NAPS Curriculum embedded Assembly line supervisor Q3602 (002)

APPRENTICESHIP CURRICULUM

For

Vehicle Manufacturing Operations – An

Integrated Approach

Under

Automotive Skills Development Council

for

NSQF compliance

National Apprenticeship Promotion Scheme

1 Program Title Vehicle Manufacturing Operations – An Integrated Approach

2 Program Code, if any NA

3 Any related NSQF approved QP/Course/ NOS and code:

Assembly Line Machine Setter; ASC/Q3603, Welding Technician Level 4; ASC/Q3103, Assembly Line Supervisor; ASC/Q3602, Automotive Paintshop Assistant; ASC/Q3302

4 Hours for Basic Training (Block I) 190 Hrs. (1 month)

5 Hours for On the Job Training (Block II) 1779 Hrs. (11 months)

6 Certifying body for Basic Training Automotive Skills Development Council Program

7 Certifying Body for On the Job Training Industry Partner

8 Any Licensing requirements, wherever NA

9 Minimum eligibility criteria 10th Class or ITI (Educational and/or Technical Qualification) BT Exemptions B.Tech (Automotive)/ B.Sc.

10 Trainer’s Qualification and Experience Diploma in Mech./Elec. 5 years for diploma holder

11 NCO code and occupation NCO-2004/7223.40 Assembly Line

12 Proposed NSQF level 4

13 Indicative list of training tools required As per annexure A to deliver this qualification

14

Formal structure of the curriculum

Modules Notional hours- Theory

Notional hours-

Practical

Total duration

1 General Introduction of the Course 1 0 1

2 Corporate Values & Culture 4 0 4

3 Introduction to Corporate Policy & Procedure

4 0 4

4 Company Code of Conduct 3 0 3

5 Introduction to Automobile Sector 6 0 6

6 Basics of Automobile 8 2 10

7 Basics of Powertrain 2 2 4

8 Safety Operating System 3 0 3

9 Energy Control & Power Lockout 3 2 5

10 Basics Ergonomics & Work Station Design

4 2 6

11 PMHV Safety 3 2 5

12 Quality Workshop 25 11 36

13 Basics of Hand Tools & Measurement Devices

6 1 7

14 Overview of Pneumatics / Hydraulics 3 1 4

15 Basic Industrial Automation 3 1 4

16 Basics of Jigs & Fixture & Basics of Gauges

4 2 6

17 Lean Manufacturing 2 0 2

18 5S Safety system 2 2 4

19 Kaizen Workshop 3 1 4

20 Operational Maintenance 4 2 6

21 Basics of Stamping Process 3 2 5

22 Basics of Metal Joining Process 3 2 5

23 Basics of Resistance Welding 3 2 5

24 Painting Technology 3 2 5

25 Basics of Assembly Operations 3 2 5

26 Material Handling & Internal Logistics 3 2 5

27 Vehicle Evaluation system 3 2 5

28 Machining Process Overview 4 2 6

29 Behavioral Training 19 2 21

30 Environmental Management 2 2 4

Total 139 51 190

On the Job

Training Program

Introduction to organizational procedures at shop floor

12 12 24

2 Work station management 3 3 6

3 Workstation Readiness 10 32 42

4 Organization policies and procedure 10 32 42

5 Practice workstation readiness 0 16 16

6 Tools and equipment required 10 32 42

7 Measuring instruments required 10 32 42

8 Pre-operation check of tools and equipment

10 32 42

9 Practice use of tools and equipment 0 42 42

10 Escalation of queries 5 27 32

11 Introduction to various types of vehicles

10 32 42

12 Assembly processes 10 32 42

13 Preparation for vehicle assembly 8 34 42

14 Perform mechanical assembly operation of the components

8 34 42

15 Perform electrical assembly operation of the components

8 34 42

16 Vehicle quality check 6 36 42

17 Practice of vehicle assembly process 0 38 38

18 Shop floor management 1 10 32 42

19 Shop floor management 2 10 32 42

20 Machining process requirements 8 34 42

21 Machining process implementation 8 34 42

22 Welding process requirements 8 34 42

23 Welding process implementation 8 34 42

24 Assembly process requirements 8 34 42

25 Assembly process implementation 8 34 42

26 Painting process requirements 8 34 42

27 Painting process implementation 8 34 42

28 Data entry 8 34 42

29 Data analysis 8 34 42

30 Practice of data entry and analysis 0 20 20

31 Process improvement 20 22 42

32 Practice process improvement techniques

5 37 42

33 Problem solving tools 20 22 42

34 Practice problem solving tools 5 37 42

35 Practice use of process improvement techniques and problem solving tools

0 32 32

36 Process verification at workstation 15 27 42

37 Support other departments 10 32 42

38 Practice process verification at workstation

0 16 16

39 Quality inspection methods 18 24 42

40 Quality inspection 6 24 30

41 Maintenance of machine and tools 10 32 42

42 Maintenance activities 15 27 42

43 Practice of maintenance activities 0 15 15

44 Hazards and safety 6 36 42

45 Workshop safety and hygiene 4 34 38

46 Maintain 5S at the work premises 8 34 42

47 Waste management 6 36 42

Total 368 1411 1779

15 Total Pass marks

Total and Pass Marks - Theory

Total and Pass Marks - Practical

Basic Training Program 484.5 / 692 1265.5 / 1808

On the Job Training Program 484.5 / 692 1265.5 / 1808

16 Job description

A vehicle manufacturing operations, carry out various processes related to vehicle manufacturing such as components assembly, painting, welding etc. The individual is also involved in cleaning and basic maintenance of work areas and equipment through Operational Maintenance procedure.

17 Progression from the qualification (Please show Professional and academic progression)

Company Apprentice (3 years), Associate (in domain like quality, maintenance, assembly, etc)

18 Employment avenues/ opportunities:

In any Auto ancillary companies like Tyre industries, Battery, Brakes and Suspension, Axles, Gears, Engines, Auto parts, Electrical parts, Two-Wheeler, Three Wheeler, Four Wheeler, Commercial Vehicles etc.

19 Assessment strategy (Basic training and On the Job)

For basic training: 1. Assessment to be conducted by ASDC as per competency output defined in the

NOS/QP and the assessment criteria provided in the NOS/QP. 2. Assessment to be carried out by a third-party Assessment Body duly affiliated to

the SSC. 3. ASDC assessments will be comprehensive and cover all aspects of acquired

knowledge, practical skills and also basic ability to communicate. Accordingly, evaluation process would include: i. Theory/Knowledge test ii. Practical demonstration test iii. Face to Face

4. Theory/Knowledge assessment will be carried out on line through a link provided for each assessment that generates a random paper from a bank of questions available at the back end. • On line test would be conducted in the presence of an ASDC assessor till web

enabled proctoring is deployed. 5. ASDC assessor would be conducting Practical and Viva as per the criteria

provided in the NOS/QP. 6. Cut off criteria for certification (Marks obtained in %): 70%

For On the Job:

1. Self-assessment for on the job training to be conducted by the industry partner. 2. Tools of Assessment that can be used are:

a. Videos of Trainees during OJT b. Answer Sheets of Question Banks c. Employer Performance Feedback.

3. Assessment will ensure that the apprentice will be able to: a. Read and extract information from sketches and drawings.

b. Identify tools and equipment required for vehicle components fitting work.

c. Perform assembly of mechanical components of vehicle.

d. Perform assembly of electrical and electronic components of vehicle.

e. Identify training and skills improvement requirement for the team members

f. Maintain a safe and healthy working environment

g. Maintain 5S at the work premises

20 Curriculum update version and date: v1.0, 20th November 2020

21 Curriculum revision date: 20th November 2025

Curriculum

Module name with duration

Key learning outcomes

Theory/Basic Training Program- PHASE 1

General Introduction of the Course Theory Duration (hh:mm) 01:00 Practical Duration (hh:mm) 00.00 Bridge Module

• Identify the salient features of the course

• Explain course contents, how this course is designed to

support AA women employee

• Interpret the scope of this course

• Describe the benefits of learning this course

• Identify the job opportunities and career path available for

future

• Explain the outcomes of the course

Corporate Values & Culture Theory Duration (hh:mm) 04:00 Practical Duration (hh:mm) 00.00 Bridge Module

• Review the organization’s Mission, vision and Core Values

to encourage inclusion

• Describe the Basics of – Culture

• Review and redesign current policies and procedures to

encourage inclusion of Persons with Disability

• Implement laws, acts and provisions defined for Persons

with Disability by the statutory bodies

• Review and adapt appropriate reasonable accommodations

to ensure accessibility in the work environment

• Adopt policies, systems and practices that actively

encourage and support the integration of Persons with

Disability.

• Encourage orientation of employees/ staff highlighting

success stories and business sense of hiring irrespective of

Gender or Disability

• Follow disability etiquettes while interacting with Persons

with Disability

• To follow the learnings of sensitivity trainings while

transacting with Persons with Disability

• Build partnerships with appropriate Organizations and other

civil society organization for making the workplace PwD

friendly, accessible & integrating inclusive practices.

• Adopt appropriate health and safety protocols for

emergency situations for Persons with Disability.

Introduction to Corporate Policy & Procedure Theory Duration (hh:mm) 04:00 Practical Duration (hh:mm) 00.00 Bridge Module

• Describe HR Policies & Procedures, timings to be followed

in the organization

• Describe the Leave Policy, Shift Pattern, working hours

criteria

• Describe the procedure for Misconduct and disciplinary

policies

• Interpret the Zero Tolerance Policy

• Adhere to Data Integrity policies and practices

Company Code of Conduct Theory Duration (hh:mm) 03:00 Practical Duration (hh:mm) 00.00 Bridge Module

• Follow the workplace environment related practices

developed by the organization.

• Describe the relevant standards, product quality followed in

the company.

• Develop and understand intellectual property, integrity of

financial & company records.

• Describe the company's commitment to doing business with

integrity

• Explain basics of plant behavior related to professional

conduct.

• Describe the expected behavior on the line during job.

Introduction to Automobile Sector Theory Duration (hh:mm) 06:00 Practical Duration (hh:mm) 00:00 Bridge Module

• Describe the Evolution of Automobiles, Automobiles History

& Key Events/Innovations

• List types of Vehicles & Classifications (HMV & LMV)

• List Automobile Companies in Indian & type of automobile

industries (OEM, TIER 1,2)

• Explain manufacturing process and functions in automobile

industry

• List the terms associated with automobile industries

Basics of Automobile Theory Duration (hh:mm) 08:00

• List Site Manufacturing Plants & Cars in India

• Develop the know-how on body & chassis Types,

Powertrain Systems, Transmission Types & Functions,

Types of Braking System, Steering System, Suspension

Practical Duration (hh:mm) 02:00 Bridge Module

System, Heating and Air Conditioning System & Safety

Systems

Basics of Powertrain Theory Duration (hh:mm) 02:00 Practical Duration (hh:mm) 02:00 Bridge Module

• Describe Engine & its Types

• Classify IC Engines

• Describe the engine working principle

• List the parts of engine & their functions

• Observe the Oil & Coolant Lubrication System & PCM &

Sensors

Safety Operational Systems Theory Duration (hh:mm) 03:00 Practical Duration (hh:mm) 00:00 ASC/N0006 (ASC/Q3603)

• List workplace Health and Safety Rules, Work Permits,

License and Compliance

• Report concerned authorities about the Accident /Near miss

• Explain the basics of lifting & rigging, electrical safety,

industrial safety, fire safety, crane & power press operation

• List the contents of basic first-aid.

• Demonstrate emergency response, fire evacuation routes &

systems

• Follow health & safety policies & procedures

• Describe the Importance & use PPE (Personal Protection

Equipment like safety gloves, safety glasses, safety shoes

and safety helmet) at workplace.

• Discuss Operator Instruction (OIS) Sheet & Job Safety Risk

Analysis (JSA)

Energy Control & Power Lockout Theory Duration (hh:mm) 03:00 Practical Duration (hh:mm) 02:00 ASC/N0006 (ASC/Q3603)

• Describe the usage of energy control and power lockout

• Describe the difference between accidents and incidents

• Follow the steps of lockout

• Follow do's and don’ts of manufacturing process.

• Develop understanding of the concept of Energy Placards

on shop floor & electric panel

• Demonstrate safe work practices for electrical power

distribution systems

Basic Ergonomics & Workstation Design Theory Duration (hh:mm) 04:00 Practical Duration (hh:mm) 02:00 ASC/N0006 (ASC/Q3603)

• Describe the concept on Industrial Ergonomics

• Follow the walking working surface

• Demonstrate workstation readiness safety standards on

shop floor

• Maintain safe work practices & standards at shop floor

• Explain the concept of Confined Space Overview

PMHV Safety Theory Duration (hh:mm) 03:00 Practical Duration (hh:mm) 02:00 ASC/N0006 (ASC/Q3603)

• Demonstrate application of various material handling

equipment’s and ensure safety at material handling

• Describe pedestrian safety practices

• Describe pedestrian and other safety practices during

material handling using forklift & towtruck

Quality Workshop Theory Duration (hh:mm) 25:00 Practical Duration (hh:mm) 11:00 ASC/N0022 (ASC/Q3603)

• Explain TQM Concept & its application of Quality Systems

• Develop understanding into basics of Gauges –

Understanding of Calibration Overview, Calibration tools

• List various problems solving tools like 7QC and

demonstrate how to use them

• Describe the drafting of Standard operating procedure

(SOP) & follow the SOP on line

• Explain Working Instructions / Operator instructions sheet

• Describe basic of quality management system its overview,

objective, benefits & system

• Describe Visual Signage - by understanding the Process,

Principles and Purpose

• Describe application of problem-solving tools like Error

Proofing/Poka- Yoke rules, Approaches & Application

Basics of Hand Tools & Measurement Devices Theory Duration

• Explain safe operating procedure of using workshop tools

and equipment

• List the types of Hand tools, purpose & uses of Hand tools

(hh:mm) 06:00 Practical Duration (hh:mm) 01:00 ASC/Q3108 (ASC/Q3103)

• Demonstrate use of right tools for the right job

• Ensure safe handling of tools

• Interpret information from sketches and engineering

drawing

• Explain the tools – devices used to create technical

drawings and models & its applications – the various uses

for technical drawings.

