Milling Technician - · PDF fileThis program is aimed at training candidates for the job of a “Milling Technician ... Assist the grain miller and supervisor in milling all types

Milling Technician

Model Curriculum

Milling Technician

SECTOR: SUB-SECTOR: OCCUPATION:

REF ID: NSQF LEVEL:

FOOD PROCESSING FOOD GRAIN MILLING PROCESSING FIC/Q1002, V1.0 5

Milling Technician

Milling Technician

TABLE OF CONTENTS

1. Curriculum 01

2. Trainer Prerequisites 09

3. Annexure: Assessment Criteria 10

Milling Technician

Milling Technician CURRICULUM / SYLLABUS

This program is aimed at training candidates for the job of a “Milling Technician”, in the “Food Processing” Sector/Industry and aims at building the following key competencies amongst the learner

Program Name Milling Technician

Qualification Pack Name & Reference ID. ID

FIC/Q1002, v1.0

Version No. 1.0 Version Update Date 15/01/2016

Pre-requisites to Training

Preferably Class 12 and 5-6 years’ experience in Milling

Training Outcomes The programme will help in building the following key competencies amongst the learner:

Assist the grain miller and supervisor in milling all types of grains

Handle various milling machineries while maintaining process parameters;

Inspect raw materials and finished goods for quality and quantity;

Observe food safety and hygiene standards at work;

Prepare and maintain work area and process machineries.

Milling Technician

This course encompasses 5 out of 5 National Occupational Standards (NOS) of “Milling Technician”

Qualification Pack FIC/Q1002, Version 1.0 issued by Food Industry Capacity and Skill Initiative”.

Sr. No.

Module Key Learning Outcomes Equipment Required

1 Introduction to the training program Theory Duration (hh:mm) 01:00 Practical Duration (hh:mm) 00:00 Corresponding NOS Code Bridge Module

Introduce each other and build rapport with fellow participants and the trainer.

White board/Chart papers, marker

2 Overview of the “Milling Technician” Role Theory Duration (hh:mm) 01:00 Practical Duration (hh:mm) 00:00 Corresponding NOS Code

Understanding the roles and responsibilities of milling technician

Awareness of the nature and availability of job opportunities

Laptop/computer white board, marker, projector, chart papers

3. Introduction to the Food Processing Industry Theory Duration (hh:mm) 01:30 Practical Duration (hh:mm) 00:00

Corresponding NOS Code

Define food processing

List the various sub-sectors in food processing industry

Laptop/computer white board, marker, projector, chart papers, Trainer’s Guide, Student handbook

4. Introduction to Food Grain Milling Sector

State the need for food grain milling process

State the common methods of milling food grains

Laptop, white/black board, marker, chart

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Theory Duration (hh:mm) 05:00 Practical Duration (hh:mm) 00:00


State the process of milling various types of grains

List the terminology used in milling process

papers, projector, trainer’s guide, student handbook, pictures/charts of different types of pulse milling

5. Organizational standards and norms Theory Duration (hh:mm) 11:00 Practical Duration (hh:mm) 05:00 Corresponding NOS Code

State the roles and responsibilities of pulse processing technician in a commercial grain milling unit

State how to conduct yourself at the workplace

State the personal hygiene and sanitation guidelines

State the food safety and hygiene standards to follow in an organization

Describe the organisation standards, process standards and procedures followed

Describe the provision of wages, working hours and accident compensation as per organisation policy

Describe the internal processes like procurement, store management, inventory management, quality management and key contact points for query resolution

Dispose waste materials as per organisation standards

State the code of business conduct

Describe the dress code to be followed

Explain the types of products produced by the organisation

Laptop, white board, marker, chart papers, projector, trainer’s guide and student handbook, protective gloves, head caps, aprons, safety goggles, safety boots, mouth masks, sanitizer, safety manual

6. Prepare and Maintain Work Area and Process Machineries Theory Duration (hh:mm) 04:00 Practical Duration (hh:mm) 08:00 Corresponding NOS Code FIC/N1004

• Identify the machines and tools required for the milling process

• Select and set the machines and tools required for production

• Demonstrate the use of different tools and machineries used in the milling process

• List the types of raw materials (various pulses) and products obtained from each raw material

• List the types of chemicals, materials and equipment required for cleaning and maintenance

• Explain the supplier / manufacturer’s instructions related to cleaning and maintenance

• Assess the working and performance of all machineries and tools used for the food grain milling process

