PROCESS INSPECTION NC III – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR PROCESS INSPECTION NC III

The TESDA Course in PROCESS INSPECTION NC III consists of competencies that a person must achieve to apply quality systems, conduct product and or process capability studies and maintain and supervise the application of quality procedures. These units cover improving the quality system, and collecting and summarizing data to support the quality improvement process. The data would be used to produce statistical information such as averages and ranges, and charts such as tally, run or control charts.

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

• Process Inspection Leader

PROCESS INSPECTION NC III – TRAINING AND REGULATION MODULE

Course Title: PROCESS INSPECTION
Level: NC III
Nominal Training Duration : 85 Hours

This course is designed to equip individual with competency to apply quality systems, conduct product and or process capability studies and maintain and supervise the application of quality procedures. These units cover improving the quality system, and collecting and summarizing data to support the quality improvement process.

Basic competencies such as: Lead workplace communication; Lead small teams; Develop and practice negotiation skills; Solve problems related to work activities; Use mathematical concepts and techniques and Use relevant technologies are included.

It also includes common competencies such as: Read, Interpret and Apply Engineering Drawings; Perform Mensuration and Calculation Read; Interpret and Apply Specifications and Manuals and; Perform Shop Maintenance

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.

• Ability to communicate both orally and in writing;
• Physically and mentally fit; and
• Must possess the Process Inspection National Certificate (NC) II

COMPETENCIES REQUIRED IN PROCESS INSPECTION NC III

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

To obtain this TESDA Course in PROCESS INSPECTION NC III, all units prescribed below for this qualification must be achieved.

These units of competency comprising this qualification include the following:

UNIT CODE	CORE COMPETENCIES (45 hours)
ALT315308	Apply quality systems
ALT315309	Conduct product and/or process capability studies
ALT315310	Maintain/supervise the application of quality procedures
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 (20 hours)
500311109	Lead Workplace Communication
500311110	Lead Small Teams
500311111	Develop and Practice Negotiation skills
500311112	Solve Problems Related to Work Activities
500311113	Use Mathematical Concepts and Techniques
500311114	Use Relevant Technologies

CORE COMPETENCIES

This section gives the details of the contents of the core units of competency required in PROCESS INSPECTION NC III

UNIT OF COMPETENCY : APPLY QUALITY SYSTEMS
UNIT CODE : ALT315308

This unit covers working within a quality improvement system, either individually or in a team situation.

1. Work within a quality system
   • Instructions and procedures are followed and duties are performed in accordance with requirements of quality improvement system.
   • Conformance to specifications is ensured.
   • Defects are detected and reported according to standard operating procedures.
   • Performance of operation or quality of product or service is monitored to ensure customer satisfaction.
2. Engage in quality improvement
   • Current performance is assessed.
   • Established performance measures are identified.
   • Specifications and standard operating procedures are identified.
   • Defects are detected and reported according to standard operating procedures.
   • Process improvement procedures are participated in.
   • The improvement of internal/external customer/supplier relationships is participated in.
   • Performance of operation or quality of product or service is monitored to ensure customer satisfaction.

UNIT OF COMPETENCY: CONDUCT PRODUCT AND/OR PROCESS CAPABILITY STUDIES
UNIT CODE : ALT315309

This unit covers conducting process capability studies, setting control limits and selecting sampling plans.

1. Conduct process capability studies
   • Procedure for conducting capability study is determined.
   • Instructions for personnel conducting trial run are prepared.
   • Data from trial run is analyzed and the process capability is calculated.
   • Possible number of product defects from a particular process is estimated.
   • Optimum target mean to suit process capability data is determined.
   • Reports listing of various options from process capability studies are prepared.
   • Design specifications based on an analysis of data are recommended.
2. Set control limits
   • Control limits for sample/subgroup average, range and standard deviation are calculated.
   • Warning limits for subgroup average, range and standard deviation are calculated.
   • Course of action resulting from out of control situation is determined and documented according to standard operating procedures.
3. Select sampling plans
   • Appropriate sampling plan to suit production schedule is selected and acceptable quality limits are determined, taking into account specified producer and consumer risks.
   • Sampling plan is documented including implementation strategy.

UNIT OF COMPETENCY : MAINTAIN / SUPERVISE THE APPLICATION OF QUALITY PROCEDURES
UNIT CODE : ALT315310

This unit covers improving the quality system, and collecting and summarizing data to support the quality improvement process. The data would be used to produce statistical information such as averages and ranges, and charts such as tally, run or control charts.

1. Improve quality system
   • Specifications to meet customer needs (internal and external) are interpreted.
   • Leadership role as a supplier is undertaken to ensure quality within the supply chain.
2. Collect and summarize data
   • Data is recorded and interpreted accurately in accordance with standard operating procedures.
   • Data is used to produce relevant statistical information, for example, average and range or the production of charts such as tally, run or control charts.

COMMON COMPETENCIES (AUTOMOTIVE MANUFACTURING-PARTS MANUFACTURING)

UNIT TITLE: 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 : ALT723204

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

The BASIC COMPETENCIES refer to non-technical skills (knowledge, skills and attitudes) that everybody will need in order to perform satisfactorily at work and in society and are considered portable and transferable irrespective of jobs and industrial settings.

UNIT OF COMPETENCY : LEAD WORKPLACE COMMUNICATION
UNIT CODE : 500311109

This unit covers the knowledge, skills and attitudes required to lead in the dissemination and discussion of ideas, information and issues in the workplace.