Basics of Pneumatics & Hydraulics Theory Duration (hh:mm) 03:00 Practical Duration (hh:mm) 01:00 ASC/N0006 (ASC/Q3603)

• Explain basics working principle for pneumatics

• Explain the working principles of hydraulics

• List components of Pneumatic/Hydraulics Systems

• Observe the applications of tools in shop floor

• List the advantages & disadvantages of operation at shop

floor

• Adhere to safety while operating the tools in shop floor

Basic Industrial Automation Theory Duration (hh:mm) 03:00 Practical Duration (hh:mm) 01:00

• Explain the types of Manufacturing ( Batch, Conveyor, Cell)

• Describe concept clarity on Mass Production & Need for

Automation

• Observe and learn the fundamentals of Robotics,

Conveyors, Gantry Systems, HMI, DC tool, AIS System,

Error proofing sensors etc.

Basics of Jigs & Fixture, Gauges Theory Duration (hh:mm) 04:00 Practical Duration (hh:mm) 02:00 ASC/N3614 (ASC/Q3602)

• Describe types, application, benefits, purpose & Significant

of Jigs & Fixtures

• List differences between Jig & Fixture

• Carry out maintenance of jigs & fixtures at shop floor

Lean Manufacturing Theory Duration

• Describe the Concept of Lean

(hh:mm) 02:00 Practical Duration (hh:mm) 00:00 ASC/N0016 (ASC/Q3603)

• Explain the difference between Mass vs. Lean

Manufacturing

• Demonstrate what is Waste and how to Identify, segregate

and eliminate waste

• Explain what is Lean Culture & Application of Lean Tools

5S Safety system Theory Duration (hh:mm) 02:00 Practical Duration (hh:mm) 02:00 ASC/N0022 (ASC/Q3603)

• Demonstrate the understanding of 5S Concept

• Follow 5S guidelines at workplace & understand the Red

Tag Procedure

• List benefits of 5S

Kaizen Workshop Theory Duration (hh:mm) 03:00 Practical Duration (hh:mm) 01:00 ASC/N0016 (ASC/Q3603)

• Define Kaizen

• Demonstrate continuous improvement at shop floor

• Demonstrate 3Mu's & 5S to identify Kaizen Opportunities

• Develop the Kaizen Mindset

• Describe the need for Error Proofing & it types of Error

Proofing

• Demonstrate the steps of Implementing Kaizen at shop floor

to benefit to Organization

Operational Maintenance Theory Duration (hh:mm) 04:00 Practical Duration (hh:mm) 02:00 ASC/N0016 (ASC/Q3603)

• Describe the meaning of operational maintenance

• Describe various types of maintenance

• Demonstrate how to conduct maintenance at shop floor

• Explain corrective, preventive, condition-based, predictive

and predetermined maintenance

• Explain the TQM approach 7 Six Big Losses

• Illustrate the OEE Calculations

Basics of Stamping Process Theory Duration

• Describe working principle of hydraulic press lines.

• Observe and understand the sheet metals rolls to blanks,

sheet metal preparation for stamping


• List stamping body parts, its tools & dies, outer & inner car

body parts.

• Explain quality defects

• Explain metal finishing process & their standards

Basics of Metal Joining Process Theory Duration (hh:mm) 03:00 Practical Duration (hh:mm) 02:00 ASC/N3108 (ASC/Q3103)

• Explain metal joining processes and their types

• Explain riveting & bolting, MIG & TIG Welding & its

application on shop floor

• Explain the concept of Strength & Durability

Basics of Resistance Welding Theory Duration (hh:mm) 03:00 Practical Duration (hh:mm) 02:00 ASC/N3108 (ASC/Q3103)

• List the Spot-Welding merits & demerits

• Observe the welding defects & weld check methods.

• Demonstrate the function of weld gun working & cooling

systems.

• Explain the concept of body in white - weld integrity & BIW

co-coordinates - CMM inspection

Painting Technology Theory Duration (hh:mm) 03:00 Practical Duration (hh:mm) 02:00 ASC/N3304 (ASC/Q3302)

• Describe paint shop & painting process

• Describe process of body preparation & chemical wash

• Describe the application of sealant

• Explain use of 3 Wet-Technology

• List the paint defects & quality inspection process

Basics of Assembly Process

• Explain basis of trim, chasse & final line process

• Explain basis of torque

Theory Duration (hh:mm) 03:00 Practical Duration (hh:mm) 02:00 ASC/N0013 (ASC/Q3602)

• List types of equipment & handling aids

• List types of tightening tools

• List types of filling process

• Describe kitting process

• Describe final assurance inspection

• Explain EOL process

Material Handling & Internal Logistics Theory Duration (hh:mm) 03:00 Practical Duration (hh:mm) 02:00 ASC/N0017 (ASC/Q3603)

• Describe Internal & External Logistics

• Explain the synchronization of Material Flow

• Define the Industrial Material Flow & Cycle Count Process

• Maintain Inventory Controls, Packaging Standards

Vehicle evaluation system Theory Duration (hh:mm) 03:00 Practical Duration (hh:mm) 02:00

• Define the Process & Procedure

• Describe in detail the vehicle testing techniques

Machining Process Overview Theory Duration (hh:mm) 04:00 Practical Duration (hh:mm) 02:00 ASC/N3616 (ASC/Q3603)

• Explain the concept of Machining a Metal Removing

Process

• Describe function of machines

• Describe process of aluminum die-casting & cast iron

machining.

• List types of tools under machining process

• Describe CNC Programming and CNC machining centers

• Define the gauge inspection & CMM Measurements

• Describe on Purity lab - Contamination inspection process

Behavioral Training Theory Duration (hh:mm) 19:00 Practical Duration (hh:mm) 02:00 ASC/N0006 (ASC/Q3603)

• Discuss the journey from corporate to campus.

• Communicate effectively with colleagues.

• List all forms of verbal and non-verbal methods to

communicate clearly and effectively with colleagues,

supervisors, customers and other stakeholders.

• Identify and resolve communication barriers.

• Identify different ways of managing resources efficiently.

• Explain various ways of time management and execute the

same.

• Identify the different ways of planning and organizing work.

• Complete the job within given time as per quality

standards/work schedule.

Environmental Management Theory Duration (hh:mm) 02:00 Practical Duration (hh:mm) 02:00 ASC/N0006 (ASC/Q3603)

• Describe Environment Operating System (EOS).

• Explain organization’s solid waste management methods.

• Describe the functioning of water and wastewater

treatment plant.

• Describe the concept of rainwater harvesting.

• Describe environment sustainability and its concept.

On the Job Training Program- Block II

Introduction to organizational procedures at shop floor Theory Duration (hh:mm) 12:00 Practical Duration (hh:mm) 12:00 ASC/N0016 (ASC/Q3603)

• Identify the salient features of the course and the scope of

the course.

• Identify the role and responsibilities at respective

workstation in the shop.

• Interpret standards and manuals of respective zone.

• Identify the different parameters of work station allocated.

• Interact with different departments and key personnel of

departments in the organization.

• Describe HR policies, timings to be followed in the

organisation, leaves, holidays, disciplinary policies etc.

• Explain the professional code of conduct relevant to the

organisation.

• Identify safety, health policies and regulations at the

workplace.

Workstation management Theory Duration (hh:mm) 03:00 Practical Duration (hh:mm) 03:00 ASC/N0017 (ASC/Q3603)

• Identify the deliverables of workstation under Productivity,

Cost, On time delivery, and Morale

• Describe the exchange of information between shifts

through the Basic Standard criteria for communication.

Workstation Readiness Theory Duration (hh:mm) 10:00 Practical Duration (hh:mm) 32:00 ASC/N3108 (ASC/Q3103)

• Identify the process and stages involved at assigned work

station.

• List the basic standards of start-up and close-out processes

(Goal, Purpose, Tools, Methods, Participants &

Expectations).

• Explain the expected behaviors during start-up and close-

out.

• Read the station documents, process sheet, FMEA, DCP,

QPS etc.

Organization policies and procedure Theory Duration (hh:mm) 10:00 Practical Duration (hh:mm) 32:00 ASC/N3108 (ASC/Q3103)

• Describe 5S and safety related aspects related to the work

station.

• Explain does and don’ts of the manufacturing process.

• Identify hazards and safety aspects involved in work station

activities.

• Demonstrate safety precautions while working on shop

floor.

• Describe organization queries escalation procedure.

• Demonstrate process of queries escalation to the

competent person.

Practice workstation readiness Theory Duration (hh:mm) 00:00 Practical Duration (hh:mm) 16:00 ASC/N3108 (ASC/Q3103)

• Identify the process and stages involved at assigned work

station.

• Read the station documents, process sheet, FMEA, DCP,

QPS etc.

• Practice safety precautions while working on shop floor.

Tools and equipment required Theory Duration (hh:mm) 10:00 Practical Duration (hh:mm) 32:00 ASC/N3614 (ASC/Q3602)

• Identify tools and equipment required in workshop.

• Explain standard safe operating procedure of using

workshop tools and equipment.

• Demonstrate safe operating procedure of workshop tools

and equipment (hand tools, power tools, marking tools etc.)

required for work.

• Inspect the working condition of tools before working.

Measuring instruments required Theory Duration (hh:mm) 10:00 Practical Duration (hh:mm) 32:00 ASC/N3614 (ASC/Q3602)

• List measuring instruments, gauges and diagnostic tools

required in workshop.

• Explain standard safe operating procedure of using

measuring instruments, gauges and diagnostic tools.

• Demonstrate safe standard operating procedure of using


• Explain calibration check process of measuring

instruments, gauges and diagnostic tools.

• Check calibration of measuring instruments, gauges and

diagnostic tools before use.

Pre-operation check of tools and equipment Theory Duration (hh:mm) 10:00 Practical Duration (hh:mm) 32:00 ASC/N3614 (ASC/Q3602)

• Identify the availability of machines, consumables and

auxiliaries required for job.

• Perform inspection of machines, consumables and

auxiliaries for proper working.

• Identify the availability of raw material required for job.

• Identify the availability of hand and power tools required for

work.

• Perform inspection of hand and power tools for proper

working.

Practice use of tools and equipment Theory Duration (hh:mm) 00:00 Practical Duration (hh:mm) 42:00

• Practice inspection of machines, consumables and

auxiliaries for proper working.

• Practice inspection of hand and power tools for proper

working.

• Practice safe operating procedure of workshop tools and

equipment (hand tools, power tools, marking tools etc.)

required for work.

ASC/N3614 (ASC/Q3602)

• Practice safe standard operating procedure of using


• Practice calibration check of measuring instruments,

gauges and diagnostic tools before use.

Escalation of queries Theory Duration (hh:mm) 05:00 Practical Duration (hh:mm) 27:00 ASC/N3614 (ASC/Q3602)

• Explain escalation matrix of organization.

• Refer the queries to a competent internal specialist if they

cannot be resolved by own.

• Obtain help or advice from specialist if the problem is

outside his/her area of competence or experience.

• Resolve all doubts and queries before the actual process

execution.

Introduction to various types of vehicles Theory Duration (hh:mm) 10:00 Practical Duration (hh:mm) 32:00 ASC/N3616 (ASC/Q3603)

• Describe manufacturer specifications, identification codes,

nomenclature related to the various components of an

automobile.

• Identify various components of a two wheeler vehicle.

• Demonstrate function of various two wheeler vehicle

components.

• Identify various components of a three wheeler vehicle.

• Demonstrate function of various three wheeler vehicle

components.

• Identify various components of a four wheeler vehicle.

• Demonstrate function of various four wheeler vehicle

components.

Assembly processes Theory Duration (hh:mm) 10:00 Practical Duration (hh:mm) 32:00 ASC/N3616 (ASC/Q3603)

• Explain various types of assembling methodology and

process such as bolting, tightening, riveting, fastening,

adhesive clamping, crimping etc.

• List tools and equipment required for bolting, tightening,

riveting and fastening processes.

• Describe bolting process.

• Demonstrate bolting process safely.

• Describe torque tightening process.

• Demonstrate torque tightening process safely.

• Describe riveting process.

• Demonstrate riveting process safely.

• Describe bolts, connectors fastening process.

• Demonstrate bolts, connectors fastening process safely.

• Describe adhesive clamping process.

• Demonstrate adhesive clamping process safely.

• Describe wire crimping process.

• Demonstrate wire crimping process safely.

• Describe soldering process.

• Demonstrate soldering process safely.

• Describe welding process.

• Demonstrate welding process safely.

Preparation for vehicle assembly Theory Duration (hh:mm) 08:00 Practical Duration (hh:mm) 34:00 ASC/N3616 (ASC/Q3603)

• Explain various assembling process parameters like cycle

time, pressure, torque etc.

• Explain impact of various assembling process parameters

like cycle time, pressure, torque etc. on vehicle.

• List material like greases, lubricant oil, adhesives required

during assembly process.

• Explain various parameters such as durability, surface

finish, part movement, aesthetics etc. need to consider

during selection of material.

• Identify the availability of material in storage.

• Demonstrate process of procuring the material like greases,

lubricant oil, adhesives from storage or manufacturer’s.

• Demonstrate setup of assembling apparatus.

• Explain industry standards while setting up the machines.

• Perform cleaning of assembling gun or bolting gun before

use.

• Explain impact of various assembly process like bolting,

torqueing, fitting, greasing, hammering, sealing, clamping

on the final component/ vehicle performance.

