Tesfay OS Spinning and Ginning Operations L2 & L3 Doc

8/3/2019 Tesfay OS Spinning and Ginning Operations L2 & L3 Doc

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Federal Democratic Republic of Ethiopia

OCCUPATIONAL STANDARD

SPINNING AND GINNINGOPERATIONS

NTQF LEVEL II and III

Ministry of Education

May 2011


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Page 1 of 85Ministry of Education

CopyrightSpinning and Ginning OperationsEthiopia Occupational Standard

Version 1May 2011

Introduction

Ethiopia has embarked on a process of reforming its TVET-System. Within thepolicies and strategies of the Ethiopian Government, technology transformation by

using international standards and international best practices as the basis, and,adopting, adapting and verifying them in the Ethiopian context is a pivotal element.TVET is given an important role with regard to technology transfer. The newparadigm in the outcome-based TVET system is the orientation at the current andanticipated future demand of the economy and the labor market.

The Ethiopia Occupational Standard (EOS) is the core element of the EthiopianNational TVET-Strategy and an important factor within the context of the NationalTVET-Qualification Framework (NTQF). They are national Ethiopian standards,which define the occupational requirements and expected outcome related to aspecific occupation without taking TVET delivery into account.

This document details the mandatory format, sequencing, wording and layout for theEthiopia Occupational Standard which comprised of Units of Competence.

A Unit of Competence describes a distinct work activity. It is documented in astandard format that comprises:

Occupational title and NTQF level

Unit title

Unit code

Unit descriptor Elements and Performance criteria

Variables and Range statement

Evidence guide

Together all the parts of a Unit of Competence guide the assessor in determiningwhether the candidate is competent.

The ensuing sections of this EOS document comprise a description of theoccupation with all the key components of a Unit of Competence:

chart with an overview of all Units of Competence for the respective levelincluding the Unit Codes and the Unit Titles

contents of each Unit of Competence (competence standard)

occupational map providing the technical and vocational education and training(TVET) providers with information and important requirements to consider whendesigning training programs for this standards and for the individual, a careerpath


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UNIT OF COMPETENCE CHART

Occupational Standard: Spinning and Ginning Operations

Occupational Code: TXT SGO

NTQF Level III

TXT SGO3 01 0511

Monitor Spinning andGinning ProductionProcess Capability

TXT SGO3 02 0511

Participate inProduction PlanningProcess

TXT SGO3 03 0511

Organize and PlanOwn Work to AchievePlanned Outcomes

TXT SGO3 04 0511Contribute to Ginningand Spinning

Production ProcessImprovements

TXT SGO3 05 0511

Interpret EngineeringDrawing

TXT SGO3 06 0511

Perform MachineSetting and

OperationalMaintenance

TXT SGO3 07 0511

Restart Machine afterStoppage

TXT SGO3 08 0511

Manage the Impact ofChange on Own Work

TXT SGO3 09 0511Set up Ginning andSpinning ProductionMachines for ProductChange

TXT SGO3 10 0511

Determine and

Correct MechanicalFaults in Loom andOther Weavin

TXT SGO3 11 0511Ensure Efficient

Operation of TextileMachines

TXT SGO3 12 0511

Sustain Process

Improvements

TXT SGO3 13 0511

Apply Quality ControlTXT SGO3 14 0511

Lead Small TeamTXT SGO3 15 0511

Lead WorkplaceCommunication

TXT SGO3 16 0511

Improve BusinessPractice


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NTQF Level II

TXT SGO2 05 0511

Use SpecializedMachinery to AssistTextile Production

TXT SGO2 03 0511

Weight and CheckTextile Materials and

Products

TXT SGO2 01 0511

Determine CottonCharacteristics

TXT SGO2 06 0511

Participate inEnvironmentallySustainable WorkPractices

TXT SGO2 02 0511

Perform MinorMaintenance

TXT SGO2 07 0511

Work TeamEnvironment

TXT SGO2 08 0511

Participate in aWorkplace EnvironmentTXT SGO2 09 0511

Develop BusinessPractice

TXT SGO2 04 0511

Repair Textile Product


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NTQF Level III


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Occupational Standard: Spinning and Ginning Operations Level III

Unit Title Monitor Spinning and Ginning Production Process

Unit Code TXT SGO3 01 0511

Unit Descriptor This unit covers the knowledge, attitudes and skills required tomonitor spinning and ginning process to ensure efficientproduction.

Elements Performance Criteria

1. Monitor process 1.1 Job specificationsare checked for requirementsincluding quantity, quality and special requirement.

1.2 Performance parametersare identified to the extentrequired to be able to report known or suspectedproblems.

1.3 Production processesare monitored to ensureconsistency with specified outcomes.

1.4 Job records and other documentation are maintained.

1.5 Monitoring is conducted according to OHS practices.

2. Identifyproduction/process

problems

2.1 Problems are identified and categorized as machine andprocess faults.

2.2 Operating manuals and documentation are referred to.

3. Determineproblem causeand solution

3.1 Production standards are communicated to teammembers.

3.2 Work allocation requirements are monitored andaddressed in order to maintain optimum productionefficiency.

3.3 Targets and procedures are communicated to appropriatepersonnel in a logical and easily understood manner.

4. Check

performanceefficiency

4.1 Regular checks of process operation are undertaken and

results assessed against job specifications.

