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I. |
Production
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A. |
Diagnose production process problems and take corrective action to meet production quality standards.
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1. |
Communicate quality problems following the appropriate reporting process.
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a. |
Review quality problems with production operators.
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b. |
Communicate quality problems promptly to appropriate parties.
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c. |
Use established processes to document quality problems.
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d. |
Summarize defective trends and report them to appropriate parties.
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2. |
Suggest or perform corrective actions to correct quality problems.
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a. |
Make minor quality issues/adjustments immediately.
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b. |
Document quality issues or adjustments properly.
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c. |
Make sure that recommendations for action are clear, concise, and supported by data.
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d. |
Make recommendations in a timely way to appropriate parties.
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e. |
Document follow-up activities and indicate that corrective action was taken.
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f. |
Document product quality following corrective action.
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3. |
Determine appropriate action for sub-standard product.
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a. |
Execute quality control procedures to catch sub-standard products promptly within the defined quality systems.
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b. |
Document decisions regarding sub-standard products for future retrieval.
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c. |
Process sub-standard products according to company policy.
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d. |
Distribute documentation required for customers to appropriate parties.
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4. |
Identify trends using records of process outcomes.
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a. |
Maintain records on quality process to appropriate standards.
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b. |
Chart outcomes of quality processes according to appropriate methods and standards.
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c. |
Check data on quality processes for accuracy.
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d. |
Analyze quality process performance data to identify trends.
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e. |
Report quality process performance data to appropriate parties in a timely way.
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5. |
Implement closed-loop corrective action to provide for ongoing production feedback.
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a. |
Document evidence of corrective action in a timely manner.
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b. |
Report change resulting from the corrective action to appropriate parties in the correct format.
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c. |
Use spot checks to verify implementation of the corrective action.
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d. |
Store reports properly for the required amount of time.
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e. |
Perform ongoing audits to optimize the outcomes of the corrective actions.
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f. |
Examine previous documentation on similar process issues to identify possible solutions.
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6. |
Research energy consumption reduction in manufacturing.
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a. |
Conduct analyses to reduce pollution or costly energy consumption.
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b. |
Identify and recommend improvements to reduce waste and pollution for a given production process.
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B. |
Manage safe and healthy production working conditions and environmental risks.
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1. |
Perform environmental and safety inspections following local, federal, and company regulations.
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a. |
Identify, report, and monitor potential hazards in the workplace.
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b. |
Take corrective action to correct potential hazards.
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c. |
Review health, safety, and environmental documentation and policies thoroughly and regularly.
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d. |
Ensure that inspections meet all relevant health, safety, and environmental laws and regulations.
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e. |
Complete inspections according to company schedule and procedures.
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f. |
Document inspection records and store them correctly.
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2. |
Perform emergency drills as part of an emergency response team.
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a. |
Confirm that first aid training and certification on emergency and first aid procedures are complete and up-to-date.
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b. |
Comply with company and regulatory policies and procedures to respond to emergencies.
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c. |
Document emergency drills and incidents according to company and regulatory procedures promptly.
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3. |
Identify unsafe conditions according to safety standards.
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a. |
Identify, report, and document conditions presenting a threat to health, safety, and the environment.
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b. |
Identify corrective actions.
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4. |
Implement corrective actions to follow safety protocols.
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a. |
Consult appropriate parties about corrective actions and take corrective actions following company procedures promptly.
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b. |
Track and report ongoing safety concerns until corrective action is taken.
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5. |
Monitor daily housekeeping activities.
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a. |
Store tools and materials safely in proper locations.
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b. |
Keep workstations clean and clear of safety hazards.
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c. |
Verify that scheduled housekeeping inspections are passed.
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d. |
Verify that safety equipment is present and in proper working order.
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C. |
Make continuous improvement recommendations based on results of production process audits and inspections.
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1. |
Perform periodic internal quality audits using company audit procedures.
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a. |
Perform audits in accordance with company and other required schedules and procedures.
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b. |
Complete all audit forms correctly in a timely manner and forward to the correct parties.
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c. |
Verify that audit data is relevant and correct.
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d. |
Verify that conformances to quality standards are properly assessed and documented.
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e. |
Include observation of operations to ensure performances meet specifications when appropriate.
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2. |
Check calibration of gauges and other data collection equipment.
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a. |
Implement calibration schedule according to specifications.
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b. |
Make thorough careful observations and review documentation to check instrument certification.
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c. |
Recalibrate out-of-calibration instruments immediately or refer them to the appropriate parties for recalibration or repairs.
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3. |
Recommend process improvements based upon audits and inspections.
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a. |
Use observation and data analysis to generate potential improvements.
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b. |
Communicate suggestions that are measurable and have data-driven benefits to the company, its customers, and its employees.
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c. |
Use proper procedures and documentation to make suggestions.
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d. |
Assure that all data is reviewed prior to making suggestions.
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4. |
Inspect materials at all stages of process to determine quality or condition.
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a. |
Sample and inspect in accordance with the schedule and procedures.
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b. |
Select correct inspection tools and procedures and use them correctly.
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c. |
Inspect materials against correct specifications.
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d. |
Identify materials not meeting specifications.
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e. |
Take corrective action on out-of specification material.