Perform mechanical assembly operation of the components Theory Duration (hh:mm) 08:00 Practical Duration (hh:mm) 34:00

• Explain information from drawings for mechanical assembly

operations requirements.

• Identify various mechanical operations need to perform on

the vehicle.

• Perform mechanical operations for the assembly of the

vehicle components.

• Perform installation of oil and lube systems by placing the

funnel, filters, hose pipes, glands, sockets, suction guns and

regulator.

ASC/N3616 (ASC/Q3603) • Perform sealing of vehicle components to prevent water

leakage.

• Perform various mechanical assembly operations like

riveting, drilling, welding, hammering etc. using hand,

power, hydraulic and pneumatic tools.

• Perform lubrication of vehicle components.

• Perform fuel filling operation in vehicle.

• Perform quality checks of assembled parts as per the

drawings and work instructions.

• Identify defects such as dents, grooves, cracks, rough

edges etc. on vehicle body.

• Perform dynamometer, head lamp focus, shower, wheel

alignment and roll & brake testing on vehicle.

• Mark all the observed defects using a chalk stick or any

other erasable substance.

Perform electrical assembly operation of the components Theory Duration (hh:mm) 08:00 Practical Duration (hh:mm) 34:00 ASC/N3616 (ASC/Q3603)

• Explain information from drawings or circuit diagrams for

electrical assembly operations requirements.

• Identify various electrical assembly operations need to

perform on the vehicle.

• Perform assembly of electrical and electronic components

in the vehicle.

• Perform routing of wire in vehicle according to circuit

diagram.

• Perform crimping of wire terminals and twisting of wire

bunch as specified in SOP.

• Identify the correct terminals/ connectors/ clips and attach

with the correct wires.

• Perform tapping operation to ensure hassle free electrical

connections.

• Place the electronic components on the blank PCB as per

the circuit diagram.

• Perform soldering for joining the electronic components and

PCB.

• Perform high frequency welding for completing the

assembly work.

• Explain testing techniques of electrical and electronic

components.

• Identify impact of various electrical conditions on the

performance of the the vehicle.

• Conduct visual inspection of the bundled electrical and

electronics wiring, circuits and harness.

• Inspect electrical and electronic terminals for correct

orientation.

• Inspect of connectors for correct Input /output.

• Conduct short circuit and open circuit test on electrical

connections and circuits.

Vehicle quality check Theory Duration (hh:mm) 06:00 Practical Duration (hh:mm) 36:00 ASC/N3616 (ASC/Q3603)

• Explain various testing procedures for components and

vehicle.

• Perform inspection of all major components of the vehicle.

• Identify and mark defects observed on the vehicle and its

components.

• Describe dynamometer testing process.

• Demonstrate testing of torque, horsepower, speed, roll

speed, acceleration and heat load of the vehicle by

dynamometer testing.

• Perform wheel balancing test and note down the readings.

• Inspect lighting circuit and headlamps focus for defects.

• Inspect vehicle dashboard, horn and indicator for defects.

• Describe shower test process.

• Demonstrate shower test for testing of nozzles, water

supply pipes, water circulation motor and the blower.

• Perform testing of components like brakes, shock absorber

for defects.

• Perform vehicle cleaning and dispatch process.

Practice of vehicle assembly process Theory Duration (hh:mm) 00:00 Practical Duration (hh:mm) 38:00 ASC/N3616 (ASC/Q3603

• List the tentative activities to be performed on the vehicle.

• Perform positioning and aligning of components for

assembly, manually or using hoists at their respective

positions.

• Perform installation of oil and lube systems by placing the

funnel, filters, hose pipes, glands, sockets, suction guns and

regulator.

• Perform insertion and tightening of bolts, screw, rivet on the

right place.

• Perform various mechanical assembly operations like

riveting, drilling, welding, hammering etc. using hand,

power, hydraulic and pneumatic tools.

• Perform lubrication of vehicle components.

• Perform assembly of electrical and electronic components

in the vehicle .

• Perform routing of wire in vehicle according to circuit

diagram.

• Perform crimping of wire terminals.

• Place the electronic components on the blank PCB as per

the circuit diagram.

• Perform soldering for joining the electronic components and

PCB.

• Perform quality checks of assembled components as per

the drawings and work instructions.

• Inspect electrical and electronic terminals for correct

orientation.

• Conduct short circuit and open circuit test on electrical

connections and circuits.

• Perform dynamometer, head lamp focus, shower, wheel

alignment and roll & brake tests on vehicle.

Shop floor management 1 Theory Duration (hh:mm) 10:00 Practical Duration (hh:mm) 32:00 ASC/N0017 (ASC/Q3603)

• Describe visual management and concept of workplace

organization through visual displays, visual controls, visual

data management etc.

• Conduct training on key process changes, similar parts

complexity.

• Conduct training on the process outcomes for quality and

delivery.

• Track OJT training issues and implement necessary actions

• Describe step by step process as per SOP at allocated work

stations.

Shop floor management 2 Theory Duration (hh:mm) 10:00 Practical Duration (hh:mm) 32:00 ASC/N0017 (ASC/Q3603)

• Verify production and material movement related data

entries in the system (manual/ ERP) for the line/ shift

• Verify that the material and work piece movement on the

shop floor conforms to the TAKT time prescribed in the SOP/

Work.

• Explain industry policies and procedures for workplace

housekeeping.

• Explain organization waste disposal methods to dispose-off

waste.

• Select and wear proper Personal Protective Equipment

(PPE) during working.

• Carryout co-ordination with various departments like

material management, stores, paint shop, assembly line,

safety, production planning, quality assurance etc.

Machining process requirements Theory Duration (hh:mm) 08:00 Practical Duration (hh:mm) 34:00 ASC/N0017 (ASC/Q3603)

• Identify requirement of raw materials used in the machining

process.

• Describe metallurgical and chemical properties of material.

• List tools and equipment required during machining work.

• Conduct maintenance of machining tools and equipment.

• List various measurement tools like vernier calipers,

micrometres, rulers, scales, weighing machines etc.

required during machining work.

• Carryout operation of machine in both, automatic and

manual mode.

Machining process implementation Theory Duration (hh:mm) 08:00 Practical Duration (hh:mm) 34:00 ASC/N0017 (ASC/Q3603)

• Identify various machining process parameters and their

impact on final output.

• Conduct monitoring on proper implementation of machining

process parameters on regular basis and ensure it is

meeting agreed standards.

• Observe that recording and reporting systems are following

properly by team members.

• Facilitate corrections if malfunctions within process control

points are identified.

Welding process requirements Theory Duration (hh:mm) 08:00 Practical Duration (hh:mm) 34:00 ASC/N0017 (ASC/Q3603)

• Identify requirement of raw materials used in the welding

process.

• List tools and equipment required during welding work.

• Conduct maintenance of welding tools and equipment.



required during welding work.


manual mode.

Welding process implementation

• Identify various welding process parameters and their


Theory Duration (hh:mm) 08:00 Practical Duration (hh:mm) 34:00 ASC/N0017 (ASC/Q3603)

• Conduct monitoring on proper implementation of welding







Assembly process requirements Theory Duration (hh:mm) 08:00 Practical Duration (hh:mm) 34:00 ASC/N0017 (ASC/Q3603)

• Identify requirement of raw materials used in the assembly

process.

• List tools and equipment required during assembly work.

• Conduct maintenance of assembling tools and equipment.



required during assembly work.


manual mode.

Assembly process implementation Theory Duration (hh:mm) 08:00 Practical Duration (hh:mm) 34:00 ASC/N0017 (ASC/Q3603)

• Identify various assembly process parameters and their


• Conduct monitoring on proper implementation of assembly







Painting process requirements Theory Duration (hh:mm) 08:00 Practical Duration (hh:mm) 34:00 ASC/N0017 (ASC/Q3603)

• Identify requirement of raw materials used in the painting

process.

• List tools and equipment required during painting work.

• Conduct maintenance of painting tools and equipment.

• List various measurement tools required during painting

work.

• Carryout operation of painting machine in both, automatic

and manual mode.

Painting process implementation Theory Duration (hh:mm) 08:00 Practical Duration (hh:mm) 34:00 ASC/N0017 (ASC/Q3603)

• Identify various painting process parameters and their


• Conduct monitoring on proper implementation of painting







Data entry Theory Duration (hh:mm) 08:00 Practical Duration (hh:mm) 34:00 ASC/N0017 (ASC/Q3603)

• Identify different types of defects in the final product which

may arise due to improper manufacturing.

• Record measurements of workpiece for the correct

specifications in terms of thickness, hardness, durability,

tightness, finesse etc.

• Identify various data entry tools and formats used in the

organization.

• Conduct random sampling on the incoming quality of

material and provide the relevant feedback on the same to

the store.

Data analysis Theory Duration (hh:mm) 08:00 Practical Duration (hh:mm) 34:00 ASC/N0017 (ASC/Q3603)

• Conduct random sampling of the process parameters and

WIP products and provide necessary feedback to the line

leaders.

• Conduct random sampling of the finished goods and provide

the necessary feedback.

• Conduct batch wise product quality check in order to ensure

that the quality of the product produced meet customer

requirements.

• Verify the final product output and decide on the key steps

and parameters to be followed.

Practice of data entry and analysis Theory Duration (hh:mm) 00:00 Practical Duration (hh:mm) 20:00

• Identify various data entry tools and formats used in the

organization.

• Practice random sampling on the incoming quality of

material and provide the relevant feedback on the same to

the store.

• Practice random sampling of the process parameters and

WIP products and provide necessary feedback to the line

leaders.

ASC/N0017 (ASC/Q3603)

• Practice random sampling of the finished goods and provide

the necessary feedback.

• Practice batch wise product quality check in order to ensure

that the quality of the product produced meet customer

requirements.

Process improvement Theory Duration (hh:mm) 20:00 Practical Duration (hh:mm) 22:00 ASC/N0013 (ASC/Q3602)

• Identify areas of improvement in the existing

processes/systems.

• Identify new trends and action points for machining work.

• Analyse internal & external rejection data of production.

• Identify process improvement techniques like Kaizens,

TQM, Poka Yoke at workplace.

• Explain process improvement techniques like Kaizens,

TQM, Poka Yoke to operators.

• Implement process improvement techniques like Kaizens,

TQM, Poka Yoke at workplace.

Practice process improvement techniques Theory Duration (hh:mm) 05:00 Practical Duration (hh:mm) 37:00 ASC/N0013 (ASC/Q3602)

• Identify areas of improvement in the existing

processes/systems.



• Practice implementation of process improvement

techniques like Kaizens, TQM, Poka Yoke at workplace.

Problem solving tools Theory Duration (hh:mm) 20:00 Practical Duration (hh:mm) 22:00 ASC/N0013 (ASC/Q3602)

• Identify corrective measures to improve production and

ensure their implementation at workplace.

• Implement 5S practices in production line.

• Identify various problems solving tools like 7QC, Why Why

Analysis, Brain storming etc.

• Explain various problems solving tools like 7QC, Why Why

Analysis, Brain storming etc. to operators.

• Implement problem solving tools on shopfloor for smooth

production.

Practice problem solving tools Theory Duration

• Identify corrective measures to improve production and

ensure their implementation at workplace.

• Implement 5S practices in production line.


• Practice implementation of problem solving tools like 7QC,

Why Why Analysis, Brain storming etc. on shopfloor for

smooth production.

Practice use of process improvement techniques and problem solving tools Theory Duration (hh:mm) 00:00 Practical Duration (hh:mm) 32:00 ASC/N0013 (ASC/Q3602)



• Practice implementation of process improvement

techniques like Kaizens, TQM, Poka Yoke at workplace.

• Practice implementation of problem solving tools like 7QC,

Why Why Analysis, Brain storming etc. on shopfloor for

smooth production.

Process verification at workstation Theory Duration (hh:mm) 15:00 Practical Duration (hh:mm) 27:00 ASC/N0017 (ASC/Q3603)

• Explain the concept of Process Verification vs defined

Standards, Procedures and Control Plans

• Demonstrate 'how to' perform the verification tasks specific

to their operation

• Describe 'good' vs. 'bad' per their specific operation

• Describe how to contain and react to any abnormality

• Describe how to solve an abnormality for resolution or

escalation if it is outside of their control

• Complete the required task as listed in the verification check

sheet

• Carry out Process Verification activity on line

Support other departments Theory Duration (hh:mm) 10:00 Practical Duration (hh:mm) 32:00 ASC/N0017 (ASC/Q3603)

• Describe functions of various operational departments of

organization such as material management, stores, paint

shop, assembly line, quality, safety, production planning etc.

• Carryout collection of information from various departments

regarding production plan and any issues in target fulfilment.

• Resolve queries of team with the support of In Charge/ Shop

head for effective line/shift work.

• Perform end of line inspection under In Charge/ Shop head

supervision.

Practice process verification at workstation Theory Duration (hh:mm) 00:00 Practical Duration (hh:mm) 16:00 ASC/N0017 (ASC/Q3603)

• Practice how to perform the verification tasks specific to

their operation.

• Practice how to solve an abnormality for resolution or

escalation if it is outside of their control.

• Practice Process Verification activity on line.

Quality inspection methods Theory Duration (hh:mm) 18:00 Practical Duration (hh:mm) 24:00 ASC/N0017 (ASC/Q3603)

• Identify various methods of quality check of material.

• Explain organization procedures and standards for quality

check.

• List tools and equipment required for quality check.

• Observe that inspection of tools and equipment is done

before quality check.

• Conduct quality inspection of the process parameters, lab

parameters and WIP products and provide feedback to line

leaders.

• Conduct quality inspection of the finished goods and provide

feedback.

• Conduct inspection and analysis of the defects observed in

the process and products.

Quality inspection Theory Duration (hh:mm) 06:00 Practical Duration (hh:mm) 24:00 ASC/N0017 (ASC/Q3603)

• Conduct quality inspection of the process parameters, lab

parameters and WIP products and provide feedback to line

leaders.