4.2 Results of checks are recorded.

4.3 Opportunities for process improvements are identified andcommunicated.


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Variable Range

Job specifications May include:

customer order

simple formula

written and verbal instructions drawings

Performanceparameters

May include:

processing time

acceptable error rate

wastage

noise

vibration

Production

processes

May include:

feeding drying

pre - cleaning

stick removing

lint cleaning

ginning

bale pressing

carding

drawing

combing

roving spinning

winding

twisting

doubling

OHS practices Includes hazard identification and control, risk assessment andimplementation of risk reduction measures specific to the tasksdescribed by this unit, and may relate to:

manual handling techniques

standard operating procedures

personal protective equipment reporting accidents and incidents

Tools andequipment

cotton - cleaning, blending, carding, combing, drawing,roving, spinning, twisting, winding

worsted - combing, gilling, drawing, roving, spinning,twisting, winding

woolen - blending, carding, spinning, twisting, winding


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Evidence Guide

Critical Aspects ofCompetence

Demonstrates skills and knowledge to:

identify the major processes to be monitored at worklocation

identify manufacturing system and quality requirements tobe monitored

identify major faults and out of specification performance

address faults or problems

conduct regular performance checks

UnderpinningKnowledge andAttitudes

Demonstrates knowledge of:

ginning technology

yarn manufacturing processes used in an enterprise

range of problems and their solutions associated with yarnmanufacturing operations

quality standards and practices OH&S practices, including hazard identification and control

measures

workplace practices

recording and reporting practices

Underpinning Skills Demonstrates skills to:

interpret technical data

monitor manufacturing system

read, interpret and follow information on work specifications,standard operating procedures and work instructions

maintain accurate records sequence operations

meet specifications

clarify and check task-related information

carry out work according to OHS practices

ResourceImplications

Access is required to real or appropriately simulated situations,including work areas, materials and equipment, and toinformation on workplace practices and OHS practices.

Methods of

Assessment

Competence may be assessed through:

Interview/Written Test Observation/Demonstration with Oral Questioning

Context ofAssessment

Competence may be assessed in the work place or in asimulated work place setting


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Unit Title Participate in Production Planning Process


Unit Descriptor This unit covers the knowledge, attitudes and skills required toparticipate in the production planning of the enterprise.


1. Confirmproductionrequirements

1.1 Projected requirements regarding stock supplies, productquantities, quality and delivery schedules are confirmed.

1.2 Identified issues and problems concerning projectedrequirements are resolved in collaboration with relevant

personnel.1.3 Requirements for implementation of organizational

systemsare determined.

2. Gather specificproductioninformation

2.1 Specific information relating to production capacity isobtained and confirmed

2.2 Details of production line requirements regarding batch orrun sizes and other relevant information are gathered andinterpreted for use in production plan preparation.

2.3 Resources, supply requirements, availability of machines

and personnel is identified and confirmed.3. Participate in

planningmeeting

3.1 Specific requirements for meetings are confirmed.

3.2 Production dataand other planning information isprepared.

3.3 Information is contributed and discussed according tomeeting procedures.

3.4 Follow-up action on meeting outcomes is taken

3.5 Production planningrecords are maintained and reportsprepared, where necessary.

Variable Range

Organizationalsystems

May include:

Just In Time

quick response

quality management systems

team processes

benchmarking


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Production data May include:

plant layout

machine operating manuals and other equipment records

production data collected manually or electronically

quality specifications

drawings, sketches and other specifications

Productionplanning

May include:

establishing an overall plan for production and delivery

repetitive production runs

short runs

quick changes

a diversity of styles

indent orders

stock services replenishment

OHS practices Includes hazard identification and control, risk assessment andimplementation of risk reduction measures specific to the tasksdescribed by this unit, and may relate to:



reporting accidents and incidents

Evidence Guide

Critical Aspects ofCompetence Demonstrates skills and knowledge to: confirm requirements for production

assemble and interpret specific production information

identify resources, supply requirements, machines,

personnel

contribute to interchange of information at planning

meetings

apply OHS practices in production operations

maintain accurate records

Underpinning

Knowledge andAttitudes


production processes, products and machines basic knowledge of fiber and yarns

an understanding of work and workplace organizationsystems

meeting procedures

quality standards and practices

OHS practices, including hazard identification and controlmeasures

workplace practices



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UnderpinningSkills

Demonstrates skills to:

participate effectively in planning production

interpret and use data from a range of sources

communicate effectively with individuals, work groups andsupervisors

document and transfer information

read, interpret and follow information on work specifications,standard operating procedures and work instructions


sequence operations

meet specifications



Resource

Implications

Access is required to real or appropriately simulated situations,

including work areas, materials and equipment, and toinformation on workplace practices and OHS practices.

Methods ofAssessment


Interview /Written Test

Observation/Demonstration with Oral Questioning


Competence may be assessed in the work place or in asimulated work place setting


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Unit Title Organize and Plan Own Work to Achieve Planned Outcomes


Unit Descriptor This unit covers the skills and knowledge to organize and planown work to achieve planned outcomes.

Element Performance Criteria

1. Confirm andinterpret workrequirements

1.1 Work requirements are confirmed with relevantpersonnel.

1.2 Work requirements are interpreted.

2. Develop

personal workplan

2.1 Steps required to complete work are identified and

confirmed with other personnel.

2.2 Quality requirements are confirmed and interpreted.

2.3 Critical deadlines, outcome objectives and sequence ofoperations are established and documented.

3. Communicatewith relevantpersonnel

3.1 Relevant personnel are identified and contacted.

3.2 Operation plan is confirmed or altered.

4. Accessresources

4.1 Specified resources are identified and accessedaccording to work plan.

4.2 Use expertise of other personnel and learningopportunities to expand ability to meet work targets.

5. Coordinate work 5.1 Work is assessed according to planned steps and qualitycriteria.

5.2 Work is regularly checked against specifications,established deadlines and identified quality standardsand action is taken to rectify work which is not accordingto requirements.

5.3 Problems are identified and investigated.

5.4 Problems are rectified or reported

6. Keep records ofwork

6.1 Record system is established.

6.2 Records are kept according to record system procedures.

7. Implement OHSpractices

7.1 OHS practicesare identified and followed.

7.2 Action is taken according to OHS practices to preventaccidents and to eliminate risks to personal safety.


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Variable Range

Legislative/regulatory

requirements

All work must comply with relevant Federal and State or Territorylegislative or regulatory requirements.