• Attend to the minor repairs/ faults of all machines, if required

Laptop, white board, marker, chart papers, projector, trainer’s guide and student handbook, authorized sanitizers, cleansers, all equipments for demonstration

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• Ensure that work area is safe and hygienic for food processing

• Keep the work area free from debris • Maintain the cleanliness of the work area ensure

that it is free from pests • Place the necessary tools required for process • Explain cleaning the machineries and tools

used with recommended sanitizers following the company specifications and standards

• Describe the cleaning process to disinfect equipment/ tools

• Clean the work area using recommended sanitizers

• Explain the method of using the ERP system • Entering details in the ERP system followed by

the organisation

7. Providing Assistance in Milling Grains Theory Duration (hh:mm) 06:00 Practical Duration (hh:mm) 18:00 Corresponding NOS Code FIC/N1004 FIC/N1005 FIC/N1006 FIC/N9001

• Revise raw materials and products • State the types of machineries used in

processing and machineries used in the organisation

• Describe the milling machines flow process • Define the basics of conveyance • Describe the pre-cleaning process of the grains • Describe the process to clean and prepare work

area and milling machineries; • Clean the machines with the recommended

sanitizer, as per company standards;

• Organize and place the required tools accessible while milling and place them in the designated area after milling;

• Set-up the machine parameters in the machineries for production;

• Change screens/sieves in the machine for adjusting the size of the milled products.

• Describe the production process and process parameters for various products;

• Load the raw materials in various machines; • Explain the conditioning science; • Move semiprocessed raw material from one

machine area to the other until the milling process is completed;

• Adjust the machine process parameters while changeover of raw materials for milling different grains;

• Remove machine rejects from the machine and dispose them in the designated area as per company standards;

• Move finished products to the designated area for cooling and packaging.

• State the types and category of packaging materials, packaging machineries;

• Move packaging materials from warehouse/storage area to packaging area;

SOP, Sieve/sorters; White/Black board/ Chart paper, Markers/ computer and projector, Trainer Guide, Student Handbook, Different types of pulses, work flow diagram/chart, SOP, spatulas, packing wrap rolls, measuring cup and spoons, utensils, digital hygrometer, Measurement Cane Cleaner/grader; Conditioning machine; De-husk machine; Splitter machine; Drier; Packaging machine; Grinding machine; Sifter, Bran separator machine, polishing machine, multicrop decorticator, protective gloves, head caps, aprons, safety shoes, mouth cover, safety

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• Set the labelling machine/date coding machine as instructed;

• Explain packing the finished product; • Evaluate the weight of the finished product; • Describe how to label/date code the packed

product;

• Move the finished goods to the storage area; • State the method to return the excess packaging

materials to store;

• Clean the packaging area. • Explain the storage procedures for raw

materials, packaging materials and finished goods.

• Explain the quality parameters and quality assessment based on physical parameters;

• Check the quality of raw materials through physical parameters;

• Sample the product for quality analysis and deliver the sample to the quality analysis lab.

• Describe the cleaning procedures like CIP and COP;

• Illustrate knowledge on sanitizers and disinfectants and its handling and storing methods.

• Plan and organize the work order and jobs received from the supervisor

• Organize raw materials and packaging materials required for all products following the instruction provided by the supervisor

• Plan to prioritize the work based on the instructions received from the supervisor

• Plan to utilise the time and equipment effectively • Organize all process / equipment manuals so

that accessing information is easy. • Support the supervisor in scheduling tasks for

helper(s).

• Explain PMS; • Maintain and manage machineries, equipment

and tools in required condition;

• Clean and lubricate equipment on regular or need basis, following the maintenance specifications of the organization;

• Carry out daily/weekly maintenance of all milling machineries, equipment and tools as per the supplier manual and organisation standards;

• Assist in dismantling and assembling of machineries while cleaning and maintenance.

• Assist in dismantling and assembling of machineries while handling repairs;

• Describe how to escalate any malfunctions or repairs of milling machineries;

• Implement suggested corrective actions immediately;

• Ensure corrective action and coordinate with quality control lab.

goggles, food safety manual

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• Ensure updating the grain miller or supervisor on the activities carried out, observations (if any).

8. Operating Grain Mill Theory Duration (hh:mm) 05:00 Practical Duration (hh:mm) 11:00 Corresponding NOS Code

Demonstrate the process of pulse processing Weigh the pulses and transfer to the rotary

screen cleaner/graders for cleaning Move the pulses the rotary screen

cleaner/grader.