• Conduct quality inspection of the finished goods and provide

feedback.

• Conduct quality inspection of the first sample/batch to

ensure that the quality of the product produced meet

customer requirements.

• Conduct inspection and analysis of the defects observed in

the process and products.

Maintenance of machine and tools Theory Duration (hh:mm) 10:00

• Explain maintenance and its types.

• Explain maintenance schedule.

• List the maintenance schedules as per organization

policies.

• List tools and equipment required during maintenance

program.

Practical Duration (hh:mm) 32:00 ASC/N0008 (ASC/Q3302)

• Demonstrate various maintenance activities performed for

machine maintenance.

• Create checklist of maintenance activities for machines.

• Identify and select necessary inspection tools as per the job

requirements.

• Inspect condition of lubrication oil in machine.

• Perform inspection of tools and machines for any

malfunction or defect.

Maintenance activities

Theory Duration (hh:mm) 15:00

Practical Duration (hh:mm) 27:00

ASC/N0008 (ASC/Q3302)

• Explain various issues and defects generally occur in

machine.

• List tools and equipment required for troubleshooting and

repairing of machines.

• Explain procedure of troubleshooting of machine for issues

and defects identification.

• Support the operator in troubleshooting of machine for

issues and defects identification.

• Explain procedure of repairing of machine for resolving

issues and defects.

• Support the operator in repairing of machine for resolving

issues and defects.

• Plan for various types of maintenance such as periodic,

preventive, breakdown maintenance, etc.

• List the maintenance schedules as per organization

policies.

• Select appropriate lubricant for the machine.

• Carry out minor repairs, adjustments and alignments on

loose bolts, belts, drive slacks, guards and covers.

• Perform lubrication of machine by using appropriate

lubricant.

• Place tags on machines for next maintenance cycles.

• Use organization procedure for reporting and

documentation of maintenance work.

Practice of maintenance activities Theory Duration (hh:mm) 00:00

• Practice inspection of tools and machines for any

malfunction or defect.

• Practice troubleshooting of machine for issues and defects

identification.

• Practice repairing of machine for resolving issues and

defects.

Practical Duration (hh:mm) 16:00 ASC/N0008 (ASC/Q3302)

• Practice lubrication of machine by using appropriate

lubricant.

Hazards and safety Theory Duration (hh:mm) 06:00 Practical Duration (hh:mm) 36:00 Corresponding NOS Code

ASC/N0006

• Discuss how to maintain safe and secure workplace.

• Use organization policies and procedures to

maintain a safe, secure working environment.

• Identify hazards at workplace such as fire, trips and fall,

electrical hazards, physical hazards etc.

• Identify hazards emerging from a natural calamity and take

appropriate safety precautions for the same.

• Execute best practices for removing potential hazards at the

workplace.

• List personal protective equipment like safety gloves,

glasses, shoes and helmet used at the workplace.

• Describe appropriate strategies to deal with emergencies

and accidents such as fires and natural calamities at the

workplace.

• Demonstrate the use of fire-fighting equipment available at

the workplace.

• Explain safety precautions need to follow during handling of

tools and equipment in the workshop.

• Demonstrate first-aid practices.

Workshop safety and hygiene Theory Duration (hh:mm) 04:00 Practical Duration (hh:mm) 34:00 Corresponding NOS Code

ASC/N0006

• Record and report potential safety issues while working in

workshop.

• Practice safety procedures at workplace.

• Maintain cleanliness and hygiene of shopfloor.

• Escalate issues related to cleanliness, hygiene, and

hazardous material to concerned department.

• Carryout work as per laid down instructions and guidelines

for preventing danger or damage of the machines and report

any abnormal observation.

Maintain 5S at the work premises Theory Duration (hh:mm)

• Practice 5S at the workshop.

• Inspect the work area, tools, equipment and materials for

their cleanliness.

08:00 Practical Duration (hh:mm) 34:00 Corresponding NOS Code ASC/N0022

• Demonstrate storage of cleaning material and equipment in

the correct location and in good condition.

• Explain good grooming practices as per company

standards.

• Demonstrate procedure of materials, tools and equipment’s

and spare parts sorting.

• Demonstrate proper labelling procedures.

• Demonstrate proper storage procedures.

• Demonstrate segregation of waste into hazardous and non-

hazardous waste and dispose the waste as per industry

SOP.

Waste management Theory Duration (hh:mm) 06:00 Practical Duration (hh:mm) 36:00 Corresponding NOS Code ASC/N0022

• Explain safe working practices for securing components

from other hazardous material.

• Demonstrate practices for securing components from any

damage due to hazardous materials.

• Define various types of wastes generated on the shop floor

such as cotton waste, oils, metal chips, papers, etc.

• Describe need of waste disposal properly in specified

manner.

• Practice safe waste disposal methods according to

organizational policies.

List of Assessable outcomes/assessment criteria

Assembly Line Machine Setter; (ASC/Q3603)

Assessable Outcome

Assessment Criteria Total Mark

Out of

Marks allocation

Theory Practica

l

1. ASC/N3616 Manage various machine setting operations

PC1. ensure that the assembly team have fully understood the job/task mentioned in the work order

100

3 1 2

PC2. ensure that the team members understand and follow all the does and don’ts of the manufacturing process as defined in sops/ work instructions or defined by supervisors/ master technicians

3 1 2

PC3. address that all queries shared by the team are resolved by the supervisor and queries beyond the scope of the supervisor are highlighted to the concerned team

3 1 2

PC4. ensure that the fitters have selected the right drawings and sketches to enable them to join the required parts as mentioned in the work instructions/ control plan/sops/work order

3 1 2

PC5. ensure material availability in the stores for the assembly team as per the production plan& bom shared for the shift/day and escalated issues to the concerned in case material unavailability

3 1 2

PC6. ensure for the specified assembly equipment, fixtures and verification setup and electrical and electronic systems selected by the fitter for conducting the process.assembly fitter arranges the parts to be assembled in the given position , feeding systems

3 1 2

PC7. ensure that the fitter team is using the right types of screws etc. for fitting the required components and also validate that the assembly of components is as per the process

5 2 3

laid out in the process manual/work instructions by verification of the “first off piece”.

PC8. ensure adherence to the takt time prescribed by the process excellence team for every assembly station and ensure that delays at a particular assembly station are identified and rectified as soon as possible

4 1 3

PC9. ensure that every manufactured vehicle/aggregate component is checked and tested as per the sop/wi and a full inspection of the auto component/automobile is carried out by the operator to detect any quality related defects related to body surface etc.

4 1 3

PC10. ensure that all the errors observed get noted in the log books as per the format shared with the operators and the errors get tagged/ marked immediately

4 1 3

PC11. in case of electrical circuits, ensure visual inspection of the bundled electrical and electronics wiring, circuits, harness, connectors and terminal orientation

3 1 2

PC12. ensure that all the tests mentioned for electrical and mechanical assembly are conducted as per the checklist and necessary steps are taken to remove the defects identified and proper inspection is carried out of key electrical and electronic components

4 1 3

PC13. ensure that all fixtures, tools, equipment and spare parts are stored in an organized way and calibrated as indicated in the equipment and manual and the designated area as defined in the 5s manual of the organization and are regularly cleaned to prevent accumulation of dust, moisture and waste material

4 1 3

PC14. coordinate with various functions like material management, stores, paint shop, assembly line, safety, production planning to ensure communication of required information and resolution of queries

4 1 3

PC15. ensure that the operator and helper are using the required personal protective equipment like goggles etc. at the time of conducting the fitting, torqueing and tightening process

3 1 2

PC16. set machine and processing equipment to specification 4 1 3

PC17. ensure adjusting of machine settings to maintain process to specification

3 1 2

PC18. ensure proper functioning of conveyors, nut runners, torque meters, wrenches for effective line running

4 1 3

PC19. carry out process monitoring checks using statistical process control techniques

3 1 2

PC20. analyse and ensure implementation of process improvement solutions

3 1 2

PC21. ensure coordination in development teams to introduce new materials, products or process technology

4 1 3

Total 100 22 78

2. ASC/N0016 Understanding process requirements, ensuring process implementation & suggesting

PC1. display detailed understanding of all the requisite processes to be adopted for completing the work order through reading the process manuals/ work instructions/ standard operating procedures for the production job

100

5 2 3

PC2. ensure first level drafting of process manuals, work instructions, control plans, process flow charts to enable the team to easily understand and implement the process

5 2 3

process improvement initiatives

PC3. ensure proper display of work instructions, control plans and flow charts at the correct places on the shop floor to enable timely and proper view of the documents

4 1 3

PC4. share knowledge of processes , inputs and outputs with the operators and in order to enhance their skill levels

5 2 3

PC5. maintain work flow by monitoring steps of the processes, setting variables, observing control points and equipment

6 2 4

PC6. monitor various process parameters on a regular basis and ensure compliance to agreed standards (e.g. ambient air quality, stack monitoring, water quality monitoring etc.)

6 2 4

PC7. ensuring recording and reporting procedures and systems are in place

4 1 3

PC8. facilitating corrections to malfunctions within process control points

5 1 4

PC9. ensure that all the tools and measuring instruments used on the shop floor are inspected, tested and calibrated internally/ externally as per the schedule

5 1 4

PC10. support the shop head/ process head in arranging for the requisite usage certificates for the tools and equipment as per the internal guidelines of the organization

4 1 3

PC11. ensure 5s implementation in the production line by analysing possible areas of systems and process improvements and ensure implementation of the recommended measures to address the gaps

4 1 3

PC12. ensure successful implementation of the completed poka yoke and kaizen on the running line

4 1 3

PC13. support the shop head/ process manager in conducting first level

4 1 3

audit of the manufacturing process on the shop floor

PC14. ensure optimum resource utilization and wastage reduction through process improvements, kaizens, TQM, Poka Yoke etc. in the shift

4 1 3

PC15. provide inputs for analysis of breakdown trends and current maintenance process to identify areas for improvement to achieve cost savings and reduce breakdown timing

5 2 3

PC16. identify areas of improvement in the existing processes/systems and take measures to adhere to the identified kaizen/ process improvement initiatives

4 1 3

PC17. ensure inputs from the line operators are considered while designing for various poka yoke , kaizen initiatives

3 1 2

PC18. encourage team members/ supervisor/ operators to suggest quality improvement measures through suggestion schemes, evaluate feasibility of the ideas and discuss their implementation with seniors

3 1 2

PC19. support in analysing internal & external rejection data, planning and ensuring implementation of the corrective measures

4 1 3

PC20. ensure team has understanding of basic analytical tools like why why analysis, 7 QC tools, TQM principles to analyse various problems and design process improvement activities

5 2 3

PC21. support the process engineering/ industrial engineering team in modifications of the process flow, process/ plant layout to improve the process TAT, operational ergonomics, work quality etc.

3 1 2

PC22. take overall responsibility to ensure adherence to safety

4 1 3

standards by all employees and establish zero accident practice in the section

PC23. implement various business excellence techniques like kaizen, 5s initiatives, etc. to enhance productivity for the plant/ shift

4 1 3

Total 100 30 70

3. ASC/N0017 Manage the production related operations of the shift/line on a day to day basis

PC1. undertake effective shift planning based on manpower allocation and shift handling of place right manpower on the right workstation in coordination with production in-charge to achieve production targets

100

3 1 2

PC2. support the shop head/ process head in finalizing the shift rosters for the week and month based on the production plan available

3 1 2

PC3. send inventory requirements to stores and purchase department and follow up with stores and purchase to ensure timely receipt of material (spares, consumables)

3 1 2

PC4. ensure that the incoming raw material quality is inspected and meets the production requirement

4 1 3

PC5. ensure that the material and work piece movement on the shop floor conforms to the TAT time prescribed in the SOP/ work plans so that production targets are met for the line/ shift

4 1 3

PC6. ensure that the production plan shared by the ppc team is fulfilled during the shift/ across lines

4 1 3

PC7. coordinate with various functions like material management, stores, paint shop, assembly line, quality, safety, production planning etc. to ensure communication of required information and resolution of queries

4 1 3

PC8. responsible for end of line inspection under supervision

4 1 3

PC9. ensure that the operators and helpers have the required tools and

4 1 3

equipment at the start of the process

PC10. identify & implement action steps to reduce losses and wastages during shift operation and ensure minimum rejection of components

5 2 3

PC11. observe and note the consumption of energy, fuel, steam on the production line and utilize these inputs for optimization of various factors of production

5 2 3

PC12. support the maintenance team in finalizing the preventive maintenance schedule for the shop

4 1 3

PC13. ensure that the operator and helper are using the required personal protective equipment like goggles, masks, gloves and other ppe’s at the time of conducting the painting operation

4 1 3

PC14. conduct random incoming quality inspection of material and provide the relevant feedback on the same to the store

5 2 3

PC15. conduct quality inspection of the process parameters, lab parameters and wip products and provide necessary feedback to the line leaders

5 2 3

PC16. conduct quality inspection of the first sample/batch to ensure that the quality of the product produced meet customer requirements

4 1 3

PC17. conduct inspection and analysis of the defects observed in the process and products

4 1 3

PC18. prepare daily and monthly production mis reports to match actual performance vis-à-vis the targets and report the same to production in-chart

4 1 3

PC19. verify the production and material movement related data entries in the system ( manual/ erp) for the shift and ensure correctness of the data

4 1 3

PC20. ensure compilation of data of breakdown maintenance and reporting the same to the maintenance team

4 1 3

PC21. collaborate with the maintenance team in conducting detailed breakdown analysis to understand problems, look out for process/ machine modifications and resolve the issues

3 1 2

PC22. conduct random sampling of the process parameters, finished goods and WIP products and provide necessary feedback to the line leaders

4 1 3

PC23. collaborate with the quality management and inspection team in conducting detailed analysis to resolve issues

3 1 2

PC24. collaborate with various supervisors to capture process data points as mentioned in the internal operating guidelines for data analytics

3 1 2

PC25. support the shop head/ process head in analysing the various data points related to production, maintenance, manpower deployment, material management, costs etc.