OHS practices OHS practices include hazard identification and control, riskassessment and implementation of risk reduction measuresspecific to the tasks described by this unit, and may relate to:



personal protective equipment

safe materials handling

taking of rest breaks

ergonomic arrangement of workplaces

following marked walkways

safe storage of equipment housekeeping


environmental practices

Evidence Guide



confirm and interpret work specifications

establish and apply required quality procedures andrequired work steps

organize and set up workstation

identify and deal with problems arising in own work

coordinate own work

set and work to deadlines

apply OHS practices in work operations


UnderpinningKnowledge andAttitude


production processes

operating procedures for production machines characteristics of typical materials and products used in

production



workplace practices



handle, receive and assemble materials and products

solve problems in own work read, interpret and follow information on work specifications,


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standard operating procedures and work instructions, andother reference material


communicate within the workplace

sequence operations

meet specifications clarify and check task-related information


ResourcesImplication



Competency may be accessed through:

Interview / Written Test

Observation / Demonstration with Oral Questioning


Competency may be assessed in the work place or in asimulated work place setting


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Unit Title Contribute to Ginning and Spinning Production ProcessImprovements


Unit Descriptor This unit covers the skills and knowledge to review productionprocesses used in textile manufacture and contribute toidentifying and implementing improvements.


1. Identify keyelements ofproduction

requirements

1.1 Key external and internal customers and their needs andexpectations are identified.

1.2 Ginning and spinning production processesaredescribed in terms of how they contribute to th e valuechain.

1.3 Key suppliersare identified and their role in the valuechain described.

1.4 Quality standards for critical points of the productionprocess are identified.

1.5 Production requirementsare identified.

2. Review

productionprocesses

2.1 Housekeeping practices are identified and reviewed

against workplace standards to assess conformity.2.2 Safety practices are identified and reviewed against OHS

practicesto assess conformity.

2.3 Production wasteis identified.

2.4 Methods of monitoring production outcomes are identifiedas required.

2.5 Textile production outcomes are assessed againstproduction goals as required.

3. Identify

improvementopportunities

3.1 Opportunities for improvement are identified.

3.2 Suggestions for improvement are made.

3.3 Improvement is testedin consultation with appropriatepersonnel.

3.4 Reports, records and recommendations for improvementare provided.

4. Implementimprovement

4.1 Implications of improvement are identified.

4.2 Desired result of improvement is identified and method ofmeasuring outcome established.

4.3 Methods of addressing any possible negative implications


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are identified and implemented.

4.4 Consultation with appropriate personnel is conducted tocommunicate improvement.

4.5 Improvement is implemented with the assistance of other

team members as required.4.6 Improvement is monitored to ensure correct

implementation and effectiveness in achieving desiredresult is reviewed with assistance from other teammembers as required.

4.7 Adjustments to improvement are made as required.

4.8 Improvement processes are documented.

Variable Range

Legislative/regulatory requirements

All work must comply with relevant Federal and State or

Territory legislative or regulatory requirements.

Textile production

processes mayinclude

receiving and processing of fibres and yarns

identification of yarn and fibre quality

specialist machine use such as tufting, spinning, weaving

repairs and alterations

testing, inspecting

dispatch, storage, packing

finishing processesSuppliers mayinclude

suppliers of materials, yarns, fibres, fabrics

personnel, specialist support, contractors

dispatch, warehousing, transport operators

publicity and promotional suppliers

machinery and equipment suppliers and repair

contractors

Productionrequirements

timing requirements

quantity

quality

specific order requirements procedural requirements

safety

personnel

resource use


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Production wastemay

include

unusable materials, off-cuts

delays

poor process design

inventory

inefficient performance of a process making defective items

Tested mayinclude

trialed

verified

piloted

measured against research

Appropriatepersonnel may

include

managers

supervisors

colleagues

specialist staff









safe storage of equipment housekeeping



Evidence Guide



review textile production processes

identify and assess improvement opportunities evaluate implications of improvement

identify and interpret workplace standards

communicate process improvement options



quality standards applying to textile handling procedures,construction processes and finished product

impact of incorrect production techniques

sequence of operations in the production process

production suppliers and value chain concepts

quality tools and benchmarking procedures


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PDCA (plan, do, check, act) cycle


quality practices

workplace practices


UnderpinningSkills


plan production processes as required

analyze and evaluate

communicate effectively within the workplace with colleaguesand management

conduct quality checks to identify non-compliances withquality standards

brainstorm

solve problems

read, interpret and follow information on work specifications,standard operating procedures and work instructions, andother reference material


sequence operations

meet specifications









Observation / Demonstration and Oral Questioning




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Unit Title Interpret Engineering Drawing


Unit Descriptor This unit covers interpreting engineering drawing applying toany of the full range of engineering disciplines.


1. Select correctengineeringdrawing

1.1 Drawing is checked and validated against jobrequirements or equipment.

1.2 Drawing version is checked and validated.

2. Interpret

engineeringdrawing

2.1 Components, assemblies or objects are recognized as

required.

2.2 Dimensions are identified as appropriate to field ofemployment.

2.3 Instructions are identified and followed as required.

2.4 Material requirements are identified as required.

2.5 Symbols are recognized in the drawing as appropriate.

Variable Range

Interpret technicaldrawing

interpretation may require guidance particularly in respect to anygeometric tolerancing line with standard operating procedures

Evidence Guide


Demonstrate knowledge and skills in:

Selecting correct engineering drawing

Interpreting engineering drawing

Underpinning

Knowledge andAttitudes

Demonstrate knowledge of:

application of AS1100.101 in accordance with standardoperating procedures

relationship between the views contained in the drawing

objects represented in the drawing

units of measurement used in the preparation of the drawing

dimensions of the key features of the objects depicted in thedrawing

understanding of the instructions contained in the drawing

the actions to be undertaken in response to thoseinstructions

the materials from which the object(s) are made


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any symbols used in the drawing as described in rangestatement

hazard and control measures associated with interpretingengineering drawings, including housekeeping

safe work practices and procedures

UnderpinningSkills

Demonstrate Skills of:

checking the drawing against job requirements/relatedequipment in accordance with standard operatingprocedures

confirming the drawing version as being current inaccordance with standard operating procedures

where appropriate, obtaining the current version of thedrawing in accordance with standard operating procedures

reading, interpreting information on the drawing, written jobinstructions, specifications, standard operating procedures,

charts, lists and other applicable reference documents checking and clarifying task related information

undertaking numerical operations, geometry andcalculations/formulae within the scope of this unit










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Unit Title Perform Machine Setting and Operational Maintenance


Unit Descriptor This unit covers the skills and knowledge required to setmachines for product changes, reset them after general fibrerelated stoppages and perform minor maintenance ofmachinery.