Operate the elevator to move the pulses to the cleaner/grader to remove impurities such as light particles, dust and smaller grains.

Transfer the pulses to de-stoner and control speed of the destoner to remove stones.

Weigh the pulse for further processing.

Explain the conditioning science.

Transfer the clean pulses to emery rollers for (scratching/pitting) process.

Fill and maintain the level of conditioning agents.

Maintain the quantity of conditioning agent required for each pulse following the process chart.

Maintain the speed of conveyor.

Adjust and control speed of the agitator.

Maintain soaking time as followed by the organization.

Repeat the conditioning and drying process several times depending on the type of pulse and standards followed by organisation to loosen the husk.

Examine and feel the conditioned pulse and transfer to the drier.

Dry the conditioned pulse in the dryer or under sun.

Adjust controls of the drier to set the temperature and time.

Repeat the drying process several times depending on the type of pulse and standards followed by organisation to loosen the husk.

Transfer the conditioned pulses into the emery coated roller mill to remove/separate outer shell (husk) of the pulses.

Manipulate the rollers to achieve desired clearance.

Maintain the speed of the aspirator fan to remove husk and to separate de-husked pulse.

Weigh the de-husked pulse and transfer to the next level.

Manipulate the rotation of the rotary blades of the splitter machine to split de husked pulse to produce dal.

Sort the split dal in sorting machine based on size, colour, etc.

Polish the split dal in the polisher

SOP, Sieve/sorters; White/Black board/ Chart paper, Markers/ computer and projector, Trainer Guide, Student Handbook, Different types of pulses, work flow diagram/chart, SOP, spatulas, packing wrap rolls, measuring cup and spoons, utensils, digital hygrometer, Measurement Cane Cleaner/grader; Conditioning machine; De-husk machine; Splitter machine; Drier; Packaging machine; Grinding machine; Sifter, Bran separator machine, polishing machine, multi crop decorticator, protective gloves, head caps, aprons, safety shoes, mouth cover, safety goggles, food safety manual, logbooks

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Polish the split dal with oil and water polisher.

Dry the polished dal in the drier.

Transfer finished products (dal) to packing machine.

Arrange the batch code, date coding, and filling quantity in the packaging machine.

Pack the finished product as per organisation standards.

Check the weight of the packed product.

Store the packed product according to the specifications and standards of the organisation.

Weigh the cleaned dal for grinding.

Change the mesh screens of the grinder to meet the standards of the final product.

Transfer the dal into the feed hopper of the grinder.

Manipulate feed chutes to regulate flow of dal through machine hopper into grinders.

Adjust the clearance between each rollers of roller mill by turning wheels according to dal size and hardness.

Manipulate controls to regulate speed, to obtain required fineness and to achieve maximum yield.

Control the heat of grinder by circulating water.

Collect the flour in the collecting bin.

Confirm the quality of the flour through physical parameters.

Weigh the flour and transfer to the sifter to achieve required fineness.

Adjust the mesh screens of the sifter to required fineness.

Manipulate slides in spouts to route pulse to sifters.

Collect the sifted flour.

Assess the quality of flour through physical parameters.

Weigh the flour produced.

Read and understand the work order and process flow chart.

State pre-cleaning process.

Operate conveyor to transfer pulses from destoner to conditioning bin.

Preparing and conditioning the pulses.

Manipulate valve to control speed and amount of the grain conveyed into drier.

Managing drying the grain.

Repeat the conditioning and drying process several times depending on the type of pulse and Operating husking machinery.

Manage polishing of pulses.

Operate length graders to grade processed pulses.

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Operate sifter to remove broken grains.

Manipulate machinery by feeling the grain and ensure that the grain is processed in accordance with specifications.

Calculate and weigh the grain before and after processing.

Explain the conveyor system and different types of conveying.

Operate the conveyor/elevator and transfer the grain from one processing machine to other.

Clean the machineries and work area using recommended sanitizers.

Maintain the work area to keep it pest free.

Explain the cleaning procedures like (CIP) and (COP).

Indicate knowledge on sanitizers and disinfectants.

Describe attending minor repairs of all machines.

Maintain equipment following daily/weekly maintenance schedules as per suppliers instructions/manuals.

Ensure timely follow up with annual maintenance contractor.

Report issues (if any) related to all processes, to the supervisor and implement.

Suggest corrective action.

