PROCESS INSPECTION NC II – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR PROCESS INSPECTION NC II

The TESDA Course in PROCESS INSPECTION NC II consists of competencies that a person must achieve to perform standard quality inspection of processes in different manufacturing processes in the assembly, foundry, metal and plastic sectors. Most often, inspection involves working autonomously and taking responsibility for overseeing inspection process and environment. Inspection may involve ‘first piece inspection’, fixed interval, sample etc. Depending on the inspection process, other technical units may need to be accessed.

This person would use a wide range of equipment/instruments and take responsibility for the reliability of inspection results to ensure conformance with specifications. He can perform any work within a quality improvement system in a manufacturing, engineering or related environment.

The person can process the data he gathered, collating and interpreting statistical data in the context of statistical quality control, for example, tally, run or control charts. Uncontrolled variations are reported to appropriate authority. He is expected to identify improvements and/or solve problems, implement/monitor the implementation of an improvement strategy, and evaluate the improvement.

A student who has achieved this TESDA Course in PROCESS INSPECTION NC II is competent to be:

• Process Inspector
• QA/QC Inspector

PROCESS INSPECTION NC II – TRAINING AND REGULATION MODULE

Course Title: PROCESS INSPECTION
Level: NC II
Nominal Training Duration : 98 Hours

This course is designed to equip individual with competency to perform inspection of process in various manufacturing fields such as assembly, stamping, machining, foundry and others in the metal and plastic sector.

It also includes competencies on interpreting specifications, drawings, technical sketches and/or customer requirements. Tasks undertaken would also include utilizing appropriate inspection techniques; designated procedures, correct and appropriate tools and equipment for measurement of parameters; sets up and operates variety of specialized precision measuring instrument in operating.

This course is also designed to provide basic and common skills to equip individual with operational skills in process inspection.

TRAINEE ENTRY REQUIREMENTS

This section specifies the qualifications of trainees and educational experience. Other requirements like health and physical requirements are also stated. Passing entry written examinations may also be indicated if necessary.

• Preferably with background in basic machining
• With good moral character;
• Ability to communicate both orally and in writing; and
• Physically and mentally fit

COMPETENCIES REQUIRED IN PROCESS INSPECTION NC II

This units of competency comprising this qualification include Basic, Common, Elective and Core Competencies.

To obtain this TESDA course in PROCESS INSPECTION NC II, all units prescribed for this qualification must be achieved.

These units of competency comprising this qualification include the following:

UNIT CODE	CORE COMPETENCIES (60 Hours)
ALT315301	Select and Control Inspection Processes and Procedures
ALT315302	Perform Inspection
ALT315303	Perform Basic Statistical Quality Control
ALT315304	Use Improvement Processes in Team Activities
UNIT CODE	COMMON COMPETENCIES (20 Hours)
ALT742201	Read & Interpret Engineering Drawings
ALT311202	Perform Mensuration and Calculation
ALT723203	Read, Interpret and Apply Specifications and Manuals
ALT723205	Perform Shop Maintenance
UNIT CODE	BASIC COMPETENCIES (18 Hours)
500311105	Participate in workplace communication
500311106	Work in a team environment
500311107	Practice career professionalism
500311108	Practice occupational health and safety procedures

CORE COMPETENCIES

UNIT OF COMPETENCY : SELECT AND CONTROL INSPECTION PROCESSES AND PROCEDURES
UNIT CODE : ALT315301

This unit covers selecting inspection and test procedures, and controlling the inspection/test environment and equipment.

1. Select inspection/test procedures
   • Appropriate methods of inspection are selected and implemented.
   • Inspection/test procedures are monitored to ensure desired outcomes.
2. Control inspection/test environment and equipment
   • Environmental conditions are monitored to ensure reliability of tests and results.
   • Equipment/instruments are checked for correct calibration.
   • Calibration of equipment/instruments is initiated or undertaken against appropriate standard as required.
   • Calibration records are maintained to standard operating procedure.
   • If equipment/instruments are found to be out of calibration, validity of previous results is checked and reported according to standard operating procedures.

UNIT OF COMPETENCY : PERFORM PRODUCTS INSPECTION
UNIT CODE : ALT315302

This unit covers inspecting products, keeping records and providing feedback on the conformance of product to specifications.

