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Federal Democratic Republic of Ethiopia

OCCUPATIONAL STANDARD

Federal Democratic Republic of Ethiopia OCCUPATIONAL STANDARD TEXTILE TECHNOLOGY AND PRODUCTION MANAGEMENT NTQF Level V

TEXTILE TECHNOLOGY AND PRODUCTION MANAGEMENT

Ethiopia OCCUPATIONAL STANDARD TEXTILE TECHNOLOGY AND PRODUCTION MANAGEMENT NTQF Level V Ministry of Education May 2011
NTQF Level V
NTQF Level V

Ministry of Education May 2011

Introduction

Ethiopia has embarked on a process of reforming its TVET-System. Within the policies 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 new paradigm in the outcome-based TVET system is the orientation at the current and anticipated future demand of the economy and the labor market.

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

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

A Unit of Competence describes a distinct work activity. It is documented in a standard 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 determining whether the candidate is competent.

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

chart with an overview of all Units of Competence for the respective level including 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 when designing training programs for this standards and for the individual, a career path

 

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UNIT OF COMPETENCE CHART

Occupational Standard: Textile Technology and Production Management

Occupational Code: TXT TPM

 

NTQF Level V

 
 

TXT TPM5 01 0511

 

TXT TPM5 02 0511

 

TXT TPM5 03 0511

Develop Manufacturing Related Business Plan

Develop and Manage Competitive Manufacturing Processes

Plan and Implement Production

TXT TPM5 04 0511

TXT TPM5 05 0511

TXT TPM5 06 0511

Manage Production Processes

Facilitate Continuous Improvement in Manufacturing

Install and Commission Process and Machine Control Programs

TXT TPM5 07 0511

TXT TPM5 08 0511

TXT TPM5 09 0511

Manage Maintenance Analysis

Manage Environment Impact of Process

Manage Value Chain

TXT TPM5 10 0511

TXT TPM5 11 0511

TXT TPM5 12 0511

Develop and Implement Sales/ Marketing Plan

Manage Quality Systems and Procedures

Develop Communication Strategy to Support Production

TXT TPM5 13 0511

TXT TPM5 14 0511

TXT TPM5 15 0511

Practice Career Professionalism

Establish and Conduct Business Relationships

Facilitate and Capitalize on Change and Innovations

TXT TPM5 16 0511

 

Manage Project Quality

 

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Occupational Standard: Textile Technology and Production Management Level V

Unit Title

Develop Manufacturing Related Business Plan

Unit Code

TXT TPM5 01 0511

Unit Descriptor

This unit covers the knowledge and skills needed to develop business plans in a competitive manufacturing environment.

Elements

Performance Criteria

1. Determine purpose of plan

1.1

Purpose/reason for developing the plan and expected outcomes are confirmed with appropriate documents and all relevant stakeholders

1.2

Expected outcomes from plan are checked with overall strategic plan for organization

1.3

Potential areas for conflict between proposed plan and strategic directions are identified

1.4

Negotiation with relevant stakeholders is performed to resolve issues

2. Determine

2.1

Objectives of the business plan are drafted and strategies to achieve them identified

objectives and

strategies

2.2

Implications for value chain are determined

2.3

Capital or workplace layout/organization implications for objectives and strategies are determined

3. Develop plan to meet objectives and strategies

3.1

Negotiation with relevant stakeholders over implications for objectives and strategies are performed in accordance with organization policies and procedures

3.2

In liaison with relevant stakeholders, plan is developed to meet objectives

3.3

Key Performance Indicators (KPIs) of the plan are determined and ensured appropriateness to the purpose of the plan

3.4

Plan is mapped and adjusted to optimize or change value chain

3.5

Plan is validated with relevant stakeholders

4. Monitor implementation of the plan

4.1

Plan is disseminated/deployed for implementation

4.2

Key progress points are checked against key stages of the plan and noted any discrepancies

 

4.3

Appropriate actions are undertaken to ensure correct implementation of the plan

 

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Variable

 

Range

Occupational Health and Safety

Safe working practices’ include compliance on accepted policies, standard, strategies legislative and enterprise requirements.

Recognize hazards commonly occurring at the workplace and follow health and safety instructions and procedures in the workplace.

Tools and

Stationary, Internet, related books and related materials and Technical manuals

equipment

Plan

May include:

Any sort of business plan and may emphasize any of the areas for sub plans over the others.

Objectives

May include:

Quality

Occupational health and safety (OHS)

Environment

Competitive manufacturing practices

Human, physical, financial and environmental/resource

Objectives and

May include:

Strategies

Human and industrial relations

Material/component and resources

Sustainable environmental practices

Sales and marketing

Financial

Relevant

May include:

stakeholders

Other team members

Other workers

Management

Technical specialists

Other members of the value chain.