8. Complete documentation and record keeping Theory Duration (hh:mm) 04:00 Practical Duration (hh:mm) 08:00 Corresponding NOS Code FIC/N1006

• Documentation system followed in the organization such as production chart, process chart and finished goods chart;

• State the methods to document and maintain records of observations (if any) related to raw materials, process and finished products.

• Describe recording details of all raw materials used in the production and document, as per company standards;

• Maintain records of observations related to raw materials and packaging.

• Load the finished product details in ERP for future reference;

• Assess the documents and track them from finished product to ingredients, in case of quality concerns and for quality management system audit.

• Describe the process of documenting production plan with details such as the product details, production sequence, equipment and machinery details, efficiency and capacity, utilization of equipment;

• Describe the process of documenting process parameters as applicable for the entire production in process chart or production log for all products produced;

Laptop, white board, marker, chart papers, projector, trainer’s guide and student handbook, logbooks, internal audit register, food safety manual, quality policy etc.

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• Maintain document of batch size, production yield, wastage of raw materials, energy utilization and final products produced;

• Maintain record of observations. • Maintain records on the types of finished

products produced;

• Describe the documents prepared for the finished products details such as batch number, time of packing, date of manufacture, date of expiry, other label details, primary and secondary packaging materials for all finished products, storage conditions etc. as per company standards;

• Maintain a record of observations or deviations (if any) related to finished products.

9. Food Safety, Hygiene and Sanitation Theory Duration (hh:mm) 06:00 Practical Duration (hh:mm) 16:00 Corresponding NOS Code FIC/N9001

• State the importance of safety, hygiene, and sanitation in food processing industry

• Observe the industry standards to maintain a safe and hygienic workplace

• Detail the principles of HACCP • Follow HACCP principles to eliminate food

safety hazards in the process and products; • State the possible physical, chemical and

biological hazards and methods of prevention of various hazards

• Follow industry standards like product recall process

• State food laws and regulations on product, packaging and labelling

• State food laws and regulations • Describe the knowledge on legal regulations

pertaining to work place like health and safety, recommended dosage for use of sanitizers, control of substances hazardous to health, handling/storage/ disposal/ cautions of use of sanitizers and disinfectants, fire precautions, occurrences, hygiene practice, disposal of waste, environmental protection, etc.

• Exercise personal hygiene by using gloves, hairnets, masks, ear plugs, goggles, shoes, aprons, etc.

• Explain using safety equipment such as fire extinguisher, first aid kit and eye-wash station, when required

• Construct workplace checklist audits before and after work to ensure safety and hygiene

• Describe food safety and hygiene practices • Describe following hygienic production of food

by • Construct workplace checklist audits before and

after work to ensure safety and hygiene • State the importance of documenting and

maintaining records for the credibility and effectiveness

Board/Chart paper/ Laptop and Projector, Trainer Handbook, Participant handbook, etc., Sanitizers, Protective Gloves , Protective Gloves, aprons, headmasks, safety goggles, safety shoes, internal audit, logbooks, quality manual, food safety manual.

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• Determine the quality of food using sensory parameters criteria and take immediate measures to prevent spoilage;

• Explain storing raw materials, finished products, allergens separately to prevent cross contamination

• Describe labelling raw materials and finished products and storing in designated storage areas according to safe food practices;

• Follow stock rotation based FEFO / FIFO. • State the importance of cleaning, and

maintaining machineries and follow the checklist.

• Describe the storage norms for raw materials, packaging material and finished products;

• Explain stock rotation of ingredients and finished products based on FIFO and FEFO;

• Exercise storing raw materials, finished products, allergens separately to prevent cross contamination

• Label raw materials and finished products and store in designated storage areas according to safe food practices

• Explain quality parameters and quality assessment based on physical parameters, basic food microbiology

10 Managing and Leading a team Theory Duration (hh:mm) 02:00

Practical Duration (hh:mm) 01:00 Corresponding NOS Code FIC/N9004

• Ensure that the team is aware of the schedule and job expectations on a daily basis

• Ensure communication to the team on any changes in policies/ processes by the organization through required verbal/ written mechanisms

• Involve the team in regular meetings to communicate information intended for them

• Ensure participation of the team in various engagement initiatives organized by the organization

• Counsel and address issues among the team for any work related issues

• Share knowledge of processes, techniques and products with the team to enhance their skill levels

• Ensure periodic training of the team and support the team by delivering trainings

