Commission New Advanced Manufacture Process
Overview
This standard identifies the competences you need to commission the new manufacturing process associated with a new product/process being developed using advanced manufacturing methods and techniques and introduced for the first time. You will be required to produce the design with relevant others in the context of your area of responsibility.
Your responsibilities will require you to comply with organisational policy and procedures for ensuring, through your technical support of the team, the commissioning of the new process. You will also report any problems that you cannot personally resolve to the relevant authority. You will be expected to work unsupervised, either on your own or with the team, which you may lead or direct, taking full responsibility for your actions, and possibly for the work of colleagues.
Your underpinning knowledge will provide a good understanding of general and discipline-specific engineering principles and processes. You will be fully conversant with organisational procedures and systems for producing designs for new products, in the context of your own expertise and area of responsibility.
You will be fully aware of any health, safety and environmental requirements, and the appropriate legislative and regulatory frameworks, applicable to your area of responsibility. You will be required to ensure that safe working practices are maintained throughout and will understand the responsibility you owe to yourself and others in the workplace.
Performance criteria
You must be able to:
- Access and accurately interpret all relevant work instructions and information
- Work safely at all times and in accordance with all relevant legislation, guidelines, policies, procedures and protocols
- Produce a risk assessment and method statement for the work activities to be carried out
- Deal promptly and effectively with any problems within your control and report those which cannot be solved
- Access and gather the appropriate equipment, accessories and components to carry out the work activities
- Comply with industry practices and organisational procedures to ensure the co-ordination of site services and work activities
- Wear PPE in accordance with organisational procedures
- Identify and apply the security requirements associated with the commissioning work and confirm with relevant others
- Approve equipment and tooling against agreed specification at the supplier premises for delivery of the goods to manufacturing area
- Ensure that adequate production materials are available for trialling equipment and tooling in the manufacturing area
- Initiate and monitor training of key personnel for the new manufacturing process
- Conduct safety checks of equipment and tooling used in the new process and address any non-conformances
- Initiate and monitor small trials for individual equipment and tooling in the new process against required quality specifications
- Initiate and monitor process trials for equipment and tooling working in tandem to produce samples of the new product against required quality specifications
- Work with specialists to line balance and achieve TAKT time for the new process
- Initiate and monitor planned production trials for the new process against an agreed master plan
- Conduct review of production trials problems with specialists and prioritise and plan actions to resolve them promptly and effectively
- Initiate and monitor fine tuning of components, jigs and fixtures to meet quality requirements for the finished product
- Record the results of the commissioning activities in accordance with agreed procedures
- Complete and store all relevant documentation in accordance with organisational procedures
- Dispose of waste in accordance with organisational procedures
- Leave the work area in a safe condition on completion of the work activities in accordance with organisational procedures
Knowledge and Understanding
You need to know and understand:
- The current legislation, guidelines, policies, procedures and protocols which are relevant to your work practice and to which you must adhere
- The scope and limitations of your own competence, responsibilities and accountability
Procedures to access and interpret all relevant work instructions and information
How to produce a risk assessment and method statement for the work
- The hazards and risks which may arise during the work and how you can minimise these
- Specific procedures for reporting issues which are beyond your competence, responsibilities and accountability
- The duty to report any acts or omissions that could be unsafe/detrimental to you or relevant others
- How to identify and apply the security requirements associated with the work
- The organisational procedures and information systems for storing commissioning data
- The organisational sign-off process and acceptance criteria for equipment and tooling checks at the supplier premises and at manufacturing area
- The organisational activities required for the NPDI team's commissioning process
- The importance of establishing and recording responsibilities for commissioning and analysis process
- Who should have responsibility for the different parts of the commissioning process
- The procedures associated with the commissioning and trialling review process
- The principles and techniques used in a structured pre-production/product problem-solving review
- The factors that should be taken into account for disseminating information before and after a commissioning process
- How to conduct a health and safety risk analysis of the new manufacturing process
- The types of problem that could occur during the commissioning process
- The methods and techniques used to evaluate product quality specifications
- How to use decision making and creativity techniques to generate ideas for process improvement
- How to prioritise and rank process improvement ideas
- The principles and practice of sustainability
- Sources of specialist advice that may be accessed during the commissioning process
- The organisational sign-off process and acceptance criteria for handover to production personnel at the end of the commissioning process
- What should be included in plans for pre-production/production trials of new products
- How to prioritise and schedule commissioning activities
- The limits of your own authority, and whom you should report to if you have problems that you cannot resolve
- The importance of communication, keeping relevant others informed during the work
- Organisational management structures, roles, and responsibilities
- The procedures and methods relating to the coordination of inter-disciplinary and multi-disciplinary teams
- How to dispose of waste in accordance with organisational procedures
- How to complete and safely store all relevant documentation in accordance with organisational procedures
Scope/range
Scope Performance
Work instructions and information
- Drawings
- Environmental requirements
- Manufacturer instructions
- Method statements
- Specifications
- Sustainability requirements
- Work schedules/programmes
* *
Equipment, accessories and components
- Access equipment
- Computer hardware
- Consumables
- Hand tools
- Materials
- Power tools
- Safety equipment (including PPE)
- Software
Organisational procedures
- Accident reporting
- Communication
- Customer services
- Emergencies
- Implementing and monitoring health and safety requirements and issues
- Implementing and monitoring issues relating to the environment and sustainability
- Information management
- Project management
- Risk assessment
* *
Relevant others
- Client representatives
- Customers/clients
- Service providers
- Site/contract/production manager
- Supervisors
- Work colleagues
Equipment and tooling safety checks
- Access points
- Coolant extraction
- Dangerous emissions/substances
- Fume extractions
- Personal protective equipment (PPE)
- Safety barriers
- Safety guards
- Trapping points
- Waste materials
Specialists
- bought-out parts suppliers
equipment specialists
equipment suppliers/designers
health & safety specialists
- logistics engineers
- maintenance personnel
- process engineers
- purchasing personnel
- quality engineers
- software specialists
- team leaders