1. Determinerequiredspecifications

1.1 Required specifications for raw materials, product andmachine are identified and interpreted for application inthe testing and setting up process.

2. Set machine 2.1 Machine is cleaned and set in accordance with rawmaterial and product specifications and machinemanufacturer and workplace procedures.

2.2 During setting and testing, condition of work area aroundmachine is maintained to meet workplace and OHSpractices.

3. Conduct sampleor trial runs andreadjust

3.1 Machine operation is checked to ensure correct operation.

3.2 Where appropriate, a sample is produced and checked forconformance with workplace requirements and product

standards and further adjustment is made until samplemeets specifications.

4. Investigate,identify andrectify machineoperatingproblems

4.1 Appropriate diagnostic procedures and tests are used tolocate and identify faults in the machine.

4.2 Correct hand tools and measuring equipmentarechosen and use to rectify problems.

4.3 Major problems in machine are identified and reported.

4.4 Minor problems, which are within the operator's skill level,are identified and adjustments or repairs are assessed .

4.5 Environmental requirements and procedures concernedwith waste, pollution and recycling of materials arecorrectly applied at all stages of the process.

5. Rectify minormachine

faults

5.1 Adjustments or corrections are assessed consistent withoperator's skill level.

5.2 Machine is checked to ensure correct operation.

5.3 Correct hand tools and measurement equipment arechosen and used to correct problem.

6. Communicateinformation 6.1 Records and other documentation of setting andmaintenance work are clearly and accurately completed.


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Variable Range

Legislative/regulatoryrequirements

All work must comply with relevant Federal and State orTerritory legislative or regulatory requirements.

Machine mayinclude:

A range of machines and equipment which may bemicroprocessor or computer controlled, including the following:

blending and carding

combing

gilling

finishing

bale pressing

scouring

super wash

backwash

carbonizingMaterials, handtools andequipment mayinclude:

cleaning equipment

detergents and other chemicals

hand and power tools normally applicable to the tasks

hand trolleys

pallet trucksOHS practices OHS practices must include hazard identification and control,

risk assessment and implementation of risk reductionmeasures specific to the tasks described by this unit, and mayinclude:

manual handling techniques standard operating procedures






safe storage of equipment

housekeeping


other OHS practices relevant to the job and enterprise

Evidence Guide



comply with all relevant safety requirements; includingisolation or shutdown of machines, use of safety and lockoutdevices, and attachment of appropriate warning tags

interpret work orders

interpret raw materials, product, and machine specificationsneeded for machine setting and maintenance

perform normal testing, setting, and maintenance of


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machines

investigate improper operation of machines and identify andrectify operating problems

conduct sample runs of machines and check productsagainst required standards perform operator maintenance of

work area document and communicate work related information

including reporting of non-conforming outcomes and otherproblems



principles of operating machines and associated equipment

technical specifications and repair manuals

principles and techniques of machine setting and adjustment

typical fault conditions and relevant fault finding procedures

maintenance and repair processes and techniques

workplace procedures and maintenance planning workplace stores procedures and procurement system

relevant product quality standards

safety and environmental aspects of relevant workplaceprocesses

general housekeeping policies and procedures


quality practices

workplace practices

practices for recording and reportingUnderpinningSkills


locate and interpret technical data

set and operate machines

test machines and analyze samples

use relevant hand tools

use lubricants, sealants, chemicals, and cleaning agents,and dispose of waste products

maintain work area

document and transfer information

read, interpret, and follow information on work specifications, standard operating procedures and work instructions, andother reference material



sequence operations

meet specifications






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Context of

Assessment

Competency may be assessed in the work place or in a

simulated work place setting


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Unit Title Restart Machine After Stoppage


Unit Descriptor The unit covers the skills and knowledge to restart a textileproduction machine for continued or new product production.


1. Confirmproductionrequirements

1.1 Reasons for machine stoppageare confirmed.

1.2 Machine is confirmed as ready for restart.

1.3 Production specifications and machine settings areconfirmed.

1.4 Status of materials supply is confirmed.

1.5 Preparation requirements for restarting production areidentified.

1.6 Relevant maintenance or repair personnel are notifiedabout reasons for stoppage.

2. Prepare torestart machine

2. 1 Materials and finished product are loaded or unloadedfrom the machine as required.

2. 2 Materials and finished product are checked againstquality standards as required.

2. 3 Areas around the machine are cleaned as required toensure work environment is maintained in a safe andproductive manner.

2. 4 Waste is sorted.

2. 5 Machine is set.

3. Restart machine 3.1 Machine is restarted according to OHS practices

3.2 Operation is monitored to ensure production meetsspecification and quality standards.

3.3 Product faults are rectified or reported.

3.4 Production records and other documentation areaccurately completed as required.


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Variable Range

Legislative/regulatory requirements


Reasons for

machine stoppagemay include

breakdown

not meeting performance specifications maintenance requirements

completion of production run

staff changeovers





safe materials handling taking of rest breaks




housekeeping



Evidence GuideCritical Aspects ofCompetence


check machine settings to meet production requirements

prepare machine for start-up

check product against quality standards

load and unload products according to workplace practices

complete records accurately and completely


UnderpinningKnowledge and

Attitudes


procedures and guidelines for safe operation of machine

basic principles of textile production processes typical fault conditions and related fault finding procedures

types of materials used in textile products

technical specifications manuals



workplace practices


Underpinning

Skills


check safety equipment


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prepare machine in timely manner

monitor operations including machine production readings

recognize, rectify and report faults or problems as required

use resources effectively and efficiently

read, interpret and follow information on work specifications,

standard operating procedures and work instructions, andother reference material



sequence operations

meet specifications




Access is required to real or appropriately simulated situations,including work areas, materials and equipment, and to

information on workplace practices and OHS practices.Methods ofAssessment







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Unit Title Manage the Impact of Change on Own Work


Unit Descriptor This unit covers the skills needed by an employee in acompetitive manufacturing organization which requires theemployee to participate in and manage the impact of theimplementation of competitive manufacturing initiatives on theirown work life.