3 1 2

PC26. support the shop head/ process head in creating various analytical presentations required for process/ shop/ plant review

3 1 2

Total 100 30 70

4. ASC/N0018 Managing the team on the line/shift on a day to day basis

PC1. ensure operators and helpers on the production line/ shift are aware of the job expectations on a daily basis

100

5 2 3

PC2. ensure that the operators are aware of the production targets and the timelines required to process a work order as finalized in the production plan

5 2 3

PC3. involve operators and helpers for the daily floor meeting/ morning meetings/ staff meetings to

3 1 2

communicate information intended for them

PC4. ensure communication to line operators/ helpers on any changes in policies/ processes by the organization through required verbal/ written mechanisms

4 1 3

PC5. ensure participation of employees in various engagement initiatives organized at the plant and other place by the organization

3 1 2

PC6. involve operators and helpers in Quality Circles, TQM & kaizen meets, brainstorming sessions, safety drills etc. to increase their involvement in manufacturing operations

5 2 3

PC7. ensure availability of tea, snacks, drinking water and basic hygiene facilities at the shop floor for the operative workforce.

4 1 3

PC8. escalate issues to concerned staff in case of any issue related to operative deployment and engagement

4 1 3

PC9. ensure employees at the shop floor are motivated and their concerns are resolved

5 2 3

PC10. finalize along with the process manager, the shift planning and manpower deployment for the shift/ line as per the proposed production plan

4 1 3

PC11. support the process manager in creating week wise shift rosters for the shift/ line manpower and ensure rotation of manpower as per the organizational norms and guidelines

4 1 3

PC12. maintain the information on leaves/ IN Out time keeping and shift/ line overtime for the operatives and helpers and share the information with the concerned as and when required

4 1 3

PC13. identify skilled manpower for the process and ensure periodic up -

4 1 3

dation of Skill Matrix/ skill chart for the shift/ line/ process area

PC14. ensure identification and deployment of right skilled people at the right places on the line/ process area

4 1 3

PC15. ensure that all the operative manpower is aware of the production targets, production plan and daily productivity targets

4 1 3

PC16. track the daily performance of the operators and helpers during the shift and note the achievement levels in a manual register/ online it enabled system

4 1 3

PC17. provide feedback to the operators and helper in case of any process deviation observed

4 1 3

PC18. provide feedback to managers pertaining to performance appraisals of operators and helpers

4 1 3

PC19. ensure that the operatives are trained and are aware of the processes which need to be followed on the shop floor during the production process

3 1 2

PC20. support the manager and the training team in training of entry level operators and helpers in the plant

3 1 2

PC21. share knowledge of processes , inputs and outputs with the operators to enhance their skill levels

3 1 2

PC22. other than technical trainings, support the team by delivering trainings related to quality and safety for the operators and helpers

3 1 2

PC23. drive a culture of creativity and innovation in the team by given the team members opportunity to think out of box and express their thoughts

4 1 3

PC24. in case the operating staff has any queries, ensure that the queries are resolved either by self or escalated to the concerned person

3 1 2

PC25. listen to issues related to workmen problems/ work men grievances/ complaints/ personal problems etc. for the operators and helpers

4 1 3

PC26. resolve issues which are under the purview of the supervisor and escalate the ones which need higher intervention to the concerned team

3 1 2

Total 100 30 70

5. ASC/N0006B Maintain a safe and healthy working environment

PC1. Identify activities which can cause potential injury through sharp objects, burns, fall, electricity, gas leakages, radiation, poisonous fumes, chemicals, loud noise

100

3 1 2

PC2. Identify areas in the plant which are potentially hazardous/ unhygienic in nature.

4 1 3

PC3. Conduct regular checks on machine health to identify potential hazards due to wear and tear of machine.

4 1 3

PC4. Ensure that all equipment are tested of conformance as per the cycle/ timelines identified in the organization.

4 1 3

PC5. Inform the shop head and the safety team about the potential risks identified in the processes, workplace area/ layout, material used, malfunctioning of safety related equipment etc.

4 1 3

PC6. Inform the maintenance team about machine breakdowns, damages which can potentially harm man/ machine during operations and analyse their defects to prevent any future damage to men/ machine.

5 1 4

PC7. Ensure that all risk involving and hazardous areas near the work place are marked/ tagged in order to caution the users of the work area/ machinery.

6 2 4

PC8. Create awareness amongst other by sharing information on the identified risks. Ensure that periodic awareness sessions are conducted

6 2 4

for the helpers and operatives to make them aware of the risks identified.

PC9. Support the Safety team in risk identification and creation of a risk mitigation plan.

6 2 4

PC10. Train team members on safety and health related issues.

6 2 4

PC11. Ensure that all team members operate the machine using the recommended Personal Protective Equipment (PPE) and also ensure self-usage of the required PPEs.

6 2 4

PC12. Ensure that all operatives follow the instructions given on the equipment manual describing the operating process of the equipment to prevent any hazard.

6 2 4

PC13. Ensure that all team members follow the Safety, Health and Environment related practices developed by the organization.

6 2 4

PC14. Ensure that a clean and safe working environment near the work place is maintained and that there is no spillage of chemicals, production waste, oil, solvents etc. in the working area.

4 1 3

PC15. Ensure that the first aid safety kit at the work place/ shop floor contains the requisite items to respond to minor injuries. Also may sure that the operatives and helpers are made aware of these items and their usage.

4 1 3

PC16. Ensure that a documented record of all minor and major injuries is kept and updated on the shop floor.

4 1 3

PC17. Ensure that the waste disposal is done in the designated area and manner as per organization SOP.

4 1 3

PC18. Attend all safety and fire drills to be self-aware of safety hazards and preventive techniques and ensure that the team participate in all the required safety and fire drills.

3 1 2

PC19. Participate in all safety related initiatives like Safety Committee participations, Safety Day Celebrations etc.

3 1 2

PC20. Maintain high standards of personal hygiene at the work place.

3 1 2

PC21. Ensure that any activity performed by the team members which may negatively impact their health and productivity is immediately brought to notice by the supervisor.

3 1 2

PC22. Periodically counsel and train employees on good health and safe working practices.

3 1 2

PC23. Inform the medical officer/ HR in case of self or an employee’s illness of contagious nature so that preventive actions can be planned for others.

3 1 2

Total 100 30 70

6. ASC/N0022 Ensure implementation of 5S activities at the shop floor & the office area

PC1. Ensure all recyclable materials are put in designated containers.

100

3 1 2

PC2. Ensure no Tools, fixtures & jigs are lying on workstations unless in use and no un-necessary items is lying on workbenches or work surfaces unless in use.

3 1 2

PC3. Ensure that the operators and other team members are segregating the waste in hazardous/ Non Hazardous waste as per the sorting work instructions

3 1 2

PC4. Ensure that all the operators are following the technique of waste disposal and waste storage in the designated bins

3 1 2

PC5. Segregate the items which are labelled at red tag items for the process area and keep them in the correct places.

3 1 2

PC6. Ensure that all the tools/ equipment/ fasteners/ spare parts are arranged as per specifications/ utility into proper trays, cabinets, lockers as mentioned in the 5S guidelines/ work instructions.

3 1 2

PC7. Check for return of any type of extra material and tools to the designated sections and make sure that no additional material/ tool is lying near the work area.

5 2 3

PC8. Oversee removal of unnecessary equipment, storage, furniture, unneeded inventory, supplies, parts and material.

4 1 3

PC9. Ensure that areas of material storage areas are not overflowing.

4 1 3

PC10. Ensure proper stacking and storage of the various types of boxes and containers as per the size/ utility to avoid any fall of items/ breakage and also enable easy sorting when required.

4 1 3

PC11. Ensure that the team follows the given instructions and checks for labelling of fluids, oils, lubricants, solvents, chemicals etc. and proper storage of the same to avoid spillage, leakage, fire etc.

3 1 2

PC12. Make sure that all material and tools are stored in the designated places and in the manner indicated in the 5S instructions.

4 1 3

PC13. Ensure that organizing the workplace takes place with due considerations to the principles of wasted motions, ergonomics, work & method study.

4 1 3

PC14. Ensure that the area has floors swept, machinery clean and is generally neat and tidy. In case of cleaning, ensure that correct displays are maintained on the floor which indicate potential safety hazards.

4 1 3

PC15. Ensure workbenches and work surfaces are clean and in good condition.

3 1 2

PC16. Ensure adherence to the cleaning schedule for the lighting system to ensure proper illumination.

4 1 3

PC17. Ensure self-cleanliness - clean uniform, clean shoes, clean gloves, clean helmets, personal hygiene.

3 1 2

PC18. Ensure that daily cleaning standards and schedules to create a clean working environment are followed across the plant.

4 1 3

PC19. Oversee that various cleaning and organizing tasks have been developed and assigned for the work area.

3 1 2

PC20. Ensure logical and user friendly documentation and file management for all activities across the plant and create guidelines around standardization of processes.

3 1 2

PC21. Ensure timely creation and sharing of the 5S checklists.

4 1 3

PC22. Ensure that the 5S manual are available as per the timelines.

3 1 2

PC23. Ensure team cooperation during the audit of 5S activities.

4 1 3

PC24. Ensure that workmen are periodically trained to address challenges related to 5S

3 1 2

PC25. Participate actively in employee work groups on 5S and encourage team members for active participation.

3 1 2

PC26. Oversee that the staff/ operators are trained and fully understand 5S procedures

3 1 2

PC27. Ensure that all the guidelines for What to do and What not to do to build sustainability in 5S are mentioned in the 5S check lists/ work instructions and are easily searchable.

4 1 3

PC28. Ensure continuous training of the team members on 5S in order to increase their awareness and support implementation.

3 1 2

PC29. Ensure that all visual controls, notice boards, symbols etc. at the manufacturing place are created,

3 1 2

working and are put up as per the requirement.

Total 100 30 70

Grand Total 600 600 172 428

Percentage Weightage (%) 30 70

Assembly Line Supervisor; (ASC/Q3602)

Assessable Outcome


Out of

Marks allocation

Theory Practica

l

1. ASC/N3614 Manage various assembly operations like fitting, tightening, torqueing for a shift/line

PC1. Ensure that the assembly team have fully understood the job/ task mentioned in the work order.

100

3 1 2

PC2. Ensure that the team members understand and follow all the does and don’ts of the manufacturing process as defined in SOPs/ Work Instructions or defined by supervisors/ master technicians.

3 1 2

PC3. Address that all queries shared by the team are resolved by the supervisor and queries beyond the scope of the supervisor are highlighted to the concerned team.

3 1 2

PC4. Ensure that the fitters have selected the specified drawings and sketches to enable them to join the required parts as mentioned in the Work Instructions/ Control Plan/ SOPs/ Work Order.

3 1 2

PC5. Check for material availability in the stores for the assembly team as per the production plan shared for the shift/ day and escalated issues to the concerned in case material unavailability.

3 1 2

PC6. Check for the correct assembly equipment’s and apparatus selected by the fitter for conducting the process.

3 1 2

PC7. Ensure that all measuring instruments used by the fitters like measuring scales, vernier caliper, micrometer, gauges, nut-runner etc. are calibrated.

3 1 2

PC8. Ensure assembly fixtures etc are validated as per frequency. 3 1 2

PC9. Ensure that the fitter regularly cleans and maintain the apparatus as per the checklist provided.

3 1 2

PC10. Ensure that the assembly fitter arranges the parts to be assembled in the given position Assemble the required parts using pneumatic, hydraulic/ PLC controlled assembly tools.

3 1 2

PC11. Ensure operator does the tightening of nuts and bolts using bolting guns/ riveting guns as per the required specifications for fitment of each part.

3 1 2

PC12. Ensure that the fitter team is using the specified types of screws, nuts, clamps, rivets for fitting the required components and also validate that the assembly of components is as per the process laid out in the process manual/ Work Instructions.

3 1 2

PC13. Ensure correct assembly of electrical and electronic systems.

3 0 3

PC14. Ensure conducting of Ultrasonic or High Frequency welding as per the SOP/WI for the required parts.

3 1 2

PC15. Ensure that the TAT time prescribed by the Process excellence team for every assembly station is rigorously followed by the fitter team.

3 1 2

PC16. In case of any delays at a particular assembly station, ensure that the problem is identified an rectified as soon as possible.

3 1 2

PC17. Ensure that every manufactured vehicle/ aggregate component is checked and tested as per the SOP/WI.

3 1 2

PC18. Ensure poke yoke, qualifying mechanism /gauge for the stations are working, verified at the start stage.

3 1 2

PC19. Ensure full inspection of the physical body of the Auto Component/ Automobile by the operator to detect any quality related defects related to body surface, paint, dents, grooves, cracks, rough edges etc.

3 1 2

PC20. Ensure that the errors get tagged/ marked immediately so that they can be rectified at the earliest and the vehicle can be prepared for dispatch.

3 1 2

PC21. Ensure that all the errors observed get noted in the log books as per the format shared with the operators.

3 1 2

PC22. Ensure part clearances are done as specified in the Work Instructions/ Standard Operating Processes.

3 1 2

PC23. Ensure inspection by operator of key electrical and electronic components.

3 0 3

PC24. In case of electrical circuits, conduct visual inspection of the bundled electrical and electronics wiring, circuits, harness, connectors and terminal orientation.

3 1 2

PC25. Ensure that the fitter conducts test for any short circuit/ open circuit in the circuit wiring.

3 1 2

PC26. Ensure that all the tests mentioned for electrical and mechanical assembly are conducted as per the checklist by the fitter and necessary steps are taken to remove the defects identified.