1. Inspect products
   • Sample products are gathered as per company standard operating procedures for inspection
   • Products are tested for conformance to specifications in accordance with standard operating procedures
2. Keep records
   • Test status identification is made on conforming and nonconforming products and records are accurately kept using standard operating procedures.
   • Inspection sheets are completely filled-out as per company standard operating procedures
3. Provide feedback
   • Products are tested/inspected/measured after rework or repair.
   • Deficiencies or deviations are reported according to standard operating procedures.

UNIT OF COMPETENCY: PERFORM BASIC STATISTICAL QUALITY CONTROL
UNIT CODE : ALT315303

This unit covers taking samples and applying a statistical process to monitor production.

1. Take samples
   • Difference between population and sample is understood and various sampling schemes are applied in accordance with standard operating procedures.
   • Samples are taken on control-state to verify the effectiveness of countermeasures
2. Apply statistical process to monitor production
   • Concept of variation in terms of average and spread is understood. Data is used to produce relevant statistical information.
   • Data is interpreted accurately and information is presented to appropriate authority according to standard operating procedures

UNIT OF COMPETENCY : USE IMPROVEMENT PROCESSES IN TEAM ACTIVITIES
UNIT CODE : ALT315304

This unit covers identifying improvements and/or solving problems, implementing/monitoring the implementation of an improvement strategy, and evaluating the improvement.

1. Identify areas for improvement and/or solve problems
   • Participation in team is used to select improvement tools and methods appropriate to the situation.
   • Teamwork is used to process improvement tools to identify improvements and/or solve problems.
2. Contribute to improvement strategy
   • Teamwork is used to implement improvement strategies as required in accordance with standard operating procedures.
   • In conjunction with work team, further action is recommended as required using standard operating procedures.
3. Monitor implementation of improvement
   • Performance is monitored for change, utilizing feedback data.
   • Analytical tools are used to monitor improvement as required.
   • In conjunction with work team, further action is recommended where required using standard operating procedures.

COMMON COMPETENCIES (AUTOMOTIVE MANUFACTURING-PARTS MANUFACTURING)

UNIT OF COMPETENCY : READ, INTERPRET AND APPLY ENGINEERING DRAWINGS.
UNIT CODE : ALT742201

This unit deals with identifying, interpreting and applying specification from Engineering blue prints or drawings that provides the measurements of the product and pattern that is to be produced.

1. Identify and access engineering drawings/specification
   • Appropriate Engineering drawings are identified and accessed as per job requirements.
   • Version and date of drawing is checked to ensure correct specification and procedure are identified.
2. Interpret drawings
   • Relevant dimensions and sections of the drawings/specifications are located in relation to the work to be conducted
   • Information in the manual are interpreted in accordance to industry practices
3. Apply information in the drawings & specifications
   • Engineering drawing is interpreted according to job requirements
   • Work steps are correctly identified in accordance with the specifications in the drawings.
   • Dimensional data and shape are applied according to the given task
4. Store drawings
   • The drawings and specification are stored properly to ensure prevention of damage, ready access and updating of information when required in accordance with company requirements

UNIT OF COMPETENCY : PERFORM MENSURATION AND CALCULATION
UNIT CODE : ALT311202

This unit includes identifying, caring for, handling, using and maintaining measuring instruments.

1. Select measuring instruments
   • Object or component to be measured is identified
   • Correct specifications are obtained from relevant source
   • Appropriate measuring instrument is selected according to job requirements
2. Carry out measurements and calculation
   • Measuring tools are selected in line with job requirements
   • Accurate measurements are obtained to job
   • Calculation needed to complete work tasks are performed using the four basic process of addition (+), subtraction (-), multiplication (x) and division (/).
   • Calculations involving fractions, percentages and mixed numbers are used to complete workplace tasks.
   • Numerical computation is self-checked and corrected for accuracy
   • Instruments are read to the limit of accuracy of the tool.
3. Maintain measuring instruments
   • Measuring instruments are kept free from corrosion
   • Measuring instruments are not dropped to avoid damage
   • Measuring instruments are cleaned before and after using.

UNIT OF COMPETENCY : READ, INTERPRET AND APPLY SPECIFICATION AND MANUALS.
UNIT CODE : ALT723203

This unit deals with identifying, interpreting and applying service specification manuals, maintenance procedure manuals and periodic maintenance manual.

