Lean manufacturing operative

Knowledge

K1: Relevant statutory, organisational and health and safety regulations relating to lean manufacturing operations and safe practices Back to Duty

K2: Compliance procedures/systems in line with regulatory requirements e.g. ISO 14001 or other relevant environmental standards Back to Duty

K3: Their individual roles and responsibilities within the organisation and the flexibility required to deliver products to meet customers costs/delivery targets/requirements e.g. Just in time (JIT) Back to Duty

K4: Manufacturing standard operation procedures (SOPs) adherence and development of lean processes Back to Duty

K5: Process equipment monitoring, data collection, error proofing and operating procedures e.g. ISO 9002 or other relevant quality standards Back to Duty

K6: The tools and methods of effective problem solving using data, reports and documents to resolve production related issues e.g. A3 report, graphs, matrices and escalate concerns Back to Duty

K7: How to study and identify ways to improve the safety, quality, cost or process efficiency using lean manufacturing tools e.g. kaizen Back to Duty

K8: How to share information using a range of methods within the manufacturing environment e.g. oral, written, electronic, information boards, visual displays Back to Duty

K9: How to maintain a safe and efficient work site through work place organisation e.g. 5s and process ownership Back to Duty

K10: The importance of following the specified assembly sequence and procedure at all times Back to Duty

K11: How to check the quality of the assembly, against the required quality standards and what tools and equipment are used Back to Duty

K12: The procedure for positioning, aligning and securing component parts during the assembly operations Back to Duty

K13: Where to obtain the necessary job instructions, operating procedures and assembly specifications that are used, and how to interpret them Back to Duty

K14: How to Identify and resolve current and potential production/assembly problems within the limits of their responsibility Back to Duty

K15: The correct methods of handling and storing the samples Back to Duty

K16: Where to obtain the necessary job instructions, inspection/quality procedures and product specifications that are used, and how to interpret them Back to Duty

K17: How to identify which samples, products and materials do not meet the quality requirements Back to Duty

K18: Procedures for the handling and segregation of defect components Back to Duty

K19: Specific safe working practices and environmental regulations that need to be observed Back to Duty

K20: The procedures and documentation required to allow the transfer of materials to take place Back to Duty

K21: Where to obtain the necessary job instructions, specification details and specific transfer/handling procedures that are used, and how to interpret them Back to Duty

K22: The procedures for the movement and transferring of materials to the correct location within given timelines Back to Duty

K23: What tools and equipment are used for the material movement operations undertaken and how to check that they are in a safe and usable condition Back to Duty

K24: The lifting and handling procedures, and load bearing capacities of the equipment being used Back to Duty

K25: What tools and equipment are used for the processing/finishing operations undertaken and how to check that they are in a safe and usable condition Back to Duty

K26: Where to obtain the necessary job instructions, processing/finishing procedures and equipment operating procedures that are used, and how to interpret them Back to Duty

K27: Specific safe working practices, processing/finishing procedures and environmental regulations that need to be observed Back to Duty

K28: The procedure for the recovery or restart of manufacturing due to quality or process concern Back to Duty

K29: The importance of following the pre-determined sequence of events in the processing/finishing operation and the consequences of not following them Back to Duty

Skills

S1: Work safely at all times, complying with health and safety legislation, regulations, and other relevant guidelines. Identifying risks within their processes and support/carry out countermeasure activities to improve safe working. Manage tooling, equipment and materials daily in-line with supplier standards e.g. COSHH (Control of Substances Hazardous to Health) Back to Duty

S2: Comply with environmental procedures and systems and contribute to the achievement of specific standards e.g. ISO 14001 or other relevant environmental standards and use the 4R’s (Reduce, Re-use, Recycle, Recover) where possible Back to Duty

S3: Demonstrate their ability to carry out their role effectively, efficiently and flexibly maintaining lean manufacturing principles to meet customer’s demands e.g. JIT Back to Duty

S4: Demonstrate their skill and knowledge following SOPs and building their versatility across a number of processes and process areas. Select and use appropriate tools, equipment and materials to carry out the manufacturing operation Back to Duty