3 1 2

PC27. Ensure that the test observations are noted by the fitter in the format shared by the QA/ QC team.

3 1 2

PC28. Verify the production and material movement related data entries in the system (manual/ ERP) for the line/ shift and ensure correctness of the data.

3 1 2

PC29. Ensure that the material and work piece movement on the shop floor

3 1 2

conforms to the TAT time prescribed in the SOP/ Work Plans so that production targets are met for the line/ shift.

PC30. Ensure that all fixtures, tools, equipment and spare parts are stored in an organized way as indicated in the equipment

3 0 3

PC31. manual and the designated area as defined in the 5S manual of the organization and are regularly cleaned to prevent accumulation of dust, moisture and waste material

3 1 2

PC32. Coordinate with various functions like material management, stores, paint shop, assembly line, safety, production planning etc. to ensure communication of required information and resolution of queries

4 1 3

PC33. Ensure that the operator and helper are using the required Personal Protective Equipment like Goggles, masks, gloves at the time of conducting the fitting, torqueing and tightening process

3 1 2

Total 100 30 70

2. ASC/N0013 Understand process requirements, ensure process implementation

PC1. Display detailed understanding of all the requisite processes to be adopted for completing the work order through reading the process manuals/ Work Instructions/ Standard Operating Procedures for the production job.

100

4 1 3

PC2. Share knowledge of processes, inputs and outputs with the operators to enhance their skill levels.

4 1 3

PC3. Ensure the various SOW/WI created by the master technician are displayed and understood at each and every work station.

4 1 3

PC4. Maintain work flow by monitoring steps of the processes, setting variables, observing control points and equipment.

4 1 3

PC5. Support in defining detailed processes for each step and line.

4 1 3

PC6. Monitor various process parameters on a regular basis and ensure compliance to agreed standards (e.g. ambient air quality, stack monitoring, water quality monitoring etc.).

6 2 4

PC7. Ensuring recording and reporting procedures and systems are in place.

6 2 4

PC8. Facilitating corrections to malfunctions within process control points.

6 2 4

PC9. Ensure 5S implementation in the production line by analyzing possible areas of systems and process improvements and ensure implementation of the recommended measures to address the gaps.

6 2 4

PC10. Ensure successful implementation of the completed Poka Yoke and kaizen on the running line

6 2 4

PC11. Ensure compilation of data of breakdown maintenance and reporting the same to the maintenance team.

6 2 4

PC12. Conduct random sampling on the incoming quality of material and provide the relevant feedback on the same to the store.

6 2 4

PC13. Conduct random sampling of the process parameters and WIP products and provide necessary feedback to the line leaders.

4 1 3

PC14. Conduct random sampling of the finished goods and provide the necessary feedback.

4 1 3

PC15. Conduct batch wise product quality check in order to ensure that the quality of the product produced meet customer requirements.

4 1 3

PC16. Support in ensuring optimum resource utilization and wastage reduction through process

4 1 3

improvements, Kaizens, TQM, Poka Yoke etc.

PC17. Support and provide inputs on analysis of breakdown trends and current maintenance process to identify areas for improvement to achieve cost savings and reduce breakdown timing.

5 2 3

PC18. Identify areas of improvement in the existing processes/systems and take counter measures to adhere to the identified Kaizens.

5 2 3

PC19. Support the master technician in sharing inputs from the line for various Poka Yoke , kaizen activities.

4 1 3

PC20. Encourage team members/ operators to suggest quality improvement measures through suggestion schemes, evaluate feasibility of the ideas and discuss their implementation with seniors.

4 1 3

PC21. Support in analyzing internal & external rejection data, planning and ensuring.

4 1 3

Total 100 30 70

3. ASC/N0014 Manage production related operations of the shift/ line on a day to day basis

PC1. Undertake effective shift planning based on manpower allocation and shift handling of place right manpower on the right workstation in coordination with Production In-charge to achieve production targets.

100

3 1 2

PC2. Support Shift In Charge/ Process head/ Shop head is finalizing the shift rosters for the week and month based on the production plan available.

4 1 3

PC3. Send inventory requirements to Stores and Purchase department and follow up with stores and purchase to ensure timely receipt of material (Spares, Consumables).

4 1 3

PC4. Ensure that the material and work piece movement on the shop floor conforms to the TAT time

4 1 3

prescribed in the SOP/ Work Plans so that production targets are met for the line/ shift.

PC5. Support the In Charge/ Shop head in fulfilment of the production plan for the shop in a given line/ shift.

4 1 3

PC6. Coordinate with various functions like material management, stores, paint shop, assembly line, quality, safety, production planning etc. to ensure communication of required information and resolution of queries.

5 1 4

PC7. Responsible for End of Line Inspection under supervision.

5 1 4

PC8. Ensure that the operators and helpers have the required tools and equipment at the start of the process.

5 1 4

PC9. Facilitate the production runs along with Engineering and Quality Function.

6 2 4

PC10. Ensure optimal resource utilization (man, machine and material) and streamlining of activities within the shift.

6 2 4

PC11. Identify & implement action steps to reduce losses and wastages during shift operation and ensure minimum rejection of components.

6 2 4

PC12. Prepare daily and monthly production MIS reports to match actual performance vis-à-vis the targets and report the same to Production In-chart.

6 2 4

PC13. Verify the production and material movement related data entries in the system (manual/ ERP) for the line/ shift and ensure correctness of the data.

3 1 2

PC14. Support the In charge/ Engineer/ Shop Head in analysing the various data sheets related to production, maintenance, manpower deployment etc.

3 1 2

PC15. Support the maintenance team in finalizing the preventive

3 1 2

maintenance schedule for the shop/ line.

PC16. Support the maintenance function to ensure execution of the maintenance schedules.

3 1 2

PC17. Ensure shift handover to the next shift supervisor.

3 1 2

PC18. Observe and note the consumption of energy, fuel, steam on the production line and support the engineer in optimization of utilization of factors of production.

3 1 2

PC19. Ensure that the operator and helper are using the required Personal Protective Equipment like Goggles, masks, gloves and other PPEs at the time of conducting the painting operation.

3 1 2

PC20. Conduct incoming quality inspection of material and provide the relevant feedback on the same to the store.

3 1 2

PC21. Conduct quality inspection of the process parameters, lab parameters and WIP products and provide necessary feedback to the line leaders.

3 1 2

PC22. Conduct quality inspection of the finished goods and provide the necessary feedback.

3 1 2

PC23. Conduct quality inspection of the first sample/batch to ensure that the quality of the product produced meet customer requirements.

3 1 2

PC24. Conduct inspection and analysis of the defects observed in the process and products.

3 1 2

PC25. Take overall responsibility to ensure adherence to Safety standards by all employees and establish zero accident practice in the section.

3 1 2

PC26. Implement various business excellence techniques like Kaizen, 5S Initiatives.

3 1 2

Total 100 30 70

4. ASC/N0015 Manage the team on the line/ shift on a day to day basis

PC1. Ensure operators and helpers on the production line/ shift are aware of the job expectations on a daily basis.

100

3 1 2

PC2. Ensure that the operators are aware of the production targets and the timelines required to process a work order as finalized in the production plan.

4 1 3

PC3. Involve operators and helpers for the daily floor meeting/ morning meetings/ staff meetings to communicate information intended for them.

4 1 3

PC4. Ensure communication to line operators/ helpers on any changes in policies/ processes by the organization through required verbal/ written mechanisms.

4 1 3

PC5. Ensure participation of employees in various engagement initiatives organized at the plant and other place by the organization.

4 1 3

PC6. Involve operators and helpers in Quality Circles, TQM & Kaizen meets, Brainstorming sessions, safety drills etc. to increase their involvement in manufacturing operations.

5 1 4

PC7. Ensure availability of tea, snacks, drinking water and basic hygiene facilities at the shop floor for the operative workforce.

5 1 4

PC8. Escalate issues to Shift In Charges/ concerned staff in case of any issue related to operative deployment and engagement.

5 1 4

PC9. Support the Shift In Charges in finalizing the shift planning and manpower deployment for the shift/ line as per the proposed production plan.

6 2 4

PC10. Support the Shift In Charge/ Production Manager is creating week wise shift rosters for the shift/ line manpower and ensure rotation of manpower as per the

6 2 4

organizational norms and guidelines.

PC11. Maintain the information on leaves/ IN Out time keeping and shift/ line overtime for the operatives and helpers and share the information with the concerned as and when required.

6 2 4

PC12. Support the Shift In Charge/ Production Manager in identifying skilled manpower and up dation of the Skill Matrix/ Skill Chart for the shift/ line/ process area.

6 2 4

PC13. Ensure identification and deployment of right skilled people at the right places on the line/ process area.

6 2 4

PC14. Ensure that all the operative manpower is aware of the production targets, production plan and daily productivity targets.

3 1 2

PC15. Track the daily performance of the operators and helpers during the shift and note the achievement levels in a manual register/ online IT enabled system.

3 1 2

PC16. Provide feedback to the operators and helper in case of any process deviation observed by the supervisor.

3 1 2

PC17. Provide feedback to Shift In Charges/ Production Managers pertaining to performance appraisals of operators and helpers.

3 1 2

PC18. Ensure that the operatives are trained and are aware of the processes which need to be followed on the shop floor during the production process.

3 1 2

PC19. Support the Shift In Charges/ Production Managers/ Training team in training of entry level operators and helpers in the plant.

3 1 2

PC20. Share knowledge of processes, inputs and outputs with the operators to enhance their skill levels.

3 1 2

PC21. Other than technical trainings, support the team in delivering trainings related to quality and safety for the operators and helpers.

3 1 2

PC22. In case the operating staff has any queries, ensure that the queries are resolved either by self or escalated to the concerned person.

3 1 2

PC23. Listen to issues related to workmen problems/ work men grievances/ Complaints/ Personal Problems etc. for the operators and helpers.

3 1 2

PC24. Resolve issues which are under the purview of the supervisor and escalate the ones which need higher intervention to the concerned team.

3 1 2

PC25. Counsel employees for any work related issues or any personal problems highlighted by the employee.

3 1 2

Total 100 30 70

5. ASC/N0006B Maintain a safe and healthy working environment

PC1. Identify activities which can cause potential injury through sharp objects, burns, fall, electricity, gas leakages, radiation, poisonous fumes, chemicals, loud noise

100

3 1 2

PC2. Identify areas in the plant which are potentially hazardous/ unhygienic in nature.

4 1 3

PC3. Conduct regular checks on machine health to identify potential hazards due to wear and tear of machine.

4 1 3

PC4. Ensure that all equipment are tested of conformance as per the cycle/ timelines identified in the organization.

4 1 3

PC5. Inform the shop head and the safety team about the potential risks identified in the processes, workplace area/ layout, material used, malfunctioning of safety related equipment etc.

4 1 3

PC6. Inform the maintenance team about machine breakdowns,

5 1 4

damages which can potentially harm man/ machine during operations and analyse their defects to prevent any future damage to men/ machine.

PC7. Ensure that all risk involving and hazardous areas near the work place are marked/ tagged in order to caution the users of the work area/ machinery.

6 2 4

PC8. Create awareness amongst other by sharing information on the identified risks. Ensure that periodic awareness sessions are conducted for the helpers and operatives to make them aware of the risks identified.

6 2 4

PC9. Support the Safety team in risk identification and creation of a risk mitigation plan.

6 2 4

PC10. Train team members on safety and health related issues.

6 2 4

PC11. Ensure that all team members operate the machine using the recommended Personal Protective Equipment (PPE) and also ensure self-usage of the required PPEs.

6 2 4

PC12. Ensure that all operatives follow the instructions given on the equipment manual describing the operating process of the equipment to prevent any hazard.

6 2 4

PC13. Ensure that all team members follow the Safety, Health and Environment related practices developed by the organization.

6 2 4

PC14. Ensure that a clean and safe working environment near the work place is maintained and that there is no spillage of chemicals, production waste, oil, solvents etc. in the working area.

4 1 3

PC15. Ensure that the first aid safety kit at the work place/ shop floor contains the requisite items to respond to minor injuries. Also may sure that the operatives and helpers

4 1 3

are made aware of these items and their usage.

PC16. Ensure that a documented record of all minor and major injuries is kept and updated on the shop floor.

4 1 3

PC17. Ensure that the waste disposal is done in the designated area and manner as per organization SOP.

4 1 3

PC18. Attend all safety and fire drills to be self-aware of safety hazards and preventive techniques and ensure that the team participate in all the required safety and fire drills.

3 1 2

PC19. Participate in all safety related initiatives like Safety Committee participations, Safety Day Celebrations etc.

3 1 2


3 1 2

PC21. Ensure that any activity performed by the team members which may negatively impact their health and productivity is immediately brought to notice by the supervisor.

3 1 2

PC22. Periodically counsel and train employees on good health and safe working practices.

3 1 2


3 1 2

Total 100 30 70

6. ASC/N0022 Ensure implementation of 5S activities at the shop floor & the office area

PC1. Ensure all recyclable materials are put in designated containers.

100

3 1 2

PC2. Ensure no Tools, fixtures & jigs are lying on workstations unless in use and no un-necessary items is lying on workbenches or work surfaces unless in use.

3 1 2

PC3. Ensure that the operators and other team members are segregating the waste in hazardous/ Non Hazardous waste as per the sorting work instructions

3 1 2

PC4. Ensure that all the operators are following the technique of waste

3 1 2

disposal and waste storage in the designated bins

PC5. Segregate the items which are labelled at red tag items for the process area and keep them in the correct places.

3 1 2

PC6. Ensure that all the tools/ equipment/ fasteners/ spare parts are arranged as per specifications/ utility into proper trays, cabinets, lockers as mentioned in the 5S guidelines/ work instructions.

3 1 2

PC7. Check for return of any type of extra material and tools to the designated sections and make sure that no additional material/ tool is lying near the work area.