1. Identify and access manual/specification
   • Appropriate manuals are identified and accessed as per job requirements.
   • Version and date of manual is checked to ensure correct specification and procedure are identified.
2. Interpret manuals
   • Relevant sections, chapters of manuals/specifications are located in relations to the work to be conducted
   • Information and procedure in the manual are interpreted in accordance to industry practices
3. Apply information in manual
   • Manual is interpreted according to job requirements
   • Work steps are correctly identified in accordance with manufacturer specification
   • Manual data is applied according to the given task
   • All correct sequencing and adjustments are interpreted in accordance with information contained on the manual or specifications
4. Store manuals
   • Manual or specification are stored appropriately to ensure prevention of damage, ready access and updating of information when required in accordance with company requirements

UNIT OF COMPETENCY : PERFORM SHOP MAINTENANCE
UNIT CODE : ALT723205

This unit deals with inspecting and cleaning of work area including tools, equipment and facilities. Storage and checking of tools/ equipment and disposal of used supplies/materials are also incorporated in this competency.

1. Inspect/clean tools and work area
   • Cleaning solvent used as per workshop/tools cleaning requirement
   • Work area is checked and cleaned
   • Wet surface/spot in work area is wiped and dried
2. Store/arrange tools and shop equipment
   • Tools/equipment are checked and stored in their respective shelves/location
   • Corresponding labels are posted and visible
   • Tools are safely secured and logged in the records
3. Dispose wastes/used lubricants
   • Containers for used lubricants are visibly labeled
   • Wastes/used lubricants are disposed as per workshop SOP
4. Report damaged tools/equipment
   • Complete inventory of tools/equipment is maintained
   • Damaged tools/equipment/facilities are identified and repair recommendation is given
   • Reports prepared has no error/discrepancy

BASIC COMPETENCIES

UNIT OF COMPETENCY : PARTICIPATE IN WORKPLACE COMMUNICATION
UNIT CODE : 500311105

This unit covers the knowledge, skills and attitudes required to gather, interpret and convey information in response to workplace requirements.

1. Obtain and convey workplace information
   • Specific and relevant information is accessed from appropriate sources
   • Effective questioning, active listening and speaking skills are used together and convey information
   • Appropriate medium is used to transfer information and ideas
   • Appropriate non- verbal communication is used
   • Appropriate lines of communication with supervisors and colleagues are identified and followed
   • Defined workplace procedures for the location and storage of information are used
   • Personal interaction is carried out clearly and concisely
2. Participate in workplace meetings and discussions
   • Team meetings are at ended on time
   • Own opinions are clear expressed and those of others are listened to without interruption
   • Meeting inputs are consistent with the meeting purpose and established protocols
   • Workplace interactions are conducted in a courteous manner
   • Questions about simple routine workplace procedures and matters concerning working conditions of employment are asked and responded to.
   • Meetings outcomes are interpreted and implemented
3. Complete relevant work related documents
   • Range of forms relating to conditions of employment are completed accurately and legibly
   • Workplace data is recorded on standard workplace forms and documents
   • Basic mathematical processes are used for routine calculations
   • Errors in recording information on forms/documents are identified and properly acted upon
   • Reporting requirements to supervisor are completed according to organizational guidelines

UNIT OF COMPETENCY : WORK IN TEAM ENVIRONMENT
UNIT CODE : 500311106

This unit covers the skills, knowledge and attitudes to identify role and responsibility as a member of a team.

1. Describe team role and scope
   • The role and objective of the team is identified from available sources of information
   • Team parameters, reporting relationships and responsibilities are identified from team discussions and appropriate external sources.
2. Identify own role and responsibility within team
   • Individual role and responsibilities within the team environment are identified.
   • Roles and responsibility of other team members are identified and recognized.
   • Reporting relationships within team and external to team are identified.
3. Work as a team member
   • Effective and appropriate forms of communications used and interactions undertaken with team members who contribute to known team activities and objectives.
   • Effective and appropriate contributions made to complement team activities and objectives, based on individual skills and competencies and workplace context.
   • Observed protocols in reporting using standard operating procedures.
   • Contribute to the development of team work plans based on an understanding of team’s role and objectives and individual competencies of the members.

UNIT OF COMPETENCY : PRACTICE CAREER PROFESSIONALISM
UNIT CODE : 500311107

This unit covers the knowledge, skills and attitudes in promoting career growth and advancement.