Evidence Guide

Critical Aspects of Competence

Critical evidence of knowledge and skills include:

Determine purpose of plan

 

Develop objectives and strategies

Develop plans to meet objectives and strategies

Monitor the implementation of the plan

Underpinning Knowledge and Attitudes

Demonstrate a knowledge of:

organizing strategic plans and directions

Planning methods and types of plans

 

Contingency planning and other risk mitigating planning tools

The organization’s value chain

 

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Analysis of value chain

Competitive manufacturing practices

Application of quality principles

Human resources and Industrial Relations

 

OHS

Underpinning Skills

Demonstrate the skill on:

Literacy skills to enable interpretation of business information,

Communication skills relevant to business performance

Numeracy skills for data analysis

Ability to relate to people from a range of social, cultural and ethnic backgrounds and physical and mental abilities

Resource

The following resources must be provided.

Implications

Workplace or fully equipped assessment location with necessary tools and equipment as well as consumable materials

Method of

Competence may be assessed through:

Assessment

Interview / Written Test

Observation/Demonstration with Oral Questioning

Context of

Competence may be assessed in the work place or in a simulated workplace setting.

Assessment

 

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Occupational Standard: Textile Technology and Production Management Level V

Unit Title

Develop and Manage Competitive Manufacturing Processes

Unit Code

TXT TPM5 02 0511

Unit Descriptor

This unit covers the knowledge, attitudes and skills required to prepare for, and manage the introduction of, a competitive manufacturing process in a jobbing/batching/contracting manufacturing environment.

Elements

Performance Criteria

1. Analyze existing

1.1

Enterprise capability for products and processes is determined

manufacturing process

1.2

Major processing steps in meeting customer orders are identified

1.3

Employees, managers and other major stakeholders are consulted on major expected benefits from a move to a competitive manufacturing strategy

1.4

Lead times, throughput times and waiting times throughout the process of meeting customer orders are identified

1.5

Variations within the process and its causes are identified

2. Draft virtual

2.1

Flow of information, material, and people for each product family are mapped

flow process

2.2

Current state value stream map for the process as a virtual flow process are drawn

2.3

Current value stream map for waste is analyzed

2.4

Possible future state value stream map(s) are drafted

2.5

Benefits flowing from future state map(s) are calculated and validated with stakeholders

3. Prepare

3.1

Options for the delivery of changes required to move to future state value stream map(s) are identified

proposals for

process

3.2

As to how changes be implemented including resource, industrial relations, workforce development and occupational health and safety considerations and implications are planned

redesign

3.3

Proposed changes are cost and benefit cost ratios determined

3.4

Recommendations for change are prepared and negotiated/consulted with relevant stakeholders to establish

 

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the preferred option.

4. Implement the plan

4.1 Altered process layout is arrange as required

4.2 Altered infrastructure needs are arrange as required

4.3 Implementation of the plan is monitored and adjustments made as required

4.4 New value stream is reviewed and checked that expected benefits have been obtained

4.5 Continuous improvement mechanism for the new value stream is put in place.

Variable

Range

Occupational Health & safety

Safe working practices’ include compliance on accepted policies, standard, strategies legislative and enterprise requirements.

Recognize hazards commonly occurring at the workplace and follow health and safety instructions and procedures in the workplace.

Tools and

Internet, related books and related materials

equipment

Technical manuals

Competitive

May include one or more of the following:

manufacturing

Six sigma

strategy

Lean Manufacturing

Agile Manufacturing

Just in Time (JIT)

Supply chain management

Value Chain Management

Total Quality

Pro Active maintenance

Elimination of waste

Balanced Scorecard

Variations

Deviations from desired targets and may cover variations in:

quality

time

cost

OHS

Waste

Activity which does not contribute to customer benefit or features in the product categorize as waste include:

excess production and early production

delays and unnecessary movement and transport

poor process design

inappropriate inventory

 

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inefficient performance of a process

 

making defective items

Waste for this unit may include activities which do not yield any benefit to the organization or to the organizations customers.

Stakeholders

May include:

managers

supervisors

employees

shareholders

OHS mechanisms/representatives

 

IR mechanisms/representatives

suppliers

customers

service providers

 

Infrastructure

May include:

needs

physical infrastructure, including plant, equipment, tools, systems and processes

information and control infrastructure

 

work organization including numbers of employees

work structure and skills and knowledge held by employees

workforce development and, where required, training

 

Evidence Guide

 

Critical Aspects of Competence

Assessment requires evidence that the candidate:

 

Analyze the existing manufacturing process.

 

Draft a virtual flow process

Implement the plan.

Prepare proposals for process redesign

Underpinning Knowledge and Attitudes

 

Demonstrate a knowledge of:

 

the customers and the benefits they derive from the products

the suppliers and their capabilities

 
 

product waste

relevant tools for their job and how to apply them

 

Factors impacting on the product, process and waste, particularly those wholly or partially under their control (and how to control them).

Underpinning

Demonstrate the Skills on:

 

Skills

analysis

communication

planning

teamwork

Problem solving.

 
 

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Resource

The following resources must be provided.

Implication

Workplace or fully equipped assessment area with necessary tools and equipment as well as consumable materials

Method of

Competence may be assessed through:

Assessment

Interview / Written Test

Observation/Demonstration with Oral Questioning

Context of

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

Assessment

 

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Occupational Standard: Textile Technology and Production Management Level V

Unit Title

Plan and Implement Production

Unit Code

TXT TPM5 03 0511

Unit Descriptor

This unit covers the knowledge, skills and attitudes required to plan and implement production within a textiles.