• Provide feedback to the manager pertaining to performance of the team

White/Black board/ Chart paper, markers/ computer and projector, Trainer’s Guide, Student Handbook

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11. Professional Skills Theory Duration (hh:mm) 03:00

Practical Duration (hh:mm) 04:00 Corresponding NOS Code

• Undertake a self-assessment test • Identify your strengths and weaknesses. • Assess your strengths and weakness. • Work on your strengths and weaknesses • Plan and organize the work order and jobs

received from the supervisor

• Organize raw materials and packaging materials required for all products following the instruction provided by the supervisor

• Plan to prioritize the work based on the instructions received from the supervisor

• Plan to utilise the time and equipment effectively • Organize all process/ equipment manuals so

that accessing information is easy

• Support the supervisor in scheduling tasks for helper(s)

• Follow instructions and work on areas of improvement identified

• Complete the assigned tasks with minimum supervision

• Complete the job defined by the supervisor within the timelines and following quality norms

• Display interest in learning all processes pertaining to the industry

• Use common sense and make judgments on day to day basis

• Use reasoning skills to identify and resolve basic problems

• Use intuition to detect any potential problems which could arise during operations

• Use acquired knowledge of the process for identifying and handling issues

• Analyze critical points in day to day tasks through experience and observation and identify control measures to solve the issue

• Support supervisor in solving problems by detailing out the problems

• Discuss possible solution with the supervisor for problem solving

• Handle issues in case the supervisor is not available


12. IT Skills Theory Duration (hh:mm) 09:00


• State the basic functionalities of the computer to perform day-to-day activities.

• Explain the method of using the ERP system. • Use the computer keyboard effectively to type • Use the MS-Word effectively • Use Excel for effective documentation and

record-keeping

• Describe basic working of computers


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13. Core and Specific Skills Theory Duration (hh:mm) 01:00


• Detail discussion of task lists, schedules and activities with the supervisor;

• Explain effectively communicating with the team members;

• Question the supervisor in order to understand the nature of the problem and to clarify queries;

• Listen and comprehend the information given by the speaker;

• Communicating clearly with the supervisor and cross department teams on the issues faced during process.


14. Field Visits Theory Duration (hh:mm) 04:00


Observe the factory location, layout and safety aspects of food processing

Observe the storage facilities for raw materials and finished products

Observe the various machineries used in pickle processing

Observe the various machineries used in pickle processing

Observe the cleaning methods and processes followed to maintain the process machineries and tools

Observe the raw materials used and their storage procedures

Observe the packaging and storage processes of raw material and finished product

Observe the post-production cleaning and maintenance process followed in the industry.

Observe the various machineries used in the milling process; •

Observe the ERP (Enterprise Resource Planning) system and the documentation process.

Observe the production process for various products;

Observe the quality parameters and quality assessment;

Observe the types of machines used in the organisation.

All the tools and equipment listed above must be available at the site of field visit

15. Revision Theory Duration (hh:mm) 02:30

Practical Duration (hh:mm) 04:00

Revised the knowledge gained so far All the tools and equipment listed above must be available at the time of revision

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16. Evaluation Theory Duration (hh:mm) 09:00


Assess the knowledge and skills acquired by the participants

All the tools and equipment listed above must be available for evaluation

17. On-the-job Training Theory Duration (hh:mm) 10:00


Apply the skills and knowledge acquired in the training program in the field

All the tools and equipment listed above must be available on the site at the time of OJT

Total Duration 240:00 Theory Duration 79:00 Practical Duration 161:00

Unique Equipment Required: Seperator Machine; Aspirator ; Disc

separator; Scourer; Magnetic separator; Washer-stoner; Conditioning machine; Drying plant; Grinding machine; Sifting machine; Purifiers; Packing machine; Cleaners; Disinfectants

Grand Total Course Duration: 240 Hours, 30 Minutes (This syllabus/ curriculum has been approved by SSC: Food Industry Capacity and Skill Initiative)

Milling Technician

Trainer Prerequisites for Job role: “Milling Technician” mapped to Qualification Pack: “FIC/Q1002, v1.0”

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Area Details

1 Description To deliver accredited training service, mapping to the curriculum detailed above, in accordance with the Qualification Pack “FIC/Q1002”, Version 1.0

2 Personal Attributes

An aptitude for conducting training, and pre/ post work to ensure competent, employable candidates at the end of the training, and pre/post work to ensure competent, employable candidates at the end of the training. Strong communication skills, ability to work as part of a team; a passion for quality and for developing others; well-organized and focused, eager to learn and keep oneself updated with the latest in the mentioned fields.