1. Examine theimpact of

change on ownwork practices

1.1 Examine changes to work flow.

1.2 Examine changes to equipment/process/physicalenvironment.

1.3 Examine changes to work relationship with teammembers and other teams.

1.4 Examine changes to data collection needs.

1.5 Examine changed work for impacts on health, safety andenvironment.

1.6 Examine changes to quality requirements.

1.7 Identify any additional individual skill needs.

1.8 Identify other areas requiring assistance.

2. Implementchange

2.1 Review changes which may have adverse impact withteam leader.

2.2 Adopt changes to individual work practice.

2.3 Seek assistance in gathering/processing data asrequired.

2.4 Implement the data collection/processing and takeactions on resulting information in accordance withprocedures.

2.5 Seek assistance/training to meet needs caused bychange.

3. Implementcontinuousimprovement

3.1 Critically examine all changes.

3.2 Identify impacts of changes both up and down theimmediate value chain.

3.3 Identify areas for improvement.

3.4 Make recommendations for improvement in accordancewith procedures.


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Variable Range

Managing impact ofchange

All Elements may be undertaken individually or as part of ateam and may require assistance from the team leader forareas outside the employee's range of responsibility andauthority.

Competitivemanufacturing

Competitive manufacturing is used to describe the range ofsystemic manufacturing practice concepts and approaches. Itcovers but is not limited to:

lean manufacturing

agile manufacturing

preventative and predictive maintenance approaches

monitoring and data gathering systems such as SystemsControl and Data Acquisition (SCADA) software, EnterpriseResource Planning (ERP) systems, ManufacturingResource Planning (MRP), and proprietary systems such asSAP

statistical process control systems including six sigma andthree sigma

Just In Time (JIT), kanban and other pull relatedmanufacturing control systems

supply, value, and demand chain monitoring and analysis

other continuous improvement systems. Competitivemanufacturing should be interpreted so as to take intoaccount the stage of implementation of competitive

manufacturing approaches, the enterprise's size and workorganization, culture, regulatory environment andmanufacturing sector

Procedures Procedures include:

all work instructions,

standard operating procedures,

formulas/recipes, batch sheets,

temporary instructions and similar instructions provided forthe smooth running of the plant. They may be:

written,

verbal, computer based or in some other form.

For the purposes of this Training Package, 'procedures' alsoincludes good operating practice as may be defined byindustry codes of practice (eg Good Manufacturing Practice(GMP), Responsible Care) and government regulations.

Continuousimprovement

Continuous improvement (also called kaizen) - the philosophyof continual improvement, that every process can and shouldbe continually evaluated and improved in terms of timerequired, resources used, resultant quality, and other aspectsrelevant to the process.

Value chain Competitive manufacturing organizations encompass the entire


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production system, beginning with the customer, and includethe product sales outlet, the final assembler, product design,raw material mining and processing and all tiers of the valuechain (sometimes called the supply chain). Any truly'competitive' system is highly dependent on the demands of its

customers and the reliability of its suppliers. No implementationof competitive manufacturing can reach its full potential withoutincluding the entire 'enterprise' in its planning.

Evidence Guide


Evidence of commitment to a range of initiatives should beavailable.

UnderpinningKnowledge and

Attitude


current process and principles of operation

sources of data on the process/plant and possibleapplications to information

methods of determining own skill needs and developingskills required

health, safety and environment (HSE) principles as relevantto own job

basic continuous improvement principles

UnderpinningSkills

Demonstrates skills of:

analysis

communication

problem solving reading and interpreting

teamwork


Access to an organization using competitive manufacturing.








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Unit Title Set up Ginning and Spinning Production Machines forProduct Change


Unit Descriptor This unit covers the skills and knowledge to perform orcoordinate the setting up of machines for production changes.


1. Set or organizesetting ofmachine

1.1 Product specifications are interpreted for correct machinesetting requirements.

1.2 Specifications are conveyed to appropriate personnel,

where required.1.3 Machine is set according to product specifications and

manufacturer instructions.

2. Conduct sampleor trial runs

2.1 Materials or productsto be used for sampling or trialingare obtained or arranged.

2.2 Machine is operated according to manufacturerrequirements and OHS practices.

2.3 Specified sample is produced.

3. Check sample

and organizequality testing

3.1 Sample is checked to ensure quality standards are met.

3.2 Quality testing is assessed or organized as required.

4. Re-adjust or onfirm machinesettings to meetrequirements

4.1 Test results are interpreted to determine adjustmentrequirements.

4.2 Adjustment changes are completed according to productand machine specifications.

Variable Range

Legislative/regulatoryrequirements

All work must comply with relevant Federal and State orTerritory legislative or regulatory requirements.

Machines mayinclude:

Ginning

Bale presser

Blowing

Carding

Drawing

Lap former

Combing

roving, spinning,


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twisting,

winding

yarn conditioning

Materials orproducts may

include:

lint

carded yarn

Combed yarn

Hosiery yarn

Open end yarnOHS practices OHS practices include hazard identification and control, risk

assessment and implementation of risk reduction measuresspecific to the tasks described by this unit, and may relate to:





taking of rest breaks ergonomic arrangement of workplaces



housekeeping



Evidence Guide


Demonstrates skills and knowledge to: interpret specifications for machine settings

arrange or conduct quality testing of samples

operate and adjust machines correctly

analyze samples or test results





machine and equipment operation

setting and adjustment requirements

technical specifications manuals maintenance planning and workplace practices



workplace practices



interpret technical data

set and operate machines

test and analyse samples


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use and dispose of a range of chemical cleaning agents,sealants and lubricants

document, assess and transfer information

read, interpret and follow information on workspecifications, standard operating

procedures and work instructions, and other referencematerial



sequence operations

meet specifications




Access is required to real or appropriately simulated situations,including work areas, materials and equipment, and to

information on workplace practices and OHS practices.Methods ofAssessment







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Unit Title Determine and Correct Mechanical Faults in Loom and OtherWeaving Equipment


Unit Descriptor This unit covers the skills and knowledge required to identify andcorrect mechanical faults in weaving looms and related weavingequipment.