1. Integrate personal objectives with organizational goals
   • Personal growth and work plans are pursued towards improving the qualifications set for the profession
   • Intra- and interpersonal relationships is are maintained in the course of managing oneself based on performance evaluation
   • Commitment to the organization and its goal is demonstrated in the performance of duties
2. Set and meet work priorities
   • Competing demands are prioritized to achieve personal, team and organizational goals and objectives.
   • Resources are utilized efficiently and effectively to manage work priorities and commitments
   • Practices along economic use and maintenance of equipment and facilities are followed as per established procedures
3. Maintain professional growth and development
   • Trainings and career opportunities are identified and availed of based on job requirements
   • Recognitions are sought/received and demonstrated as proof of career advancement
   • Licenses and/or certifications relevant to job and career are obtained and renewed

UNIT OF COMPETENCY : DEVELOP CAREER AND LIFE DECISIONSUNIT OF COMPETENCY : PRACTICE  OCCUPATIONAL HEALTH AND SAFETY PROCEDURES
UNIT CODE : 500311108

This unit covers the outcomes required to comply with regulatory and organizational requirements for occupational health and safety.

1. Identify hazards and risks
   • Safety regulations and workplace safety and hazard control practices and procedures are clarified and explained based on organization procedures
   • Hazards/risks in the workplace and their corresponding indicators are identified to minimize or eliminate risk to co-workers, workplace and environment in accordance with organization procedures
   • Contingency measures during workplace accidents, fire and other emergencies are recognized and established in accordance with organization procedures
2. Evaluate hazards and risks
   • Terms of maximum tolerable limits which when exceeded will result in harm or damage are identified based on threshold limit values (TLV)
   • Effects of the hazards are determined
   • OHS issues and/or concerns and identified safety hazards are reported to designated personnel in accordance with workplace requirements and relevant workplace OHS legislation
3. Control hazards and risks
   • Occupational Health and Safety (OHS) procedures for controlling hazards/risks in workplace are consistently
     followed
   • Procedures for dealing with workplace accidents, fire and emergencies are followed in accordance with organization OHS policies
   • Personal protective equipment (PPE) is correctly used in accordance with organization OHS procedures and practices
   • Appropriate assistance is provided in the event of a workplace emergency in accordance with established organization protocol
4. Maintain OHS awareness
   • Emergency-related drills and trainings are participated in as per established organization guidelines and procedures
   • OHS personal records are completed and updated in accordance with workplace requirements

DEFINITION OF TERMS

• Bore gauge – Bore gauge is a measuring tool used for measuring the internal diameter of a cylindrical tube.
• Data – Data is the information collected about a product, service, process, person or machine.
• Domain – Domain is the set of possible values specified for a given mathematical function.
• Flashing – Flashing is a defect where resin flow out to the parting line of the mold and adheres to the part of the product, especially commonly seen in old mold.
• Flowchart – Flowchart is a pictorial summary of the flows and decisions that comprise a process. It is used for defining and documenting the process.
• Gantt chart – Gantt chart is a scheduling chart in which horizontal lines show the actual and projected amounts of time involved in completing a particular task or reaching specific levels of production it is is a bar chart that plots tasks and subtask against time.
• Histogram – Histogram is a statistical graph of frequency distribution in which vertical rectangles of different heights are proportionate to corresponding frequencies.
• Ishikawa diagram – Ishikawa diagram is a tool used to organize the possible causes of a problem, select the most probable cause, and verify the cause and effect relationship between the most probable cause and the problem under study.
• Jetting – Jetting or sometimes called flow marks is a defect that shows visible marks of movement as the materials enter the mold.
• Mean – Mean is a numerical representation of the arithmetic average it is the sum of the numerical values of the measurement divided by the number of items examined.
• Median – Median is the middle value when the data are arranged in ascending order. When there are an even number of observations, the median value is the arithmetic average of the middle two values.
• Mode – Mode of a distribution is the value that occurs most frequently, or the value corresponding to the highest point on a frequency polygon or histogram.
• Pareto analysis – Pareto analysis is the tool of analysis using the concept that focuses attention on the vital few against the trivial many.
• Process – Process is a collection of interacting components that transform inputs into outputs toward a common aim.
• Short shot – Short shot is a defect that occurs when the resin cools and solidifies before the material fills the mold completely.
• Shrinkage – Shrinkage is a defect that forms a cavity in a casting caused by insufficient amount of metal during solidification
• The range – The range is the simplest measure of dispersion; for raw data from an enumerative or an analytic study, it is defined as the difference between the largest data point and the smallest.
• Tolerance – Tolerance is the allowable variance from a nominal value established by design engineers that is deemed non harmful to the functioning of the product.