3 Minimum Educational Qualifications

B.Sc /B.Tech/BE or PG Diploma in Food Process Engineering/ Grain Milling with 2-3 years of hands on experience in a Milling Industry

M.Sc /M.Tech/ME or PG Diploma in Food Engineering/ Grain Milling with 1-2 years of hands on experience in a Milling Industry

4a Domain Certification

Certified for Job Role: “Milling Technician” mapped to QP: “FIC/Q1002, v1.0”. Minimum accepted score is 80%

4b Platform Certification

Recommended that the Trainer is certified for the Job Role: “Trainer”, mapped to the Qualification Pack: “SSC/Q1402”. Minimum accepted score is 80 % as per FICSI guidelines.

5 Experience B.Sc /B.Tech/BE or PG Diploma in Food Engineering/ Grain Milling with 2-3 years of hands on experience in a Grain Milling Unit

M.Sc /M.Tech/ME or PG Diploma in Food Process Engineering/ Grain Milling with 1-2 years of hands on experience in a Grain Milling Unit

Milling Technician

Annexure: Assessment Criteria

Assessment Criteria

Job Role Milling Technician

Qualification Pack FIC/Q1002, v1.0

Sector Skill Council Food Processing

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Guidelines for Assessment

1 Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of marks for Theory and Skills Practical for each PC.

2 The assessment for the theory part will be based on knowledge bank of questions created by the SSC.

3 Individual assessment agencies will create unique question papers for theory part for each candidate at each examination/training centre(as per assessment criteria below)

4 Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/training canter based on this criteria

5 To pass the Qualification Pack, every trainee should score a minimum of 70% (overall) in every QP

6 The marks are allocated PC wise; however, every NOS will carry a weight age in the total marks allocated to the specific QP

Milling Technician

Assessable Outcome

Assessment Criteria Total Mark (500)

Out Of

Marks Allocation

Theory Skills Practical

1. FIC/N1004: Prepare and maintain work area and process machineries for execution of the grain milling process

PC.1 Prepare, clean and maintain the

cleanliness of the work area using

approved sanitizers and keep it free

from dust, waste, flies and pests

100

25 10 15

PC2. Ensure that the work area is safe and

hygienic for food 10 3 7

PC3. Dispose waste materials as per defined

SOPs and industry requirements 15 5 10

PC4. Check the working and performance of

all machineries and tools used such as

de-stoner, de-huller, polisher, blender,

pulverizer, stone mill / roller mill, sifter,

packaging machines, etc.

15 5 10

PC5. Clean the machineries and tools used with approved sanitizers following SOP

15 5 10

PC6. Place the necessary tools required for process

5 2 3

PC7. Attend the minor repairs/ faults of all machines, if required

7.5 2.5 5

PC8. Select and set the machines and tools required for production

7.5 2.5 5

Total 100 35 65

2. FIC/Q1005: Grain Milling

PC1. Clean process machineries with recommended sanitizers following SOP

2 0.5 1.5

PC2 Ensure working and performance of each machinery and equipment required for milling process

2 0.5 1.5

PC3. Clean and change screens/sieves in process machineries (as applicable) following SOP for milling different types of grains to produce various type of products

2 0.5 1.5

PC4. Set the process parameters of all

processing machineries, start

machines to ensure working and

performance

2 0.5 1.5

PC5. Adjust/reset process parameters during changeover of raw materials or for production of various types of products

2 0.5 1.5

PC6. Maintain and manage machineries, equipment and tools in required condition

1 0.5 0.5

PC7. Clean and lubricate equipment on regular or need basis, following the maintenance specifications of the organization

2 0.5 1.5

Milling Technician

PC8. Carry out daily maintenance of all milling machineries, equipments and tools as per the supplier manual and organisation standards

2 0.5 1.5

PC9. Organize and keep the tools accessible

to attend repairs/faults in case of

breakdown

1 0.5 0.5

PC10. Assist in dismantling and assembling

of machineries while cleaning,

maintenance and handling repairs

2 0.5 1.5

PC11.Escalate any malfunctions or repair of milling machineries (beyond own scope of work) to the concerned person

1 0.5 0.5

PC12.Implement suggested corrective actions immediately

1 0.5 0.5

PC13.Organize grains from warehouses and maintain enough stock to meet weekly production requirement