1. Determine thecause of loom orrelated weaving

equipmentbreakdowns

1.1 Operator is consulted on loom operation and conditionprior to breakdown

1.2 Visual check is made of the loom and woven productfor

any obvious damage or faulty mechanical components

1.3 Fault finding skills are used to determine cause of loombreakdown

1.4 Loom engineering drawings, product specificationsandoperation manual are consulted where necessary

2. Solvemechanical loomand relatedweavingequipmentproblems

2.1 Gauges and toolsare used correctly to adjust machineand in accordance with OHS practices

2.2 Parts are dismantled and assessed for disposal,reconditioning or continued use

2.3 Parts are reconditioned, where required including anyneeded grinding, milling or turning

2.4 Replacement parts are fitted and/or adjusted and testedin accordance with manufacturer specifications andworkplace requirements

2.5 Loom or related weaving equipment is checked forcorrect operation after repair

2.6 Operator is advised of any special requirements as aconsequence of the repair

3. Overhaul andreconditionweaving loomsand relatedweavingequipment

3.1 Loom condition assessed and estimated schedule ofwork to be performed prepared

3.2 Loom and related equipment overhauls are carried out inaccordance with manufacturer specifications andworkplace requirements

3.3 Parts are reconditioned, where required, including anyneeded grinding, milling or turning

3.4 Loom or related weaving equipment is checked forcorrect operation at end of overhaul

4. Maintain records 4.1 Records are maintained and reports prepared, where

necessary


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Variable Range

Legislative/regulatory

requirements


Woven productmay includemay include

broadloom and narrowloom carpets

apparel

terry towelling

furnishing and upholstery fabrics

woven industrial products

woven healthcare products

Productspecificationsmay include

may include

quality name

pile height

beat-up

width weaving construction (pattern)

Gauges andtools mayinclude

hand and power tools

analogue and digital measuring equipment

grinders

OHS practices OHS practices must include hazard identification and control, riskassessment and implementation of risk reduction measuresspecific to the tasks described by this unit, and may include:



personal protective equipment safe materials handling





housekeeping


other OHS practices relevant to the job and enterprise

Evidence Guide



interpret appropriate documentation including wherenecessary standard operating procedures, loom and relatedequipment specifications, operating guidelines, workshopmanuals and technical drawings

determine the condition of parts

identify faults and determine appropriate repair strategies

set loom correctly

operate loom safely and correctly


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perform sample runs

make appropriate readjustments

apply workplace health and safety policies in productionoperations




loom components and loom operation

textile terminology and weaving theory

setting up and adjustment requirements for the range oflooms and equipment in the enterprise and the range ofwoven textiles produced

machine manufacturer specifications

safety and environmental aspects of relevant enterpriseactivities

OHS practices, including hazard identification and control

measures quality practices

workplace practices


UnderpinningSkills


set and operate looms and other textile machines

use appropriate hand and power tools and workshopmachinery appropriate for loom part or equipment repair

dismantle, repair and replace loom and related weavingequipment components

operate primary mechanisms, eg shed forming, weftinsertion, beat up, let off and take up

test loom performance

read, interpret and follow information on work specifications,standard operating procedures and work instructions andother reference material



sequence operations

meet specifications

clarify and check task-related information carry our work according to OHS practices










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Unit Title Ensure Efficient Operation of Textile Machines


Unit Descriptor This unit covers the skills and knowledge to ensure efficientoperation of textile machines.


1. Check machineperformance

1.1 Machine performance is monitored and reviewed andadjustments made as required, in accordance withmanufacturer specifications and OHS practices.

1.2 Machine operations and processes are monitored toensure correct procedures are assessed and productmeets quality standards.

1.3 Machine operator is consulted to assess machineoperations and processes.

1.4 Records and documentation of machine performance andmaintenance are maintained.

2. Identifyproblems with

machineoperation

2.1 Symptomsof machinery fault are identified.

2.2 Visual inspection of machine and product is used to locatefault.

2.3 Fault is located within section or component of machine.

2.4 Operating manuals or documentation are referred to asrequired.

3. Determineproblem causeand solution

3.1 Possible causes of problem are determined.

3.2 Further information is gathered to confirm or eliminatepossible cause.

3.3 Appropriate personnelare consulted to confirm cause.

3.4 Immediate solutionis determined and trialled orimplemented.

3.5 Permanent solution is determined in consultation withappropriate personnel.

4. Conduct routinechecks ofperformanceefficiency

4.1 Routine checks of machine performance are assessedagainst production specifications in accordance withmanufacturer instructions.

4.2 Preventative maintenance strategy for machine is checkedand assessed in accordance with manufacturer

instructions.


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4.3 Periodic servicing such as lubrication and greasing, etc. isassessed in accordance with manufacturer instructions asrequired.

4.4 Machine is cleaned in accordance with manufacturer

cleaning instructions.5. Perform

preventativemaintenanceprocedures

5.1 Inspection of parts is conducted according to operatingprocedures and manufacturer instructions.

5.2 Service and production records are maintained to assistwith life cycle monitoring of parts and machine as required.

5.3 Faulty parts are identified for repair, replacement oradjustment as required.

5.4 Parts and consumablesto be repaired or replaced areidentified and repaired or replaced as required.

5.5 Replacement parts and consumables are inspected,checked and monitored to ensure compliance withoperational specifications.

Variable Range

Legislative/

regulatoryrequirements

All work must comply with relevant Federal and State or

Territory legislative or regulatory requirements.

Symptoms mayinclude:

product does not meet specification machine is not operating to specification

sounds not attributed to normal operation

current faults such as yarn breaking, etc.

