Lean manufacturing operative - Production Processing/Finishing

Relevant statutory, organisational and health and safety regulations relating to lean manufacturing operations and safe practices

Compliance procedures/systems in line with regulatory requirements e.g. ISO 14001 or other relevant environmental standards

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)

Manufacturing standard operation procedures (SOPs) adherence and development of lean processes

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

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

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

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

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

The correct methods of handling and storing the samples

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

How to identify which samples, products and materials do not meet the quality requirements

Procedures for the handling and segregation of defect components

Specific safe working practices and environmental regulations that need to be observed

The procedures and documentation required to allow the transfer of materials to take place

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

The procedures for the movement and transferring of materials to the correct location within given timelines

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

The lifting and handling procedures, and load bearing capacities of the equipment being used

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

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

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

The procedure for the recovery or restart of manufacturing due to quality or process concern

The importance of following the pre-determined sequence of events in the processing/finishing operation and the consequences of not following them

The importance of following the specified assembly sequence and procedure at all times

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

The procedure for positioning, aligning and securing component parts during the assembly operations

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

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

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)

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

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

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

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

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

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)

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

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

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

Collect production samples at the required frequency in accordance with inspection specification and operating procedures

Carryout inspection and testing activities using the specified methods and equipment

Prepare, Handle, transfer and store samples safely and correctly in accordance with quality control procedures

Accurately interpret the data/results gained from the inspection and testing procedures being used

Record and report inspection findings to relevant person

Safely move materials to the correct location using the relevant equipment

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

Move materials using the appropriate procedures, ensuring the materials are correct, safely loaded and secure.

Check materials selected to be moved are in line with job requirements

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

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

Carryout quality checks on component parts and completed assemblies and deal with quality concerns and defects in line with their responsibility

Perform one processing/finishing operation method e.g. hand processing, manually operated machine processing, fully automated machine processing, combined processing

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

Perform the processing/finishing operation according to instructions and safe operating procedures

Monitor and control the processing/finishing operation

Carryout quality checks on component parts and completed assemblies and deal with quality concerns and defects in line with their responsibility

Produce processed/finished products which comply with processing specification

Check components for damage and that they are in a usable condition

Correctly position, align and secure the components

Secure the components in position using the specified fastening device/method

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

Produce components which comply with the specification and quality requirements

Punctual, reliable and takes responsibility for their own actions.

Show respect for others, having regard for diversity and equality.

Respond positively to change in the working environment.

Integrates within the team and supports others.

Can work independently and effectively in challenging situations.

Maintains quality of work under pressure.

An open and honest communicator.

Listens to other people’s opinions.

A positive and respectful attitude.

Follows instructions and guidance and demonstrates attention to detail.

Seeks opportunities to develop and adapt to different situations, environments or technologies.