Elements

Performance Criteria

 

1. Determine

1.1

Projected quantity and quality requirements, standard and production capacities are identified

times

production

requirements

1.2

Production process and material handling options are identified

1.3

Resources required for the project or production order are established

2. Prioritize and

2.1

Work is prioritized taking into account production demands, customer requests and requirements and efficiency standards of the workplace

sequence

production

2.2

Steps required for the process are identified ensuring most efficient use of resources

2.3

Documentation is prepared in accordance with workplace practices

2.4

Implement selected solutions

3. Organize team

3.1

Work team is selected and organized in accordance with workplace practices

and resources

3.2

Facility, equipment and material and resources required for the production process are identified and organized in accordance with the production schedule and OHS practices

4. Implement and

4.1

Work flow is monitored to ensure production schedule is maintained

monitor work

flow

4.2

Methods are implemented to ensure that work is directed to each work area or location as required, and potential congestion areas are identified

4.3

Troubleshooting occurs on a regular basis in response to breakdowns, absenteeism and other factors

5. Implement variations to production plan

5.1

Systematic implementation of variations to the production plan are coordinated to ensure production meets the schedule and specifications

5.2

Work is re-allocated in accordance with production priorities,

 

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where required

5.3

Inefficiencies are identified and dealt with in accordance with workplace production practices

5.4

Team or individual responsibilities are defined and communicated

6. Maintain

6.1

Records are maintained and updated

records

6.2

Reports are prepared, where necessary, in accordance with workplace procedures

6.3

Necessary documentation is accomplished in accordance with standard procedures

Variable

 

Range

Production

May relate to:

planning

establishing an overall plan for manufacture/product

delivery

repetitive production runs

short runs

quick changes

a diversity of styles

indent orders

stock services replenishment

Production

May include:

process

just in time

quick response

quality circles

team processes

benchmarking

Product schedule

May include:

plant layout and machine involvement and personnel required for particular operations

OHS practices

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

manual handling techniques

standard operating procedures

personal protective equipment

safe materials handling

taking of rest breaks

ergonomic arrangement of workplaces

following marked walkways

safe storage of equipment

housekeeping

 

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 reporting accidents and incidents  other OHS practices relevant to the job and enterprise
 reporting accidents and incidents  other OHS practices relevant to the job and enterprise

reporting accidents and incidents

other OHS practices relevant to the job and enterprise

Evidence Guide

Critical Aspects of Competence

Assessment requires evidence that the candidate:

 

established production requirements

 
 

prioritized work

 

selected and organize work team

 

ensured efficiency of production schedule

 

dealt with inefficiencies

 

applied OHS practices in production operations

 

maintained accurate records

 

Underpinning Knowledge and Attitudes

Demonstrates knowledge of:

 

work

organization

systems

and

workplace

organization

features

 
 

production planning processes, such as material supply etc.

safety

and

environmental

aspects

of

relevant

workplace

activities

 

OHS practices, including hazard identification and control measures

quality practices

 

workplace practices

recording and reporting practices

 

Underpinning

Demonstrates skills to:

 

Skills

interpret and use data from a range of sources

 

sequence production

 

monitor workflow

 

organize resources

respond to breakdowns, absenteeism, etc.

 

coordinate variations to production plan

 

document and transfer information

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

procedures

and

work

instructions

and

other

reference

material

 

maintain accurate records

 

communicate within the workplace

 

sequence operations

 

meet specifications

 

clarify and check task-related information

 

carry out work according to OHS practices

Resource

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

Implications

 

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Method of

Competence may be assessed through:

Assessment

Interview / Written Test

Observation/Demonstration with Oral Questioning

Context of

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

Assessment

 

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Occupational Standard: Textile Technology and Production Management Level V

Unit Title

Manage Production Processes

Unit Code

TXT TPM5 04 0511

Unit Descriptor

This unit covers the skills, attitudes and knowledge required to manage the technical processes in the preparation of resource, monitoring production stages and measuring specified process parameters.

Elements

Performance Criteria

1. Coordinate

1.1

Technical process requirements are interpreted in terms of resources and procedures

resource use

1.2

Schedules and technical resources are confirmed with relevant personnel

1.3

Process and occupational health and safety requirements are clarified, where necessary

2. Manage the

2.1

Roles and responsibilities are allocated as required

process

2.2

Technical process is monitored and guidance provided where required

2.3

Process parameters are monitored to ensure conformance to requirements

2.4

Safety associated with the process including chemical handling is monitored

3. Facilitate

3.1

Methods to solve process problems are identified through facilitation of meetings or discussions

process

problem

3.2

Knowledge of process improvement and technical systems are used to assist in the systematic identification and resolution of process problems

resolution

3.3

Preferred option to resolve the problem is recommended and documented

3.4

Implementation of the recommended problem resolution option is facilitated

4. Monitor

4.1

Improvements and variations to process are monitored to ensure outcome meets specifications, production schedule and workplace requirements

process

improvements

and variations

4.2

Data is collated and analyzed to evaluate the effectiveness of process improvements or variations