Machines mayinclude:

knitting machines

carding machines

spinning machines

weaving looms

dyeing equipment

tufting looms

finishing equipment creeling and warping machines

Appropriatepersonnel may

Include:

textile mechanic

supervisor

senior operator

Immediate solutionmay

Include:

decommission machine

change settings

adjust operation

perform temporary fix

refer to textile mechanic

Parts and items that require periodic replacement as a result of


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consumables

may include:

normal machine and production operations, e.g. belts,globes, combs










housekeeping



Evidence Guide



operate machines correctly

monitor machine performance against specifications and

undertake minor adjustments

clean machines

identify faults identify and replace replaceable parts and consumables

used in normal machine operations

communicate and cooperate with mechanics/technicians

and production personnel

complete records accurately and completely




procedures and guidelines for safe operation of machines

typical fault conditions and related fault finding procedures

routine maintenance processes and practices preventative maintenance concepts

root cause analysis concepts

range and use of replacement parts and consumables

techniques to replace parts and consumables

characteristics of materials and fibres

technical specifications manuals



workplace practices



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UnderpinningSkills


assess operating performance of machine

undertake root cause analysis

carry out preventative maintenance activities

start and stop machines according to specifications

monitor machine operations including machine productionreadings

recognize fault conditions

use hand tools and hand-held power tools

undertake cleaning and servicing

recognize, rectify machine faults or problems as required

check machine maintenance records

check and confirm compliance to operational specifications

solve problems brainstorm

read, interpret and follow information on work specifications,standard operating

procedures and work instructions, and other referencematerial



sequence operations

meet specifications

clarify and check task-related information carry out work according to OHS practices











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Unit Title Sustain Process Improvements


Unit Descriptor This unit covers the skills needed to prevent implementedprocess improvements slipping back to former practices ordigression to less efficient practices.


1. Implementcorrective

actions

1.1 Identify impact of process improvements on systems inown work area.

1.2 Examine process improvements.

1.3 Clarify changes to process improvements as required.

1.4 Identify any additional, personal skill gaps and seek skilldevelopment.

1.5 Adopt improved process.

2. Check changes 2.1 Identify claimed improvements.

2.2 Identify methods of observing claimed improvements.

2.3 Check if claimed improvements are occurring and reportproblems in accordance with procedures.

3. Check forfurtherimprovements

3.1 Look for areas of possible further improvement.

3.2 Take action to make improvements in accordance withprocedures.

Variable Range

Performance Performance may be thought of as the rate of output of theplant compared to the rate required to meet demand.

Performance might also be thought of in terms of task wheretask time is the allowable time to produce one product at therate customers is demanding it. This is NOT the same ascycle time, which is the normal time to complete anoperation on a product (which should be less than or equalto task time).

Proceduresinclude:

All work instructions,

standard operating procedures,

formulas/recipes,

batch sheets,

temporary instructions and similar instructions provided for


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the smooth running of the plant

They may be:

written,

verbal,

computer based or in some other form.

For the purposes of this Training Package, 'procedures' alsoincludes good operating practice as may be defined by industrycodes of practice (e.g. Good Manufacturing Practice (GMP),Responsible Care) and government regulations.

Improvements Improvement procedures in some enterprises is also known bybaka-yoke which is a manufacturing technique of preventingmistakes by designing the manufacturing process, equipmentand tools so that an operation literally cannot be performedincorrectly. An attempt to perform incorrectly, as well as beingprevented, is usually met with a warning signal of some sort; the

term poka-yoke is sometimes referred to as a system whereonly a warning is provided.

Evidence Guide


Evidence of having sustained improvements in their own job andof assessing these improvements for their real impact.



existing procedures

modified proceduresUnderpinningSkills

Demonstrates skills of:

technical competence to perform job

problem solving

teamwork

communication


Access to a workplace implementing competitive manufacturingstrategies or appropriate simulated environment is required. Noother specific resources are required.

Methods of

Assessment


Interview / Written Test Observation / Demonstration with Oral Questioning




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Unit Title Apply Quality Control


Unit Descriptor This unit covers the knowledge, skills and attitudes required in

applying quality control to apparel production.


1. Determinequalitystandards

1.1 Quality standard documents are acquired and reviewed

1.2 Quality standards and procedures are introduced to staff /personnel.

1.3 Quality standard procedures are ensured to be implementedin accordance with the organization/workplace policy.

1.4 Standard procedures are revised / updated when necessary

2. Assessquality ofwork andproductdelivered

2.1 Products/work outputs and work performance are checkedagainst organization quality standardsand specifications

2.2 Work outputs and performance delivered are evaluated usingthe appropriate evaluation parametersand in accordancewith organization standards

2.3 Causes of any identified faults are identified and correctiveactions are taken in accordance with organization policies and

procedures3. Record

information3.1 Basic information on the quality performance is recorded in

accordance with organization procedures

3.2 Records of work quality are maintained according to therequirements of the organization

4. Study causesof qualitydeviations

4.1 Causes of deviations from final outputs or services areinvestigated and reported in accordance with organizationprocedures

4.2 Suitable preventive action is recommended based on

organization quality standards and identified causes ofdeviation from specified quality standards of final service oroutput

5. Completedocumentation

5.1 Information on quality and other indicators of serviceperformance is recorded.

5.2 All service processes and outcomes are recorded.


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Variable Range

Quality check visual inspection

physical measurements

check against design/specifications

Qualitystandards

materials component parts

final product

production process

conformity to specifications

Qualityparameters

finish

size

durability

product variations

materials

alignment color

damage and imperfections

Evidence Guide

Critical Aspectsof Competence

Assessment requires evidence that the candidate:

checked completed work continuously against organizationstandard

identified and isolated faulty or poor product/output

checked service delivered against organization standards

identified and applied corrective actions on the causes ofidentified faults or error

recorded basic information regarding quality performance

investigated causes of deviations of services against standard

recommended suitable preventive actions



relevant quality standards, policies and procedures

characteristics of products/outputs

safety environment aspects of production processes

relevant evaluation techniques and quality checkingprocedures

workplace procedures and reporting procedures

UnderpinningSkills


interpret work instructions, specifications and standardsappropriate to the required work or product

carry out relevant performance evaluation

maintain accurate work records in accordance with procedures

meet work specifications and requirements

communicate effectively within defined workplace procedures


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The following resources should be provided:

access to relevant workplace or appropriately simulatedenvironment and materials relevant to the activity/ task


Competence may be accessed through:

Interview / Written Test Observation / Demonstration with Oral Questioning

Context forAssessment

Competence may be assessed in the work place or in a simulatedwork place setting


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Unit Title Lead Small Team


Unit Descriptor This unit covers the knowledge, skills and attitudes to lead small

teams including setting and maintaining team and individualperformance standards.