5 2 3

PC8. Oversee removal of unnecessary equipment, storage, furniture, unneeded inventory, supplies, parts and material.

4 1 3


4 1 3

PC10. Ensure proper stacking and storage of the various types of boxes and containers as per the size/ utility to avoid any fall of items/ breakage and also enable easy sorting when required.

4 1 3

PC11. Ensure that the team follows the given instructions and checks for labelling of fluids, oils, lubricants, solvents, chemicals etc. and proper storage of the same to avoid spillage, leakage, fire etc.

3 1 2


4 1 3

PC13. Ensure that organizing the workplace takes place with due considerations to the principles of wasted motions, ergonomics, work & method study.

4 1 3

PC14. Ensure that the area has floors swept, machinery clean and is generally neat and tidy. In case of

4 1 3

cleaning, ensure that correct displays are maintained on the floor which indicate potential safety hazards.


3 1 2

PC16. Ensure adherence to the cleaning schedule for the lighting system to ensure proper illumination.

4 1 3


3 1 2

PC18. Ensure that daily cleaning standards and schedules to create a clean working environment are followed across the plant.

4 1 3

PC19. Oversee that various cleaning and organizing tasks have been developed and assigned for the work area.

3 1 2

PC20. Ensure logical and user friendly documentation and file management for all activities across the plant and create guidelines around standardization of processes.

3 1 2

PC21. Ensure timely creation and sharing of the 5S checklists.

4 1 3

PC22. Ensure that the 5S manual are available as per the timelines.

3 1 2

PC23. Ensure team cooperation during the audit of 5S activities.

4 1 3

PC24. Ensure that workmen are periodically trained to address challenges related to 5S

3 1 2


3 1 2

PC26. Oversee that the staff/ operators are trained and fully understand 5S procedures

3 1 2

PC27. Ensure that all the guidelines for What to do and What not to do to build sustainability in 5S are mentioned in the 5S check lists/

4 1 3

work instructions and are easily searchable.

PC28. Ensure continuous training of the team members on 5S in order to increase their awareness and support implementation.

3 1 2

PC29. Ensure that all visual controls, notice boards, symbols etc. at the manufacturing place are created, working and are put up as per the requirement.

3 1 2

Total 100 30 70

Grand Total 600 600 180 420

Percentage Weightage (%) 30 70

Welding Technician Level 4; (ASC/Q3103)

Assessable Outcome


s

Out of

Marks allocation

Theory Practic

al

1. ASC/N3107 Understanding & interpreting the engineering drawings

PC1. Check the version of the engineering drawing provided.

100

7 2 5

PC2. Select the latest version of the available engineering drawing so that the final measurements and design is available with the team

7 2 5

PC3. Thoroughly understand the work order ( work output – Trail or production) required from the process

7 2 5

PC4. Refer all engineering drawings and sketches related to the work output to understand the measurement dimensions, geometric dimensions and shape of the required work output

13 4 9

PC5. Identify the required activities which need to be executed in order achieve the final output as per the work order

13 4 9

PC6. Ensure that the processes adopted including parameters and process sequences are according to the Work Instructions/ Standard Operating Procedures adopted

13 4 9

PC7. Understand the checking method and the frequency as mentioned in the work instructions

13 4 9

PC8. Clearly understanding the does and don’ts of the manufacturing process as defined in SOPs/ Work Instructions or defined by supervisors

13 4 9

PC9. Store the drawings in a proper place where they cannot be damaged by moisture, chemicals, fire and can be easily accessed by the user

7 2 5

PC10. Observe any modification, changes required in the drawing and communicate the same to the concerned team in the organization

7 2 5

Total 100 30 70

2. ASC/N3108 Understand the process & equipment requirement for the task

PC1. Understand the right welding methodology and process to be adopted for completing the work order through discussions with the supervisor/ master technician for the new job and reading the process manuals/ Work Instructions/Standard Operating Procedures for the production job

100

8 2 6

PC2. Understand the various welding parameters like temperature, pressure, electrode type, electrode distance, process cycle time etc. before starting the welding process, as mentioned in the Work Instructions/ SOP manual

9 3 6

PC3. Understand the material required and the equipment availability for executing the activity

13 4 9

PC4. Understand the type of electrodes – material wise & dimension wise, type of filler material etc. used for the welding process

13 4 9

PC5. Understand the application of fixtures, process sequence, poka- yoke as applicable

13 4 9

PC6. Correctly understand the type of electrode in terms of electrode material and thickness, filler aterial

13 4 9

and flux which will be required for the selected welding process before the initiation of the welding process

PC7. Refer the queries to a competent internal specialist if they cannot be resolved by the welder on own

13 4 9

PC8. Obtain help or advice from specialist if the problem is outside the area of competence or experience

10 3 7

PC9. Confirm self- understanding to the specialist during discussion so that all doubts & queries can be resolved before the actual process execution

8 2 6

Total 100 30 70

3. ASC/N3109 Preparing the machine, auxiliaries & work pieces for the welding operation

PC1. Understand the material required and the equipment availability for executing the activity

100

7 2 5

PC2. Ensure that the required material is procured from the store before starting the welding process

7 2 5

PC3. Ensure that the helper/ assistant technician brings the required material and tools before the start of the welding operations

7 2 5

PC4. Ensure that the helper/ assistant operator clean the surface of the electrodes and the welding gun to remove dust and any other impurities

11 3 8

PC5. Ensure that the helper/ assistant operator clean other welding machine auxiliaries (Welding Transformer, Gas Discharge unit, Flux wire) before the initiation of the welding process, as mentioned in the Work Instructions/ Standard Operating Procedures (SOP)

12 4 8

PC6. Setup the welding apparatus as per the selected welding process and the internal SOPs/ Work Instructions and the setting standards for the machine

12 4 8

PC7. Ensure that the helper/ assistant operator clean the surface to the metal parts (work pieces) which need to be joined

12 4 8

PC8. Correctly compare the dimensions of the work pieces available on the

11 3 8

welding line with the product drawing/ sketches available with the operator

PC9. Ensure that in case the parts are not as per the given measurements, the helper/ assistant operator remove any extra material, sharp edges etc. which might impact the final welded products

7 2 5

PC10. Immediately refer the queries to the supervisor to avoid any delay in the actual process

7 2 5

PC11. Confirm self- understanding to the supervisor/ master technician once the query is resolved so that all doubts & queries can be resolved before the actual process execution

7 2 5

Total 100 30 70

4. ASC/N3110 Support the Robotics Engineer/ Master Technician in programming

PC1. Understand the capabilities of the Robotic Welding Machine and link it to the nature of job, location of the weld, axis movements, speed, hydraulics etc.

100

11 3 8

PC2. Understand basic Robotic Operations by referring the user manual for the welding apparatus

11 3 8

PC3. Support the Programming Engineer/ Master Technician/ Machine Setter in correctly programming the basic level activities related to path plan, extension and trajectory of various parts of the Robotic Welding apparatus - arm, gripper, joints, extensions across X, Y and Z axis and the welding cycle time (ON/ OFF) time

14 4 10

PC4. Support the Programming Engineer/ Machine Setter in programming the start/stop time of weld machine and cycle time for the arm movements (acceleration, slowing)

18 6 12

PC5. Observe the coordination of robotic arm movement and sensors with the movement of the work pieces on the welding platform and loading/ unloading of the work pieces, Tip cleaning process etc.

18 6 12

PC6. Monitor the welding process ( Pressure, Temperature, gas discharge flow, electrode force, electrode distance etc.) by observing the readings on the panels/ measuring instruments to prevent any harm to the work pieces due to overheating, burning, over melting, change in applied pressure etc.

17 5 12

PC7. Inform the Supervisor/ Master Technician about any process irregularities observed in the Robotic Welding Process

11 3 8

Total 100 30 70

5. ASC/N3111 Conduct the welding process & join the work-pieces

PC1. Hold the parts (Jigs) which need to be welded together using a clamp and align them with the electrodes as per the job requirement so that the work pieces do not fall down/ turn

100

3 1 2

PC2. Install the work pieces on the Welding apparatus keeping in mind the electrodes distance, contact area, pressure, temperature application etc as specified in the Welding SOP/ Control plan Documents/ Work Instructions

3 1 2

PC3. Check for operation of core welding equipment like welding gun, welding transformer, gas cylinders and gas discharge guns (in case of MIG/ MAG welding) as per setup documentation

3 1 2

PC4. Conduct destructive and non- destructive test activity to ensure conformance to the SOPs/ Work Instructions

3 1 2

PC5. Inform machine setter/ engineer/ supervisor to make modifications in the welding parameters as per the test activity outcomes and the prescribed standards for Destructive/ Non Destructive Tests

3 1 2

PC6. Adjust the current/ voltage, temperature application as per the welding requirement and the activity test conducted earlier so that the desired heat can be created for the welding process

6 2 4

Resistance Welding PC7. Check for the positioning of the spot

and the welding gun as per the work instructions and the work order

6 2 4

PC8. In case of Spot & Projection Welding ensure setting electrode contact, bringing the electrodes/ welding gun close to the metal sheets/ work pieces and apply current as per the Work Instructions/ Standard Operating Procedure

6 2 4

PC9. Ensure that the application of current is stopped once the weld time is over and the weld is cooled so that the weld does not become brittle

6 2 4

Gas Discharge Welding PC10. For Gas Arc welding process like

MIG, MAG and TIG, hold the filler metal/ Flux material wire and the Welding Gun at the recommended angle and distance mentioned in the setup document, keeping the work pieces stationary to ensure the required melting of base metal

6 2 4

PC11. Ensure the flow of filler material/ gas discharge as per the welding standards prescribed in the SOP/ Work Instructions

6 2 4

PC12. Operate the welding equipment and guide the flames from the torch from the prescribed distance to melt the electrode, filler metal, slag etc as per the welding process requirement so that the right quality of weld is created

5 1 4

PC13. Ensure cooling of the welded pieces (if required) as per the welding process guidelines

6 2 4

PC14. Monitor the welding process (Pressure, Temperature, gas discharge flow, electrode force, electrode distance etc) by observing the readings on the panels/ measuring instruments to prevent any harm to the work pieces due to overheating, burning, over melting, change in applied pressure etc

6 2 4

PC15. Ensure that the Assistant Operators note down the observations in the prescribed format

4 1 3

PC16. Observe and analyze any irregularity in the welding process and take preventive steps so that the overall quality of weld is as per the desired standards

4 1 3

PC17. Inform the supervisor of any irregularity in process/ equipment malfunctioning

4 1 3

PC18. Ensure frequency of setting, checking, recording as per WI

4 1 3

PC19. Measure the final welded piece and compare the dimensions as prescribed in the work order engineering drawing

4 1 3

PC20. In case the parts are not as per the given measurements, ensure that the assistant operators/ helpers remove extra material by using chippers, grinders etc.

4 1 3

PC21. In case of any dents or bulges, ensure hammering of the bulges to give the work pieces the desired shape

4 1 3

PC22. Keep the supervisor informed of any inconsistency in the welding process, quality issues etc so that the same can be dealt immediately

4 1 3

Total 100 30 70

6. ASC/N3112 Conduct post process activities of Inspection, Storage & maintenance

PC1. Ensure inspection of output products at defined frequency by comparing the dimensions of the output pieces with the specifications of the finished product using devices like micrometers, Vernier calipers, gauges, rulers and any other inspection equipment

100

3 1 2

PC2. Compare texture, color, surface properties, hardness and strength with the given product specifications described the in work order/ Work Instructions

3 1 2

PC3. Separate the defective pieces into two categories – pieces which can be repaired/ modified and pieces

3 1 2

which are beyond repair by putting tags/ markings on the welded jig/ work piece surface

PC4. Ensure that the pieces which are not OK and not meeting the specified standards and cannot be repaired are discarded

6 2 4

PC5. Escalate all issues related to change in visual parameters, colour, surface properties, spots, hardness etc. so that the manufacturing equipment can be reset to achieve the specified output

6 2 4

PC6. Ensure the unit wise production data is captured in the prescribed format. Ensure that the production log sheets are filled correctly at the end of the shift by the Assistant operator

6 2 4

PC7. Maintain data records for quality defects and pieces which are beyond repair

7 2 5

PC8. Maintain data of process wise consumption of raw material

7 2 5

PC9. Ensure that the output pieces are correctly clamped and lifted using suitable equipment like hoist, lifts, crane, etc.

7 2 5

PC10. Ensure that there is no damage to the lifted work pieces

7 2 5

PC11. Carry the output product to the designated area using hangars, conveyor belts, cranes, forklifts etc.

7 2 5

PC12. Ensure that the final OK output pieces are tagged and stored in the correct place/ transported to the next production station as per the process specified in the Standard Operating Procedures/ Process flow diagrams

7 2 5

PC13. Ensure that all fixtures, tools, equipment and spare parts are stored in an organized way as indicated in the equipment manual and the designated area as defined in the 5S manual of the organization

7 2 5

PC14. Ensure that the relevant tags are put on items as per part number or

6 2 4

serial number so that sorting of items becomes easy

PC15. Ensure that the equipment and the work place are regularly cleaned and that there is not accumulation of dust, moisture and waste material

6 2 4

PC16. Check the working of all bearing, rollers, shafts etc. and oil all moving parts of the equipment on a periodic basis

4 1 3

PC17. Check the working of non- moving parts and conduct preventive maintenance to prevent machine failure as per the checklist/ work instructions shared by the maintenance team

4 1 3

PC18. Periodically check the equipment calibration status and report any non-conformance to the maintenance teams for rectification

4 1 3

Total 100 30 70

7. ASC/N0006 Maintain a safe and healthy working environment

PC1. Identify and prevent activities which can cause potential injury through sharp objects, burns, fall, electricity, gas leakages, radiation, poisonous fumes, chemicals, loud noise.