 

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Variable

Range

Occupational Health and Safety (OHS) requirements

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

manual handling techniques

 

standard operating procedures

personal protective equipment

safe materials handling

taking of rest breaks

ergonomic arrangement of workplaces

following marked walkways

safe storage of equipment

housekeeping

reporting accidents and incidents

other OHS practices relevant to the job and enterprise

Process

Process parameters may Include:

parameters

speed

RH%

Efficiency

machine utilization

production

production capacity of machines

temperature

pressure

chemical values

time

volume

quantities

pH (BE)

concentration

viscosity

Evidence Guide

Critical Aspects of Competence

Demonstrates skills and knowledge to:

allocate tasks and roles to relevant personnel

 

manage process

solve problems and monitor process improvements

Underpinning Knowledge and Attitudes

Demonstrates knowledge of:

industry and product and technical processes and equipment and resources

 

technical and specified process parameters

characteristics or raw materials and their properties

processing, measurement, matches

 

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monitoring processes and procedures

quality standards and manual handling procedures

safety and environmental aspects of relevant processes, including use of chemicals

workplace procedures and reporting and documentation processes and procedures

chemical processes relating to production

OHS practices, including hazard identification and control measures

recording and reporting practices

Underpinning

Demonstrates skills to:

Skills

interpret requirements

determine schedules and resources

match personnel to tasks and roles

facilitate problem solving associated with process variations

analyze process parameters

monitor process requirements

communicate effectively within the workplace

document, assess and transfer information

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

maintain accurate records

sequence operations

meet specifications

clarify and check task-related information

carry out work according to OHS practices

Resource

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

Implications

Method of

Competence may be assessed through:

Assessment

Interview / Written Test

Observation/Demonstration with Oral Questioning

Context of

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

Assessment

 

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Occupational Standard: Textile Technology and Production Management Level V

Unit Title

Facilitate Continuous Improvement in Manufacturing

Unit Code

TXT TPM5 05 0511

Unit Descriptor

This unit covers the knowledge, attitudes and skills required to facilitate continuous improvement (kaizen) in an organization.

Elements

Performance Criteria

1. Facilitate team

1.1

Improvement team is assisted and selected appropriate improvement projects

improvement

1.2

Resources required and arrangements for the team to undertake improvement projects are facilitated

1.3

Provision of required data is arranged for the improvement team

1.4

Improvement team is assisted in developing the scope and benefit statements

1.5

Training of improvement team members is organized as required

2. Build a

2.1

Training as required for work group members is organized

continuous

2.2

Work group members are encouraged to routinely monitor key process indicators

improvement

process

 

2.3

Capacity of the work group to critically review the relevant parts of the value chain is developed

2.4

Work group members are assisted to formalize improvement suggestions

2.5

Work group members are assisted to develop implementation plans and resources needed facilitated

2.6

Implementation of improvement plans is monitored and appropriate actions undertaken to assist implementation where required.

Variable

Range

Occupational Health & Safety (OH&S)

Safe working practices’ include compliance on accepted policies, standard, strategies legislative and enterprise requirements.

implement and monitor defined OHS policies and procedures for a work group or area, within their scope of responsibilities

OHS management system (OHSMS) within the area of managerial responsibility, in order to ensure that the

 

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workplace is so far as is practicable, consistently safe and without risks to the health and safety of employees. It assumes that the OHSMS has been developed by persons with the relevant specialist knowledge and skills.

Scope and benefit statements may include:

target work process

what the key stakeholders seek from the improvement project

mission for the event

set of goals

 

statement of the do's and don'ts for the improvement project

Key process

Key process indicators may include:

indicators

statistical process control data/charts

orders

lost time, injury and other OHS records

equipment reliability charts etc.

Evidence Guide

Critical Aspects of Competence

Assessment requires evidence that the candidate:

facilitated resources and arrangements for the team to undertake improvement projects

 

assisted the improvement team develop scope and benefit statements

built capacity in the work group to critically review the

relevant parts of the value chain

resourced and assisted to facilitate relevant work group members to develop implementation plans

Underpinning Knowledge and Attitudes

Demonstrate a knowledge of:

current process and principles of operation

sources of data on the process/plant and possible

 

applications to information

methods of determining and developing own skill needs

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

basic continuous improvement principles

Underpinning

Demonstrate the Skill on:

Skills

analysis and problem solving skills

communication

reading and interpreting

teamwork

 

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Resource

The following resources must be provided:

Implications

Workplace or fully equipped assessment area with necessary tools and equipment as well as consumable materials

Method of

Competence may be assessed through:

Assessment

Interview / Written Test

Observation/Demonstration with Oral Questioning

Context of

Competency may be assessed in the work place or in a simulated work place setting

Assessment

 

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Occupational Standard: Textile Technology and Production Management Level V

Unit Title

Install and Commission Process and Machine Control Program

Unit Code

TXT TPM5 06 0311

Unit Descriptor

This unit covers the skills, attitudes and knowledge required to install and commission process and machine control system programs in machines and equipment.