1. Provide teamleadership

1.1 Work requirementsare identified and presented to teammembers

1.2 Reasons for instructions and requirements are communicatedto team members

1.3 Team members queries and concernsare recognized,

discussed and dealt with

2. Assignresponsibilities

2.1 Duties and responsibilities are allocated having regard to theskills, knowledge and aptitude required to properly undertakethe assigned task and according to company policy

2.2 Duties are allocated having regard to individual preference,domestic and personal considerations, whenever possible

3. Setperformanceexpectations

for teammembers

3.1 Performance expectations are established based on clientneeds and according to assignment requirements

3.2 Performance expectations are based on individual team

members duties and area of responsibility3.3 Performance expectations are discussed and disseminated to

individual team members

4. Supervisedteamperformance

4.1.Monitoring of performancetakes place against definedperformance criteria and/or assignment instructions andcorrective action taken if required

4.2. Team members are provided with feedback, positive supportand advice on strategies to overcome any deficiencies

4.3.Performance issueswhich cannot be rectified or addressed

within the team are referenced to appropriate personnelaccording to employer policy

4.4. Team members are kept informed of any changes in thepriority allocated to assignments or tasks which might impacton client/customer needs and satisfaction

4.5. Team operations are monitored to ensure that employer/ clientneeds and requirements are met

4.6. Follow-up communication is provided on all issues affectingthe team

4.7. All relevant documentation is completed in accordance with

company procedures


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Variable Range

Workrequirements

Client Profile

Assignment instructions

Team membersconcerns

Roster/shift details

Monitorperformance

Formal process

Informal process

Feedback Formal process

Informal process

Performanceissues

Work output

Work quality

Team participation Compliance with workplace protocols

Safety

Customer service

Evidence Guide



Maintained or improved individuals and/or team performance

given a variety of possible scenario

Assessed and monitored team and individual performanceagainst set criteria

Represented concerns of a team and individual to next level ofmanagement or appropriate specialist and to negotiate on theirbehalf

Allocated duties and responsibilities, having regard toindividuals knowledge, skills and aptitude and the needs of thetasks to be performed

Set and communicated performance expectations for a rangeof tasks and duties within the team and provided feedback toteam members



Company policies and procedures

Relevant legal requirements

How performance expectations are set

Methods of Monitoring Performance

Client expectations

Team members duties and responsibilities


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UnderpinningSkills


Communication skills required for leading teams

Informal performance counseling skills

Team building skills

Negotiating skills


Access to relevant workplace or appropriately simulatedenvironment where assessment can take place

Materials relevant to the proposed activity or task



Interview/Written Test





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Unit Title Lead Workplace Communication


Unit Descriptor This unit covers the knowledge, skills, and attitudes to lead in

the dissemination and discussion of information and issues inthe workplace.


1. Communicateinformationabout workplaceprocesses

1.1 Appropriate communication methodis selected

1.2 Multiple operations involving several topics areas arecommunicated accordingly

1.3 Questions are used to gain extra information

1.4 Correct sources of information are identified

1.5 Information is selected and organized correctly

1.6 Verbal and written reporting is undertaken when required

1.7 Communication skills are maintained in all situations

2. Lead workplacediscussion

2.1 Response to workplace issues are sought

2.2 Response to workplace issues are provided immediately

2.3 Constructive contributions are made to workplace

discussions on such issues as production, quality andsafety

2.4 Goals/objectives and action plan undertaken in theworkplace are communicated.

3. Identify andcommunicateissues arising inthe workplace

3.1 Issues and problems are identified as they arise

3.2 Information regarding problems and issues are organizedcoherently to ensure clear and effective communication

3.3 Dialogue is initiated with appropriate staff/personnel

3.4 Communication problems and issues are raised as theyarise


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Variable Range

Methods ofcommunication

Non-verbal gestures

Verbal

Face to face

Two-way radio Speaking to groups

Using telephone

Written

Using Internet

Evidence Guide



Dealt with a range of communication/information at one time Made constructive contributions in workplace issues

Sought workplace issues effectively

Responded to workplace issues promptly

Presented information clearly and effectively written form

Used appropriate sources of information

Asked appropriate questions

Provided accurate information



Organization requirements for written and electroniccommunication methods

Effective verbal communication methods

Apparel/Garments Terminology

UnderpinningSkills


Organize information

Understand and convey intended meaning

Participate in variety of workplace discussions

Comply with organization requirements for the use of writtenand electronic communication methods


The following resources must be provided: variety of information,communication tools, simulated workplace



Interview/Written Test





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Unit Title Improve Business Practice


Unit Descriptor This unit covers the knowledge, skills and attitudes required in

promoting, improving and growing business operations.


1. Diagnose thebusiness

1.1 Data requiredfor diagnosis is determined and acquired

1.2 Competitive advantageof the business is determined fromthe data

1.3 SWOT analysisof the data is undertaken

2. Benchmarkthe business

2.1 Sources of relevant benchmarking data are identified

2.2 Key indicatorsfor benchmarking are selected in consultationwith key stakeholders

2.3 Like indicators of own practice are compared with benchmarkindicators

2.4 Areas for improvement are identified3. Develop

plans toimprove

businessperformance

3.1 A consolidated list of required improvements is developed

3.2 Cost-benefit ratios for required improvements are determined

3.3 Work flow changes resulting from proposed improvementsare determined

3.4 Proposed improvements are ranked according to agreedcriteria

3.5 An action plan to implement the top ranked improvements isdeveloped and agreed

3.6 Organizational structuresare checked to ensure they aresuitable

4. Develop

marketingandpromotionalplans

4.1 The practice vision statement is reviewed

4.2 Practice objectivesare

Documents

Tesfay OS Spinning and Ginning Operations L2 & L3 Doc