100

9 3 6

PC2. Inform the concerned authorities about the potential risks identified in the processes, workplace area/ layout, materials used etc.

8 2 6

PC3. Inform the concerned authorities about damages which can potentially harm man/ machine during operations

8 2 6

PC4. Create awareness amongst other by sharing information on the identified risks.

6 1 5

PC5. Follow the instructions given on the equipment manual describing the operating process of the equipment.

10 3 7

PC6. Follow the Safety, Health and Environment related practices developed by the organization.

11 3 8

PC7. Operate the machine using the recommended Personal Protective Equipment (PPE)

11 3 8

PC8. Maintain a clean and safe working environment near the workplace and ensure there is no spillage of chemicals, production waste, oil, solvents etc.

10 2 8


9 2 7

PC10. Ensure that the waste disposal takes place in the designated area as per organization SOP.

11 3 8


7 1 6

Total 100 25 75

8. ASC/N0021 Maintain 5S at the work premises

PC1. Follow the sorting process and check that the tools, fixtures & jigs that are lying on workstations are the ones in use and un-necessary items are not cluttering the workbenches or work surfaces.

100

4 1 3

PC2. Ensure segregation of waste in hazardous/ non Hazardous waste as per the sorting work instructions.

4 1 3

PC3. Follow the technique of waste disposal and waste storage in the proper bins as per SOP.

4 1 3

PC4. Segregate the items which are labeled as red tag items for the process area and keep them in the correct places.

4 1 3

PC5. Sort the tools/ equipment/ fasteners/ spare parts as per specifications/ utility into proper trays, cabinets, lockers as mentioned in the 5S guidelines/ work instructions.

4 1 3


4 1 3

PC7. Properly stack the various types of boxes and containers as per the size/ utility to avoid any fall of items/ breakage and also enable easy sorting when required.

4 1 3

PC8. Return the extra material and tools to the designated sections and make

4 1 3

sure that no additional material/ tool is lying near the work area.

PC9. Follow the floor markings/ area markings used for demarcating the various sections in the plant as per the prescribed instructions and standards.

4 1 3

PC10. Ensure proper labeling mechanism of instruments/ boxes/ containers and maintaining reference files/ documents with the codes and the lists.

4 1 3

PC11. Check that the items in the respective areas have been identified as broken or damaged

4 1 3

PC12. Follow the given instructions and check for labeling of fluids, oils. Lubricants, solvents, chemicals etc. And proper storage of the same to avoid spillage, leakage, fire etc.

4 1 3


4 1 3

PC14. Check whether safety glasses are clean and in good condition.

4 1 3

PC15. Keep all outside surfaces of recycling containers are clean

4 1 3

PC16. Ensure that the area has floors swept, machinery clean and generally clean. In case of cleaning, ensure that proper displays are maintained on the floor which indicate potential safety hazards

4 1 3

PC17. Check whether all hoses, cabling & wires are clean, in good condition and clamped to avoid any mishap or mix up.

4 1 3


4 1 3

PC19. Follow the cleaning schedule for the lighting system to ensure proper illumination.

4 1 3

PC20. Store the cleaning material and equipment in the correct location and in good condition.

4 1 3


4 1 3

PC22. Follow the daily cleaning standards and schedules to create a clean working environment.

4 1 3

PC23. Attend all training programs for employees on 5S.

2.5 0.5 2

PC24. Support the team during the audit of 5S.

4 1 3


2.5 0.5 2

PC26. Follow the guidelines for What to do and What not to do to build sustainability in 5S as mentioned in the 5S check lists/ work instructions.

3 1 2

Total 100 25 75

Grand Total 800 800 230 570

Percentage Weightage (%)

30 70

Automotive Paintshop Assistant; (ASC/Q3302)

Assessable Outcome


s

Out of

Marks allocation

Theory Practic

al

1. ASC/N3303 Support the Operator in the Pre-Treatment Process

PC1. clearly understanding the does and don’ts of the manufacturing process as defined in sops/ work instructions or defined by supervisors

100

10 2 8

PC2. check the incoming body parts for dents as per the instructions given in the work instructions/ sop

10 2 8

PC3. check the incoming body parts for burrs, metal wires as per the instructions given in the work instructions

10 2 8

PC4. check the incoming body parts for rustas per the instructions given in the work instructions

10 2 8

PC5. return the body part if quality parameters not adhered to

10 2 8

PC6. check visual/manual while loading the panel

10 2 8

PC7. check the condition of the connector, if is not ok then bypass the hanger. 10 2 8

PC8. check the pin point of the rested part of the body for alignment, if not properly rested,align with the help of rod.

10 2 8

PC9. check visual/manual while feeding the data otherwise the hanger will not move

10 2 8

PC10. ensure proper wire cutting so that the wire doesn`t come in contact with the body and body shell.

10 2 8

Total 100 20 80

2. ASC/N3304 Support the operator/ painter in Body Surface Preparation, Sealant Application and Sanding Operation

PC1. ensuring pressure of the sealer in sealer line as per specification.

100

10 2 8

PC2. after gun application at each defined location if there is excess sealer or a sealer defects observed at the station, immediate rectify at the station.

10 2 8

PC3. checking the sealer supply 10 2 8

PC4. quality of the sealer: sealer should be homogenous, off-white paste free from lumps& foreign particulate matter

10 2 8

PC5. ensuring that there must be no edge at corners of the sanded area.

10 2 8

PC6. ensure completion of the sanding process flow: sanding must done in anticlockwise direction.

10 2 8

PC7. sealant application process: sealant to be applied with sealant gun and then recti

10 2 8

PC8. application to be done for smooth finish

10 2 8

PC9. ensuring lux level of the booth 10 2 8

PC10. the putty drying process: after putty drying, role holder needs to do uniform sanding for leveling the surface with body level, otherwise putty patch mark may generate after paint application

10 2 8

Total 100 20 80

3. ASC/N0008 Conduct regular cleaning and maintenance of the equipment

PC1. arrange all equipment in a proper order as indicated in the equipment manual

100

10 2 8

PC2. store equipment auxiliaries and spare parts in proper designated areas

10 2 8

PC3. clearly tag process related equipment parts/ spare parts as per part number or serial number so that sorting of equipment becomes easy

9 2 7

PC4. cover equipment so that there is limited dust collection and moisture contact

8 1 7

PC5. regularly clean the equipment and process auxiliaries to remove any dust, moisture, waste material which would have got collected on the equipment

10 2 8

PC6. regularly open the equipment and clean the internal parts of the equipment

9 2 7

PC7. regularly clean the working area under the process and create a healthy, clean and safe working environment

9 2 7

PC8. check the working of all bearing, rollers, shafts etc and oil all moving parts of the equipment on a periodic basis

9 2 7

PC9. check the working of non-moving parts and periodically conduct preventive maintenance to prevent machine failure

9 2 7

PC10. periodically check the equipment calibration and report any errors to the maintenance teams for rectification

9 2 7

PC11. prepare periodic log sheets of equipment maintenance dates, maintenance schedules and

8 1 7

maintenance activity conducted on the equipment

Total 100 20 80

4. ASC/N0006 Maintain a safe and healthy working environment

PC1. Identify and prevent activities which can cause potential injury through sharp objects, burns, fall, electricity, gas leakages, radiation, poisonous fumes, chemicals, loud noise.

100

9 3 6

PC2. Inform the concerned authorities about the potential risks identified in the processes, workplace area/ layout, materials used etc.

8 2 6

PC3. Inform the concerned authorities about damages which can potentially harm man/ machine during operations

8 2 6

PC4. Create awareness amongst other by sharing information on the identified risks.

6 1 5

PC5. Follow the instructions given on the equipment manual describing the operating process of the equipment.

10 3 7

PC6. Follow the Safety, Health and Environment related practices developed by the organization.

11 3 8

PC7. Operate the machine using the recommended Personal Protective Equipment (PPE)

11 3 8

PC8. Maintain a clean and safe working environment near the workplace and ensure there is no spillage of chemicals, production waste, oil, solvents etc.

10 2 8


9 2 7

PC10. Ensure that the waste disposal takes place in the designated area as per organization SOP.

11 3 8


7 1 6

Total 100 25 75

5. ASC/N0021

PC1. follow the sorting process and check that the tools, fixtures & jigs that are

100 4 1 3

Maintain 5S at the work premises

lying on workstations are the ones in use and unnecessary items are not cluttering the workbenches or work surfaces.

PC2. ensure segregation of waste in hazardous/ non hazardous waste as per the sorting work instructions

4 1 3

PC3. follow the technique of waste disposal and waste storage in the proper bins as per sop

4 1 3

PC4. segregate the items which are labelled as red tag items for the process area and keep them in the correct places

4 1 3

PC5. sort the tools/ equipment/ fasteners/ spare parts as per specifications/ utility into proper trays, cabinets, lockers as mentioned in the 5s guidelines/ work instructions

4 1 3

PC6. ensure that areas of material storage areas are not overflowing

4 1 3

PC7. properly stack the various types of boxes and containers as per the size/ utility to avoid any fall of items/ breakage and also enable easy sorting when required

4 1 3

PC8. return the extra material and tools to the designated sections and make sure that no additional material/ tool is lying near the work area

4 1 3

PC9. follow the floor markings/ area markings used for demarcating the various sections in the plant as per the prescribed instructions and standards

4 1 3

PC10. follow the proper labeling mechanism of instruments/ boxes/ containers and maintaining reference files/ documents with the codes and the lists

4 1 3

PC11. check that the items in the respective areas have been identified as broken or damaged

4 1 3

PC12. follow the given instructions and check for labelling of fluids, oils. lubricants, solvents, chemicals etc.

4 1 3

and proper storage of the same to avoid spillage, leakage, fire etc

PC13. make sure that all material and tools are stored in the designated places and in the manner indicated in the 5s instructions

4 1 3

PC14. check whether safety glasses are clean and in good condition

4 1 3

PC15. keep all outside surfaces of recycling containers are clean

4 1 3

PC16. ensure that the area has floors swept, machinery clean and generally clean. in case of cleaning, ensure that proper displays are maintained on the floor which indicate potential safety hazards

4 1 3

PC17. check whether all hoses, cabling & wires are clean, in good condition and clamped to avoid any mishap or mix up

4 1 3

PC18. ensure workbenches and work surfaces are clean and in good condition

4 1 3

PC19. follow the cleaning schedule for the lighting system to ensure proper illumination

4 1 3

PC20. store the cleaning material and equipment in the correct location and in good condition

4 1 3

PC21. ensure self-cleanliness - clean uniform, clean shoes, clean gloves, clean helmets, personal hygiene

4 1 3

PC22. follow the daily cleaning standards and schedules to create a clean working environment

4 1 3

PC23. attend all training programs for employees on 5 s

2.5 0.5 2

PC24. support the team during the audit of 5 s

4 1 3

PC25. participate actively in employee work groups on 5s and encourage team members for active participation

2.5 0.5 2

PC26. follow the guidelines for what to do and what not to do to build sustainability in 5s as mentioned in the 5s check lists/ work instructions

3 1 2

Total 100 25 75

Grand Total 500 500 110 390

Percentage Weightage (%)

30 70

Annexure A:

Tools and Equipment for Basic Training (Block 1 & Block 2)

Batch: 30 Candidates

Sector: Automotive

Block I QP Code with Version No. or Course Code:

Block I QP Name or Course Name:

Block I NSQF Level: 4

S. No.

Equipment Name

Minimum number

of Equipment

required

Unit Type

Is this a mandatory Equipment

to be available (Yes/No)

PwD specific equipment

1 Body Outer Panel Metal Finish/Repair Tools

1 Set Yes No

2 Resistance Spot Weld Guns 1 No. Yes No

3 MIG Welding Machines 1 No. Yes No

4 Sealant Application 1 No. Yes No

5 Paint Spray Guns 1 No. Yes No

6 Tear Down Test Kit – To Test Spot Weld Strength

1 Set Yes No

7 Co-Ordinate Measuring Machine (CMM)

1 No. Yes No

8 DC Nut Runner & Controller Units 1 Set Yes No

9 DC Angle Nut Runner 1 Set Yes No

10 Digital ST Torque Wrench 1 Set Yes No

11 Go – NOGO Gauges 1 Set Yes No

12 Training vehicles of all types i.e.

Petrol, Diesel, CNG 1 No. Yes

No

13 Digital Variable Gauge with inbuilt SPC

1 No. Yes No

14 Jigs & Fixtures 1 No. Yes No

15 Gantry System for Part Loading /Transfers

1 No. Yes No

16 CNC Horizontal Machining Centers 1 No. Yes No

17 Vehicle 4 Post Test Lab NA No. Yes No

18 Vehicle S&R Test NA Set Yes No

19 Personal Protection Equipment: Gloves, Safety Shoes, goggles, ear plugs etc.

30 Set Yes No

20 Workshop Safety: Fire extinguishers, First Aid

1 No. Yes No

21 Consumable: cotton waste, Dusters etc.

1 No. Yes No

22 Teaching Aids: Charts, CBTs, Videos, Assembly, Process Flow Charts - for Different Aggregates

1 Set Yes No

23

Other tools: hand tools, power tools,

Special purpose Tools for different

Aggregates.

1 Set Yes

No

24

Cut sections of engine and vehicle

aggregates and assemblies i.e.

engine, gear box, brake clutch,

steering, transmission, suspension

etc. for Training & Demo

1 Set Yes No

25 Main Components of all Aggregates 1 Set Yes No

26 Helmet with reflective strips 30 No. No Yes

27 High visibility vest 30 No. No Yes

28 Whistles / Buzzer 30 No. No Yes

29 Alarm system 30 No. No Yes

29 High wavelength flashlight in shop floor & washroom

30 No. No Yes

30 Refresher Sign Language Training for supervisors (SHI candidates)

1 - - Yes

31 Grab Bars 10 No. - Yes