Elements

Performance Criteria

1. Install

1.1

Appropriate program loading technique is selected and external loading devices connected to automatic process and machine control system correctly

automatic

process and

machine

1.2

Process and machine control system are placed in correct operational mode to accept program loading

control

program

1.3

Program is downloaded in accordance with manufacturers' recommended procedure or appropriate standard operating procedures and OHS practices

1.4

Checks are undertaken appropriately during and after downloading to ensure data transfer is accurate and complete

1.5

All external program loading devices and connections are disconnected from process and machine control system

2. Commission

2.1

Program format and operational intent are accurately determined and correctly understood

automatic

process and

2.2

Program instructions are checked for compliance with specifications

machine

control

program

2.3

Software timers are counter set to specification, where required

2.4

Program is stepped through manually and outputs are checked and measured for compliance with specifications

2.5

External inputs are checked for compliance with specifications, according to specified procedures

2.6

Program is run and total operation is checked for compliance with specifications, where applicable

2.7

Confirmation of program master copy storage is assessed

3. Maintain

3.1

Necessary records are updated and maintained

records

3.2

Reports are prepared, where necessary, in accordance with workplace practices

3.3

Necessary documentation is accomplished in accordance with workplace procedures

 

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Variable

Range

Regulatory

All work must comply with relevant Federal and Regional regulatory requirements.

requirements

Machine

Microprocessor or computer control and include production and facility equipment used within the enterprise

OHS practices

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

manual handling techniques

standard operating procedures

personal protective equipment

safe materials handling

taking of rest breaks

ergonomic arrangement of workplaces

following marked walkways

safe storage of equipment

housekeeping

reporting accidents and incidents

other OHS practices relevant to the job and enterprise

Evidence Guide

Critical Aspects of Competence

Demonstrates skills and knowledge to:

 

select and use appropriate loading technique

 
 

perform checks to ensure accurate data transfer

check program instructions

 

run program to ensure compliance with specifications

 

apply OHS practices in work operations

 

maintain accurate records

 

Underpinning Knowledge and Attitudes

Demonstrates knowledge of:

 

appropriate installation and commissioning procedures

quality requirements and relevant standards

 
 

machine and equipment manufacturer's specifications and instructions

safety

and

environmental

aspects

of

relevant

workplace

activities

 

OHS practices, including hazard identification and control measures

quality and workplace practices

 

recording and reporting practices

 

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Underpinning

Demonstrates skills to:

Skills

apply appropriate technical skills

carry out checking processes

monitor performance

apply all the relevant safety practices when working in the industry

document and transfer information

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

maintain accurate records

communicate within the workplace

sequence operations

meet specifications

clarify and check task-related information

carry out work according to OHS practices

Resource

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

Implications

Method of

Competence may be assessed through:

Assessment

Interview / Written Test

Observation/Demonstration with Oral Questioning

Context of

Assessment may occur on the job or in an appropriately simulated environment.

Assessment

 

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Occupational Standard: Textile Technology and Production Management Level V

Unit Title

Manage Maintenance Analyses

Unit Code

TXT TPM5 07 0511

Unit Descriptor

This unit covers the knowledge, skills and attitudes needed for the most common forms of analyses associated with planned and corrective maintenance strategies.

Elements

Performance Criteria

1. Liaise with

1.1

Relationship with the operator/s of equipment/plant is established

operator

1.2

Operators are ensured to have the required skills and resources to keep the equipment/plant clean

1.3

Operator is ensured to be able to effectively monitor the operation of the equipment/plant

1.4

Regularly communication with operator about the Overall Equipment Efficiency (OEE) of their equipment/plant is performed

1.5

Operator, team leader and other key personnel are involved in the identification of skill needs and means of skill acquisition to fill any identified gaps

2. Analyze

2.1

Mean Time Between Failures ( MTBF ) (or similar statistical history analysis)from maintenance records is analyzed

history

2.2

Performance data of the equipment/plant is analyzed

2.3

Causes of changes to historic trends/status are identified

2.4

Methods of ensuring causes of improvements are determined and locked in and deterioration resolved

3. Undertake

3.1

Failure effect analysis is undertaken and results documented

Failure Mode

 

Effects

3.2

Methods of eliminating possibility of failure and/or minimizing the impact of the failure are investigated

Analysis

(FMEA) (or

3.3

Possible solutions are liaised and communicated with operator, team leader and other key personnel

similar)

3.4

Most appropriate solutions are select and implemented

4. Undertake

4.1

Data for condition monitoring analysis are obtained and interpreted

Required maintenance type and timing from condition monitoring data is predicted

condition

monitoring

analysis

4.2

4.3

Implications of condition monitoring report are communicated / liaised with operator, team leader and other key personnel

4.4

Team members are involved in developing changes to

 

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maintenance strategy to ensure awareness, learning and commitment

maintenance strategy to ensure awareness, learning and commitment

Variable

Range

Occupational

Safe working practices’ include compliance on accepted policies, standard, strategies legislative and enterprise requirements.

health and

safety

Recognize hazards commonly occurring at the workplace and follow health and safety instructions and procedures in the workplace.