2 1 1

PC14.Receive raw materials from external or internal warehouse following sop

1 0.5 0.5

PC15.Check the quality of incoming raw materials through physical parameters like appearance, colour, visual defects, odor, infestation etc

2 1 1

PC16.Sample incoming raw materials and transfer to quality lab for analysis, ensure transfer of grains into specified silos and store following sop

2 0.5 1.5

PC17.Check the stored grains periodically for any infestation and arrange for immediate fumigation and implement other suggested corrective action

2 1 1

PC18.Ensure implementation of pest control for warehouse, loading and unloading area, process and storage area etc

1 0.5 0.5

PC19.Check control points of process area and milling machineries to ensure performance, hygiene and safety working condition

1 0.5 0.5

PC20.Read and understand work order/production order and process flow chart

1 0.5 0.5

PC21.Ensure specified quantity and variety of raw materials are moved from warehouse/silos and blended

2 1 1

PC22.Set, monitor and control process parameters like flow rate of raw material and air, speed, rotation etc of grain cleaning machineries like destoner, separator, scourer, aspirator etc for removal of stones straw, sticks, mud, light particles/husk, foreign materials etc

6 2 4

PC23.Open, adjust and close raw material feed chute to allow specified quantity

3 1 2

Milling Technician

of raw material into processing machineries for process

PC24. Set, monitor and control process parameters like flow rate/intake of raw materials, oil, water to maintain moisture content or oil content,

6 2 4

PC25. Set, control and maintain process parameters like raw material flow rate, speed, time etc of rice processing machines like paddy husker, paddy separator, whitener, sifter, polisher, length grader, sortex, blender machine to remove husk and produce brown rice, separate unhusked paddy from brown rice, remove bran and germ from brown rice, remove impurities and brokens, improve appearance of rice, separate rice based on length, electronic colour sorting, blend rice of various grades to meet customer and legal requirement

6 2 4

PC26. Set, control and maintain process parameters like material flow rate, speed, time etc of pulse processing machines like abrasive huller with aspirator, splitter, sifter, polisher, grader, sortex, blender machines to remove hull and produce dehusked legume, to split legume and produce dhal, remove impurities and chips, improve appearance of dhal, separate dhal based on size, electronic colour sorting, blend pulse of various grades to meet customer and legal requirement

6 2 4

PC27. Set, control and maintain process parameters like material flow rate, speed, rotation, time, moisture content etc of wheat processing machineries like tempering bins/conveyors, roller mill, plansifter, purifier to mix wheat with specified amount of water to achieve desired moisture content, grind wheat, sieve wheat flour to required fineness, electronic colour sorting to remove undesirable dark specks from semolina (sooji/rava)

6 2 4

PC28. Open valves, adjust controls, control speed of conveyor to maintain flow of material to and from each processing machineries to maintain production requirements and achieve continuous processing

4 1 3

PC29. Stop process machineries in case of any breakdown or emergency situation with proper approvals, attend break down/repairs/faults (or) inform

5 2 3

Milling Technician

maintenance team and ensure immediate maintenance to reduce downtime and meet the production target

PC30.Collect in-process samples and transfer to quality lab for analysis, conducts in-process tests like grain moisture content to monitor product quality during processing

3 1 2

PC31. Identify products, process and equipment performance nonconforming to specification and standards, rectify or report, and implement suggested corrective action immediately

3 1 2

PC32. Collect machine rejects and waste generated from each process, use (e.g. use bran in boiler) or dispose following SOP

2 0.5 1.5

PC33. Load packing materials in packaging/bagging machine and set packing quantity, set date coding machine for date code details like batch number, date of manufacture, date of expiry etc

2 0.5 1.5

PC34. Start automatic packaging/bagging machine to fill and seal (or) form, fill and seal measured quantity of finished products, check weight of packed/bagged product periodically to ensure its conformance to standards

1 0.5 0.5

PC35. Sample packed product and transfer to quality lab for analysis and to ensure its conformance to quality standards

1 0.5 0.5

PC36. Place packed and labelled products in cartons/other secondary packaging material and seal, transfer to storage area and store maintaining storage conditions following SOP

1 0.5 0.5

PC37.Report discrepancies/concerns to department supervisor for immediate action

1 0.5 0.5

PC38. Clean the work area, machineries, equipment and tools using recommended cleaning agents and sanitizers

4 1 3

PC39. Attend minor repairs/faults of all machines (if any)