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f. |
Document inspection results properly and report them to the correct parties in a timely manner.
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5. |
Document the results of quality testing using reliable data.
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a. |
Check data forms for completeness and accuracy.
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b. |
Evaluate and interpret information correctly.
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c. |
Forward data to correct parties.
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d. |
Select and use the appropriate analytical tools.
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6. |
Adjust processes to restore or maintain quality, based on data from audit or inspection reports.
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a. |
Identify appropriate correction actions and make sure that approvals are received when needed.
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b. |
Make adjustments to eliminate deviations and bring the process back into control.
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c. |
Make adjustments, and document them in a timely manner.
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D. |
Coordinate work teams when producing products to enhance production process and performance.
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1. |
Coordinate work teams when producing products to enhance production process and performance.
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a. |
Provide cross training as appropriate.
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b. |
Assess training needs on a regular basis.
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c. |
Identify new requirements and training issues.
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d. |
Use varied approaches to achieve training goals.
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e. |
Document training outcomes.
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2. |
Develop team goals to enhance performance.
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a. |
Make goals specific, measurable, and achievable.
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b. |
Align team goals to customer and business needs.
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c. |
Focus team goals to meet team objectives.
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d. |
Document team goals and share information with all parties.
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3. |
Make job assignments to avail the use of the best personnel in key assignments.
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a. |
Make job assignments to match the skills needed for the work to be done and to maximize the use of available skills.
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b. |
Make job assignments to ensure that business and customer needs are met.
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c. |
Confirm that workers are notified of assignments effectively.
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4. |
Coordinate work flow with team members and other work groups.
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a. |
Make sure that production schedules are met effectively.
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b. |
Notify team members of schedule requirements in a timely way.
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c. |
Make sure that production work flow runs efficiently.
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d. |
Take necessary action to minimize downtime.
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e. |
Explain the significance of relationships with others in facilitating work flow.
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f. |
Verify that workers actively participate in meetings and problem-solving groups.
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5. |
Communicate material specifications, production requirements, product specifications, and delivery issues in a timely and accurate manner.
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a. |
Initiate communication to meet product requirements, product specifications, or other customer or business needs cross-functionally as required.
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b. |
Evaluate, track, and report production and product issues to original communicator.
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c. |
Communicate delivery schedules clearly and address any issues.
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d. |
Track and document material specifications and delivery schedules.
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E. |
Demonstrate the safe use of manufacturing equipment.
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1. |
Train others to use equipment following safe production practices.
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a. |
Give new operators a complete orientation of equipment.
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b. |
Make sure that all important information regarding equipment safety is communicated clearly and effectively.
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c. |
Make sure that maintenance workers obtain certification to train others in technical skills and knowledge where applicable.
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d. |
Make suggestions regarding training materials and content to appropriate parties.
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e. |
Use evaluations and feedback to improve training materials and methods.
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f. |
Make sure trainees have the correct tools to do the job during training.
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g. |
Conduct post-training evaluation to assure that workers can operate equipment safely.
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h. |
Use training and facilitation techniques appropriate for the audience.
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i. |
Document the quality and effectiveness of training appropriately.
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2. |
Recommend processes and procedures to support safety and effectiveness in the work environment.
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a. |
Consult health and safety representatives to develop suggestions.
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b. |
Solicit operator feedback for use in creating a safer, more effective work environment.
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c. |
Make sure suggestions for training improvement are documented and sent to the appropriate parties.
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d. |
Make sure that content of suggestions addresses safety, quality, and productivity issues.
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3. |
Maintain, install, and repair equipment following required safety and health requirements.
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a. |
Make regular safety communications to all employees.
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b. |
Review job safety analyses regularly according to company policy.
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c. |
Follow hazardous materials procedures and policies such as Material Safety Data Sheet (MSDS) and "right to know" accurately.
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d. |
Perform environmental testing of workplace on a regular basis as required by company policy or regulation.
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e. |
Audit equipment to ensure there are no bypasses of safety guards.
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f. |
Verify that regulatory and company safety procedures are followed including lock-out/tag-out, confined space, and ergonomics.
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g. |
Follow good housekeeping procedures.
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h. |
Verify that safety and personal protective equipment (PPE) is available, performs correctly, and has current certification.
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4. |
Monitor equipment and operator according to workplace safety and compliance with both company and national regulations.
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a. |
Perform monitoring responsibilities regularly.
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b. |
Report out-of-compliance or unsafe conditions immediately.
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c. |
Take corrective action on out-of-compliance or unsafe conditions.
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d. |
Check equipment to ensure it is operating according to specifications.
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e. |
Check tools for compliance with specifications.
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f. |
Forward accident and injury data to appropriate personnel for inclusion in OSHA recordables.
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g. |
Gather information on equipment use from operators to reveal existing or potential problems.
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h. |
Adjust equipment and processes as required.
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i. |
Document all monitoring data accurately.
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5. |
Perform preventive maintenance and routine repair by contacting appropriate people and securing needed supplies.
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a. |
Verify that preventive maintenance schedule or equipment is in place and updated as appropriate.
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b. |
Verify that preventive maintenance is performed to schedule and documented in a timely manner.
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c. |
Verify that necessary repair work is checked through follow-up.
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