Competitive

Is used to describe the range of systemic manufacturing practice concepts and approaches. It covers but is not limited to:

manufacturing

Lean manufacturing

Agile manufacturing

Preventative and predictive maintenance approaches

Monitoring and data gathering systems such as Systems

Control and Data Acquisition (SCADA) software, Enterprise Resource Planning (ERP) systems, Manufacturing Resource Planning (MRP), and proprietary systems such as SAP etc.

Statistical process control systems including six sigma and three sigma

Just in Time (JIT), kanban and other pull related manufacturing control systems

Supply, value, and demand chain monitoring and analysis

Other continuous improvement systems.

Competitive manufacturing should be interpreted so as to take into account the stage of implementation of competitive manufacturing approaches, the enterprise's size and work organization, culture, regulatory environment and manufacturing sector.

Overall Equipment Efficiency (OEE)

is the combination of the main factors causing loss of productive capacity from equipment/plant and is: OEE = availability x performance x quality rate where:

availability takes into account losses due to breakdown, set up and adjustments

performance takes into account losses due to minor stoppages, reduced speed and idling

quality rate takes into account t losses due to rejects, reworks and start up waste

 

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Mean Time Between Failure (MTBF)

Is one key measure of the effectiveness of a maintenance procedure, and is an indicator as to whether root causes are being found and resolved. If MTBF is reducing, then it is an indicator that the maintenance regime is failing. There are many possible causes of any problem. Eliminating some will have no impact, others will ameliorate the problem. However, elimination of the root cause will eliminate the problem. There should only be one root cause for any problem and so the analysis should continue until this one cause is found. Elimination of the root cause permanently eliminates the problem.

Failure Mode

Is a systematic approach that identifies potential failure modes in a system, product, or manufacturing/assembly operation caused by

and Effects

Analysis

either design or manufacturing/assembly process deficiency. It also identifies critical or significant design or process characteristics that require special controls to prevent or detect failure modes. FMEA is

(FMEA)

a

tool used to prevent problems from occurring. Some industry

sectors have highly adapted forms of FMEA and may practice traditional FMEA in say their routine maintenance while using another technique (such as HAZOP) for design and modification.

Hazard and Operability Studies (HAZOP)

Is a form of FMEA which has been practiced by the process industries for over 30 years and examines the implications of changes in process conditions to process stability.

Condition

In this unit condition monitoring is used to describe the process of

monitoring

analyzing the implications of condition monitoring data for proactive maintenance whether it be obtained from non-destructive testing reports, visual assessment by experts, diagnostic reports obtained from SCADA or other enterprise or equipment software and product or process quality analyses. It does not require the actual undertaking of the NDT or condition monitoring assessment or test.

this is required appropriate units from other Training Packages will be required.

If

Evidence Guide

Critical Aspects of Competence

Evidence should be available as to the analyses undertaken and the support provided.

Underpinning Knowledge and Attitudes

Demonstrate a knowledge of:

Cleaning needs, techniques and principles

Methods of assessing skill gaps and filling them

 

Techniques for determining MTBF or similar

Techniques for undertaking FMEA or similar

Underpinning principles of competitive manufacturing strategies being implemented and how to adapt them to maintenance

Root cause analysis

 

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Condition monitoring.

Underpinning

Demonstrate the Skills on:

skills

 

Analysis and problem solving

communication

documenting

Resource

The following resources must be provided. Workplace or fully equipped assessment area with necessary tools and equipment as well as consumable materials

Implications

Method of

Competence may be assessed through:

Assessment

 

Interview / Written Test

Observation/Demonstration with Oral Questioning

Context of

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

Assessment

 

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Occupational Standard: Textile Technology and Production Management Level V

Unit Title

Manage Environmental Impact of Process

Unit Code

TXT TPM5 08 0511

Unit Descriptor

This competence covers managing waste and environmental threats from a plant and/or a process. It covers all resources used and products made by the plant, and are performed by more experienced operators who might be expected to develop and implement improvements to processes within the plant. This unit may be performed individually or as part of a team.

Elements

Performance Criteria

1. Develop resource conservation practices and/or procedures

1.1

Nature and primary source of resources used in the plant/process are identified

1.2

Impact of the depletion of these resources on the environment and society are determined

 

1.3

Resource(s) that will yield a greater benefit from their conservation are identified

1.4

Methods to reduce the consumption of these resources are developed

1.5

Required documentation to implement change is accomplished in accordance with workplace procedures

2. Develop pollution management practices and/or procedures

2.1

Nature of pollutants produced by the plant/process and their sources within the plant/process are determined

2.2

Impact of these pollutants in the environment and society are determined

 

2.3

Pollutant(s) that will yield a greater benefit from their reduction is identified

2.4

Methods to reduce the production of this pollutant is developed

2.5

Complete required documentation to implement change is accomplished in accordance with workplace procedures.