4 1 3

PC40.Ensure periodic (daily/weekly/monthly/quarterly/hal f yearly/annual) maintenance of all machines and equipment following the SOP or following suppliers instructions/manuals

2 1.5 0.5

100 35 65

Milling Technician

3. FIC/N1006: Complete documentation and record keeping related to execution of grain milling process

PC1. Document and maintain records of

details of raw materials and packaging

materials as per organizational

standards

100

10 6 4

PC2. Document and maintain record on

observations (if any) related to raw

materials and packaging materials

5 3 2

PC3. Load the raw material details in ERP for future reference

5 3 2

PC4. Verify the documents and track from

finished products to raw materials, in

case of quality concerns and during

quality management system audits

5 3 2


production plan with details 10 6 4


process details for entire production in

process chart or production log for all

products produced

15 9 6

PC7.Document and maintain records of batch

size, production yield, wastage of raw

materials, energy utilization and final

product produced

10 6 4

PC8. Document and maintain record of

observations or deviations 5 3 2

PC9. Load the production plan and process details in ERP for future reference

5 3 2

PC10.Verify documents and track from

finished product to ingredients, in case

of quality concerns and for quality

management system audit

5 3 2

PC11.Document and maintain records of finished products

3 2 1

PC12.Document and maintain records of the

finished product details as per

organizational standards

7 4 3

PC13. Document and maintain record on

observations or deviations related

to finished products 5 3 2

PC14. Load the finished product details in ERP for future reference

5 3 2

PC15.Verify the documents and track from

finished product to ingredients, in case

of quality concerns and for quality

management system audits

5 3 2

Total 100 60 40

4. FIC/N9001: Food Safety, hygiene and sanitation for processing food products

PC1. Comply with food safety and hygiene procedures followed in the organization

100

5 2 3

PC2. Ensure personal hygiene by use of gloves, masks ,hair net, ear plugs, boots etc.

6 1 5

PC3. Ensure hygienic production of food by inspecting raw materials, ingredients, finished products etc for compliance to

5 2 3

Milling Technician

physical, chemical and microbiological procedures

PC4. Pack products in appropriate packaging material, label and store them in designated area free from pests, flies etc.

10 4 6

PC5. Clean, maintain and monitor food processing equipments periodically, using it only for the specified purpose

5 2 3

PC6. Use safety equipment such as fire extinguisher, eye wash unit, first aid kit when required

10 4 6

PC7. Follow housekeeping practices by having designated area for machines/tools

5 2 3

PC8. Follow industry standards like GMP, HACCP and product recall

10 4 6

PC9. Attend training on hazard management to understand type of physical, chemical and microbiological hazards

5 1 4

PC10.Identify, document and report problems such as rodents and pests to management

5 1 4

PC11.Conduct workplace checklist audit before and after work to ensure safety and hygiene

5 1 4

PC12. Document and maintain raw material, process, packaging material to maintain the effectiveness of quality system

4 1 3

PC13.Determine the quality of food using criteria such as odor, color, taste and best before date and take immediate measures to prevent spoilage

5 2 3

PC14.Store raw materials, finished products and allergens separately to prevent cross contamination

5 2 3

PC15.Label raw materials and finished products and store them in different storage areas according to safe food practices

5 2 3

PC16.Follow stock rotation based on FEFO/FIFO

10 4 6

5. FIC/N9004: Manage and lead a team

PC1. Ensure that the team is aware of the schedule and job expectations on a daily basis

12 4 8

PC2. Involve the team in regular meetings to communicate information intended for them

12 4 8

PC3. Ensure communication to the team on any changes in policies/ processes by the organization through required verbal/ written mechanisms

12 4 8

Milling Technician

PC4. Ensure participation of the team in various engagement initiatives organized by the organization

12 4 8

PC5. Counsel and address issues among the team for any work related issues

12 4 8

PC6. Support the manager in deployment of the team as per production schedule and the organizational norms and guidelines

10 4 6

PC7. Ensure periodic training of the team and support the team by delivering trainings

10 3 7

PC8. Share knowledge of processes, techniques and products with the team to enhance their skill levels

10 4 6

PC9. Provide feedback to the manager pertaining to performance of the team

10 4 6

Total 100 35 65

Grand total 500 500 300 200

Percentage Weightage 100 60% 40%

Minimum Pass% to qualify (aggregate): 70%

Milling Technician

Documents

Milling Technician - · PDF fileThis program is aimed at training candidates for the job of a “Milling Technician ... Assist the grain miller and supervisor in milling all types