PPM

6 CAN TRAIN OTHERS

7 GOOD SOFT SKILLS LIKE TEAM WORK AS AN INITIATIVE

*PASSING CRITERIA MIN 50% MARKS

SIGN OF OPERATING ENGINEER SIGN OF CERTIFYING AUTHORITY - PRODU
 SKILL EVALUATION FORM
TROUBLE SHOOTING & TRAIN OTHERS

VALUATION

QUESTIONS

E TROUBLE SHOOTING FOR MACHINE PROCESS & QUALITY ISSUES

STAND THE STATUS OF JIGS /FIXTURES

SET THE MACHINE FOR NEW PRODUCT.

E THE CELL SHIFT ACTIVITY INDEPENDENTLY

IMPROVEMENT ACTIONS RELATED TO OEE & PPM

N OTHERS

T SKILLS LIKE TEAM WORK AS AN INITIATIVE

*PASSING CRITERIA MIN 50% MARKS

G ENGINEER SIGN OF CERTIFYING AUTHORITY - PRODUCTION MANAGER
Revision # 1, Date - 25 March 2010
Date -

DATE OF LAST EVALUATION -

CELL -

ANSWERS MARKS

10

10

15

20

15

15

15

100
DUCTION MANAGER CELL , CO-ORDINATOR
 - 25 March 2010

VALUATION -

REMARKS
CELL , CO-ORDINATOR
S/N
1
2
3
4
5
6
7
8
9
 Requirements
How you are going to train your subordinates ?
What are the frequent problem occurring and how you are solving the same ?
What are the minor problems related to maintenance and how you are going to solve ?
What do you understand by R&R study, Bias Study ?
Explain the process for production planning of your work unit ?
Specific Questions to come here
Specific Questions to come here
Specific Questions to come here
Specific Questions to come here
Pertaining to Scoring
Point Number

15
15
10
10
10
10
10
10
10
100
 1
2
3
4
5
6
7
8
9
10
11
12

Evaluation

Minimum No.of
working days after
L3

Skill Index
 Trainings Needed L4
Training on MSA
Training on 'Problem Solving"
Training on AM Step 1,2,3 & machine mechanism
Basics of Pneumatics, Hydraulics & Electrical
APS- 4 Days Regular Training
APS- 2 Days Training focused on 20 keys implementation
TPM
5S
SPC
OEE and PPM Improvement Actions
Problem solving techniques
8D Methodology

On the Job Evaluation

Total Marks =100
Qualifying Mark =50
Written Examination
Total Marks =100
Qualifying Mark =50

90