3. Develop waste management practices and/or procedures

3.1

Nature and sources of wastes produced by the plant/process are identified

3.2

Impact of these wastes on the environment and society are determined and described

 

3.3

Waste(s) that will yield a greater benefit from their reduction is determined

3.4

Methods to reduce the production of this waste is developed

 

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3.5 Complete required documentation to implement change is accomplished in accordance with workplace procedures

3.5

Complete required documentation to implement change is accomplished in accordance with workplace procedures

Variable

Range

HSE(health safety environment)

All operations to which this unit applies are subject to stringent health, safety and environment requirements, which may be imposed through State or Federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and HSE requirements, the HSE requirements take precedence.

Evidence Guide

Critical Aspects of competence

Demonstrates knowledge and skills on:

Procedures are developed to reduce the consumption of resources or to minimize pollution and/or waste products

 

Appropriate documentation is completed to implement changes

Greatest yield is achieved by appropriate selection of type of resource usage, type of pollutant or waste product.

Underpinning Knowledge and Attitudes

Demonstrates knowledge of:

Nature and severity of potential environmental hazards caused by the plant/process

 

Sensitivity of local environment to these environmental threats

Pathways of entry to the environment from the plant

Regulatory requirements such as environment protection regulations, OHS, duty of care, dangerous goods

External licensing requirements such as environment and waste management, water authorities and regional councils

Enterprise procedures and practices

Underpinning Skills

Demonstrates skills on:

Developing resource conservation procedures

Developing pollution management procedures

Developing waste management procedures

Resource

Assessment will require access to an operating plant over an extended period of time, or a suitable method of gathering evidence of operating ability over a range of situations. A bank of scenarios/case studies/what ifs will be required as will a bank of questions which will be used to probe the reasoning behind the observable actions.

Implications

 

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Method of

Competence may be assessed through:

Assessment

Interview / Written Test

Observation/Demonstration with Oral Questioning

Context of

Assessment for this unit of competency will be on an operating plant.

Assessment

 

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Occupational Standard: Textile Technology and Production Management Level V

Unit Title

Manage Value Chain

Unit Code

TXT TPM5 09 0511

Unit Descriptor

This unit covers the knowledge, attitudes and skills needed to manage a value chain, a supply chain or a demand chain including the close liaison with suppliers and customers and even the managing of the supply/demand chain of smaller suppliers/customers.

Elements

Performance Criteria

1. Evaluate the

1.1

All members in the value chain for product/s in area of responsibility are identified

value chain

1.2

Value added by each member of the chain are identified

1.3

Acute and chronic issues which impact on the value chain are identified

1.4

Priority list of items for improvement is developed

2. Liaise regularly

2.1

Regular liaison with all chain members is established and maintained

with chain

members

2.2

Current and forecast issues with each member are identified and assisted them in addressing their issues

2.3

Trust and confidence in the relationship are built

2.4

Priority list of items for improvement is developed

2.5

Negotiated with all chain members to ensure improvements benefit chain members and improve the benefits/features perceived by the ultimate customer

3. Monitor the value added at each step

3.1

Changes in value added by each chain member are identified

3.2

Areas where changes to value added required are identified

 

3.3

Priority list of items for improvement is developed

3.4

Worked with chain member to bring about improvements to value added

4. Continue to

4.1

Waste in supply chain is identified

reduce waste

4.2

Work with chain members to continually reduce waste

 

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Variable

Range

Value chain

Competitive manufacturing organizations encompass the entire supply system, beginning product design, raw material mining and processing and all tiers of the value chain. Any truly 'competitive' system is highly dependent on the demands of its customers and the reliability of its suppliers. No implementation of competitive manufacturing can reach its full potential without including the entire 'enterprise' in its planning.

Value added

Value added is measured against its contribution to the customer benefits/features and may be in the form of:

technical benefits/features

location benefits/features

aesthetic benefits/features

Information benefits/features.

Waste

Waste (also known as mud in the Toyota Production System and its derivatives) is any activity which does not contribute to Customer benefit/features in the product. Within manufacturing, categories of waste include:

excess production and early production

delays

movement and transport

poor process design

inventory

inefficient performance of a process

Making defective items.

Waste for this unit may include activities which do not yield any benefit to the organization or any benefit to the organizations customers.

Evidence Guide

Critical Aspects of competence

Demonstrate knowledge and skills to:

Evaluate the value chain

 

Liaise regularly with chain members

Monitor the value added at each step

Continue to reduce waste

Underpinning Knowledge and Attitudes

Demonstrate knowledge on:

Purpose of value chain analysis

Methods of value chain analysis

 

Types of waste and methods of reducing it

Process used to make product

Processes employed by other members of the value chain sufficient to have meaningful dialog with them

 

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Methods of value analysis

Underpinning

Demonstrates skills to:

Skills

plan product construction

analyze and evaluate

communicate with management

conduct quality checks to identify non-compliances with quality standards

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

procedures and work instructions, and other reference material

maintain accurate records

communicate within the workplace

sequence operations

meet specifications

clarify and check task-related information

carry out work according to OHS practices

Resource

The following resources MUST be provided.