S5: Demonstrate appropriate process documentation control. Accurately completing check sheets, monitoring process and equipment data efficiently and legibly using the correct terminology required to meet the quality standard e.g. ISO 9002 Back to Duty

S6: Demonstrate their ability to identify and resolve problems within the lean manufacturing environment using effective problem solving tools and techniques. Manage problems that may occur during the manufacturing process within the limits of their responsibility and escalate as appropriate Back to Duty

S7: Generate ideas and contribute to process improvement activities individually or as part of a team through fact finding and analysis to improve the safety, environment, quality, cost or production process. Identifying and eliminating the 7 wastes (defects, over production, transportation, waiting, inventory, motion and processing) Back to Duty

S8: Demonstrate communication skills which include oral, written, electronic (PC), information boards or visual displays to effectively share information Back to Duty

S9: Maintains and monitors the work site efficiently and effectively at all times using the elements of sifting, sorting, sweeping, spick & span (5’s) within the lean manufacturing environment Back to Duty

S10: Check components for damage and that they are in a usable condition Back to Duty

S11: Correctly position, align and secure the components Back to Duty

S12: Secure the components in position using the specified fastening device/method Back to Duty

S13: Obtain and follow the correct Job instructions/Standard operating procedures production/assembly specifications in accordance with time constraints and the roles and responsibilities identified for the production/assembly activity Back to Duty

S14: Produce components which comply with the specification and quality requirements Back to Duty

S15: Carryout quality checks on component parts and completed assemblies and deal with quality concerns and defects in line with their responsibility Back to Duty

S16: Obtain and follow the correct Job instructions, inspection/quality procedures and product specifications in accordance with time constraints and the roles and responsibilities identified for the inspection/quality assurance activity Back to Duty

S17: Collect production samples at the required frequency in accordance with inspection specification and operating procedures Back to Duty

S18: Carryout inspection and testing activities using the specified methods and equipment Back to Duty

S19: Prepare, Handle, transfer and store samples safely and correctly in accordance with quality control procedures Back to Duty

S20: Accurately interpret the data/results gained from the inspection and testing procedures being used Back to Duty

S21: Record and report inspection findings to relevant person Back to Duty

S22: Safely move materials to the correct location using the relevant equipment Back to Duty

S23: Obtain and follow the correct Job instructions, specification details and specific transfer/handling procedures in accordance with time constraints and the roles and responsibilities identified for the logistic/material handling activity Back to Duty

S24: Move materials using the appropriate procedures, ensuring the materials are correct, safely loaded and secure. Back to Duty

S25: Check materials selected to be moved are in line with job requirements Back to Duty

S26: Carryout quality checks on materials that are to be moved and deal with quality concerns and damage in line with their responsibility Back to Duty

S27: Return equipment to its correct location on completion of the activities and leave it in a safe and usable condition Back to Duty

S28: Perform one processing/finishing operation method e.g. hand processing, manually operated machine processing, fully automated machine processing, combined processing Back to Duty

S29: Obtain and follow the correct Job instructions, processing/finishing procedures and equipment operating procedures in accordance with time constraints and the roles and responsibilities identified for the processing/finishing activity Back to Duty

S30: Perform the processing/finishing operation according to instructions and safe operating procedures Back to Duty

S31: Monitor and control the processing/finishing operation Back to Duty

S32: Carryout quality checks on component parts and completed assemblies and deal with quality concerns and defects in line with their responsibility Back to Duty

S33: Produce processed/finished products which comply with processing specification Back to Duty

Behaviours

B1: Punctual, reliable and takes responsibility for their own actions. Back to Duty

B2: Show respect for others, having regard for diversity and equality. Back to Duty

B3: Respond positively to change in the working environment. Back to Duty

B4: Integrates within the team and supports others. Back to Duty

B5: Can work independently and effectively in challenging situations. Back to Duty

B6: Maintains quality of work under pressure. Back to Duty

B7: An open and honest communicator. Back to Duty

B8: Listens to other people’s opinions. Back to Duty

B9: A positive and respectful attitude. Back to Duty

B10: Follows instructions and guidance and demonstrates attention to detail. Back to Duty

B11: Seeks opportunities to develop and adapt to different situations, environments or technologies. Back to Duty