1. Communicate information about workplace processes
   • Appropriate communication method is selected
   • Multiple operations involving several topics areas are communicated accordingly
   • Questions are used to gain extra information
   • Correct sources of information are identified
   • Information is selected and organized correctly
   • Verbal and written reporting is undertaken when required
   • Communication skills are maintained in all situations
2. Lead workplace discussions
   • Response to workplace issues are sought
   • Response to workplace issues are provided immediately
   • Constructive contributions are made to workplace discussions on such issues as production, quality and safety
   • Goals/objectives and action plan undertaken in the workplace are communicated
3. Identify and communicate issues arising in the workplace
   • Issues and problems are identified as they arise
   • Information regarding problems and issues are organized coherently to ensure clear and effective communication
   • Dialogue is initiated with appropriate personnel
   • Communication problems and issues are raised as they arise

UNIT OF COMPETENCY : LEAD SMALL TEAMS
UNIT CODE : 500311110

This unit covers the knowledge, skills and attitudes to lead small teams including setting and maintaining team and individual performance standards.

1. Provide team leadership
   • Work requirements are identified and presented to team members
   • Reasons for instructions and requirements are communicated to team members
   • Team members’ queries and concerns are recognized, discussed and dealt with
2. Assign responsibilities
   • Duties, and responsibilities are allocated having regard to the skills, knowledge and aptitude required to properly undertake the assigned task and according to company policy
   • Duties are allocated having regard to individual preference, domestic and personal considerations, whenever possible
3. Set performance expectations for team members
   • Performance expectations are established based on client needs and according to assignment requirements
   • Performance expectations are based on individual team members duties and area of responsibility
   • Performance expectations are discussed and disseminated to individual team members
4. Supervised team performance
   • Monitoring of performance takes place against defined performance criteria and/or assignment instructions and corrective action taken if required
   • Team members are provided with feedback, positive support and advice on strategies to overcome any deficiencies
   • Performance issues which cannot be rectified or addressed within the team are referenced to appropriate personnel according to employer policy
   • Team members are kept informed of any changes in the priority allocated to assignments or tasks which might impact on client/customer needs and satisfaction
   • Team operations are monitored to ensure that employer/client needs and requirements are met
   • Follow-up communication is provided on all issues affecting the team
   • All relevant documentation is completed in accordance with company procedures

UNIT OF COMPETENCY : DEVELOP AND PRACTICE NEGOTIATION SKILLS
UNIT CODE : 500311111

This unit covers the skills, knowledge and attitudes required to collect information in order to negotiate to a desired outcome and participate in the negotiation.

1. Plan negotiations
   • Information on preparing for negotiation is identified and included in the plan
   • Information on creating non verbal environments for positive negotiating is identified and included in the plan
   • Information on active listening is identified and included in the plan
   • Information on different questioning techniques is identified and included in the plan
   • Information is checked to ensure it is correct and up-to- date
2. Participate in negotiations
   • Criteria for successful outcome are agreed upon by all parties
   • Desired outcome of all parties are considered
   • Appropriate language is used throughout the negotiation
   • A variety of questioning techniques are used
   • The issues and processes are documented and agreed upon by all parties
   • Possible solutions are discussed and their viability assessed
   • Areas for agreement are confirmed and recorded
   • Follow-up action is agreed upon by all parties

UNIT OF COMPETENCY : SOLVE PROBLEMS RELATED TO WORK ACTIVITIES
UNIT CODE : 500311112

This unit of covers the knowledge, skills and attitudes required to solve problems in the workplace including the application of problem solving techniques and to determine and resolve the root cause of problems.

1. Identify the problem
   • Variances are identified from normal operating parameters; and product quality
   • Extent, cause and nature are of the problem are defined through observation, investigation and analytical techniques
   • Problems are clearly stated and specified
2. Determine fundamental causes of the problem
   • Possible causes are identified based on experience and the use of problem solving tools / analytical techniques.
   • Possible cause statements are developed based on findings
   • Fundamental causes are identified per results of investigation conducted
3. Determine corrective action
   • All possible options are considered for resolution of the problem
   • Strengths and weaknesses of possible options are considered
   • Corrective actions are determined to resolve the problem and possible future causes
   • Action plans are developed identifying measurable objectives, resource needs and timelines in accordance with safety and operating procedures
4. Provide recommendation/s to manager
   • Report on recommendations are prepared
   • Recommendations are presented to appropriate personnel.
   • Recommendations are followed-up, if required

UNIT OF COMPETENCY : USE MATHEMATICAL CONCEPTS AND TECHNIQUES
UNIT CODE : 500311113

This unit covers the knowledge, skills and attitudes required in the application of mathematical concepts and techniques.

1. Identify mathematical tools and techniques to solve problem
   • Problem areas are identified based on given condition
   • Mathematical techniques are selected based on the given problem
2. Apply mathematical procedure/solution
   • Mathematical techniques are applied based on the problem identified
   • Mathematical computations are performed to the level of accuracy required for the problem
   • Results of mathematical computation is determined and verified based on job requirements
3. Analyze results
   • Result of application is reviewed based on expected and required specifications and outcome
   • Appropriate action is applied in case of error

UNIT OF COMPETENCY : USE RELEVANT TECHNOLOGIES
UNIT CODE : 500311114

This unit of competency covers the knowledge, skills, and attitude required in selecting, sourcing and applying appropriate and affordable technologies in the workplace.

1. Study/select appropriate technology
   • Usage of different technologies is determined based on job requirements
   • Appropriate technology is selected as per work specification
2. Apply relevant technology
   • Relevant technology is effectively used in carrying out function
   • Applicable software and hardware are used as per task requirement
   • Management concepts are observed and practiced as per established industry practices
3. Maintain/enhance relevant technology
   • Maintenance of technology is applied in accordance with the industry standard operating procedure, manufacturer’s operating guidelines and occupational health and safety procedure to ensure its operative ability
   • Updating of technology is maintained through continuing education or training in accordance with job requirement
   • Technology failure/ defect is immediately reported to the concern/responsible person or section for appropriate action

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.