Implications

Workplace or fully equipped assessment area with necessary tools and equipment as well as consumable materials

Method of

Competence may be assessed through:

Assessment

Interview / Written Test

Observation/Demonstration with Oral Questioning

Context of

Assessment needs to occur in an organization pursuing competitive manufacturing or by a suitable project or case study. This unit could be assessed concurrently with other units related to development and improvements of systems for competitive manufacturing.

Assessment

 

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Occupational Standard: Textile Technology and Production Management Level V

Unit Title

Develop and Implement Sales or Marketing Plan

Unit Code

TXT TPM5 10 0511

Unit Descriptor

This unit covers the knowledge, skills and attitudes to develop and implement a sales and marketing plan.

Elements

Performance Criteria

1. Analyzes

1.1

Business goals and objectives are defined and analyzed to assist formulation of a sales and marketing plan.

business goals

and industry

1.2

Market trends are researched and issues related to work place are analyzed.

market trends

1.3

Statistical analysis of market data is used to interpret market trends and development

1.4

Trends and developments are analyzed for their potential impact on the business

1.5

Production and marketing practices and their effects on workplace are analyzed.

2. Establish

2.1

Directions for marketing are assessed in line with aims of business plan, customer requirements, market position, objectives, opportunities and resources of the business.

strategic

directions

2.2

Sales and marketing strategies are identified and prioritized in order to optimize sales and profit.

2.3

Outcomes expected from marketing activities are identified

3. Develop sales

3.1

Business resources and appropriate personnel are identified.

or marketing

3.2

Liaison occurs with relevant personnel, including external specialist advice where applicable.

plan

3.3

Marketing strategy and activities are developed which reflects overall directions and parameters relating to company business plan, identified long and short term objectives and budget for marketing.

3.4

Marketing or sales plan is documented and finalized

4. Implement and

4.1

Implementation of sales and marketing plan is coordinated with all relevant personnel.

monitor sales

and marketing

4.2

Business resources and identified personnel are utilized to optimize effectiveness of sales and marketing plan.

plan

4.3

Monitoring procedures are established.

4.4

Financial data is measured and monitored against objectives to ensure progress towards target is achieved.

 

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4.5

Implementation of plan is monitored to establish overall performance.

5.

Conduct plan

5.1

Review of sales and marketing plan is conducted and results assessed.

review

 

5.2

Sales and marketing plan is modified, as necessary, to reflect dynamics of market place.

5.3

Reporting of review outcomes is assessed.

6.

Maintain

6.1

Records of sales and marketing planning activities are maintained and reports prepared.

records

 

6.2

Presentations on sales and marketing plan are made at management meetings.

Variable

Range

Market

May include:

local markets

national markets

global markets

Production and

May include:

marketing

import and export of materials, components or complete products

practices

direct marketing

wholesale and retail store distribution

exhibitions, shows, events

Develop a sales and marketing plan

May include:

analysis of business goals and market trends

marketing strategy options

 

monitoring and measuring of financial data

review procedures and liaison with other departments

OHS practices

OHS practices include hazard identification and control, risk assessment and implementation of risk reduction measures

specific to the tasks described by this unit, and may relate to:

manual handling techniques

standard operating procedures

personal protective equipment

safe materials handling

taking of rest breaks

ergonomic arrangement of workplaces

following marked walkways

safe storage of equipment

housekeeping

reporting accidents and incidents

environmental practices

 

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Evidence Guide

Critical Aspects of Competence

Demonstrates skills and knowledge to:

interpret and analyze goals and market trends

 

identify, develop and prioritize sales and marketing plans and strategies

optimize sales and profits

monitor financial information against objectives

review, analyze and modify sales and marketing strategy and plan to ensure objectives are met

ensure OHS practices are applied to work activities

maintain accurate records

Underpinning Knowledge and Attitudes

Demonstrates knowledge of:

the industry, including markets, local and global trends and how these impact on the workplace

 

workplace products

key elements of production capability in terms of its implications for sales and marketing plan

sourcing procedures

range of distribution channels (eg direct marketing, chain stores, niche markets)

SWOT analysis techniques

workplace policies and procedures, structure and technical competency in relation to the sales and marketing plan

quality standards and practices

OHS practices, including hazard identification and control measures

workplace practices

recording and reporting practices

Underpinning

Demonstrates skills to:

Skills

appraise outcomes against business plan

identify budget parameters

develop and implement promotional strategies

prepare plans and reports

communicate effectively within the workplace, including liaising with other departments

establish or interpret procedures, where required

determine report requirements and present information in appropriate formats

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

maintain accurate records

communicate within the workplace

sequence operations

 

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meet specifications

clarify and check task-related information

carry out work according to OHS practices

Resource

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

Implications

Method of

Competence may be assessed through:

Assessment

Interview / Written Test

Observation/Demonstration with Oral Questioning

Context of

Assessment may occur on the job or in an appropriately simulated environment.

Assessment

 

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Occupational Standard: Textile Technology and Production Management Level V

Unit Title

Manage Quality Systems and Procedures

Unit Code

TXT TPM5 11 0511

Unit Descriptor

This unit covers the skills, attitudes and knowledge required to manage the implementation of a quality assurance system and procedures within a textiles enterprise.