tesfay os textile chemical processing l3 & l2

8/3/2019 Tesfay OS Textile Chemical Processing L3 & L2

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Federal Democratic Republic of Ethiopia

OCCUPATIONAL STANDARD

TEXTILE CHEMICAL PROCESSING

NTQF Level II and III

Ministry of Education

May 2011


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Page 1 of 68Ministry of Education

CopyrightTextile Chemical Processing

Ethiopia Occupational StandardVersion 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: Textile Chemical Processing

Occupational Code: TXT CHP

NTQF Level III

NTQF Level II

TXT CHP3 01 0511Prepare Chemicals,Dyes or OtherSubstance Used inTextile Production

TXT CHP3 02 0511

Produce Textile Designfor CommercialProduction

TXT CHP3 03 0511

Perform Machine Settingand OperationalMaintenance

TXT CHP3 04 0511

Monitor Work ActivitiesTXT CHP3 05 0511

Ensure EfficientOperation of Textile

Machines

TXT CHP3 06 0511

Sustain ProcessImprovements

TXT CHP3 07 0511

Manage Impact ofChange of Own Work

TXT CHP3 08 0511

Make PrototypeTXT CHP3 09 0511

Apply Quality Control

TXT CHP3 10 0511

Lead Small TeamTXT CHP3 11 0511Lead WorkplaceCommunication

TXT CHP3 12 0511

Improve BusinessPractice

TXT CHP2 05 0311Participate inEnvironmentallySustainable WorkPractices

TXT CHP2 03 0311

Perform MinorMaintenance

TXT CHP2 01 0311

Weigh and CheckTextile Materials andProducts

TXT CHP2 06 0311

Participate in WorkplaceCommunication

TXT CHP2 02 0311

Use SpecializedMachinery to AssistTextile Production

TXT CHP2 07 0311Work in a TeamEnvironment

TXT CHP2 08 0311Develop BusinessPractice

TXT CHP2 04 0311

Apply Cost Factors toWork Practices


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NTQF Level III


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Occupational Standard: Textile Chemical Processing Level III

Unit TitlePrepare Chemicals, Dyes or Other Substance in TextileProduction

Unit Code TXT CHP3 01 0511

Unit Descriptor This unit covers the knowledge, skills and attitudes to handle andprepare chemicals and other substances used in chemicalprocessing of textiles.

Elements Performance Criteria

1. Identifystorageproceduresforsubstances

1.1 Location and storage conditionsfor substancesareidentified based on the property of the substance

1.2 Storage and access documentation requirements are identifiedbased on the location and storage condition

1.3 Workplace practices for accessing stored substances areidentified

1.4 Housekeeping requirements for stored substances areidentified based on the property of the substance

2. Identifyhazards andrisk controlmeasuresassociated

withsubstances

2.1 Hazardsassociated with the handling and uses of substancesused in the workplace are identified based on safety data sheetof the substances

2.2 Emergency procedures for workplace are identified

2.3 Risk control measuresassociated with substances are

identified based on the nature of the substances2.4 Personal protective equipmentto be used when working with

substances is identified based on the associated with thesubstance

2.5 Special handling procedures for substances are identified

3. Preparesubstance

3.1 Substances required for production processes are identifiedbased on the product

3.2 Specifications for required substances are identified

3.3 Mixing or preparing procedures are confirmed based on the

type of substance to be used3.4 Substances are prepared according to OH&S practices

3.5 Substances are directed to next process

3.6 Spillages or incidents are reported to appropriate personnel

4. Storesubstance

4.1 Substances are stored according to storage requirements

4.2 Required documentation is completed

4.3 Spillages are cleared according to workplace practices andhousekeeping requirements completed


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Variable Range

Storageconditions

May include:

temperature

security

labeling containers used

organization

Substances May include:

dyes

chemicals

cleaning agents

solvents

substances used in the preparation of yarns or textile

products for production processes

other liquid or particle additives used in textile productionHazards May include:

exposure to chemicals, other harmful substances, machinery andequipment including:

chemicals, dangerous or other hazardous substances

load shifting equipment such as overhead cranes, forklifts

processing machinery and equipment

inflammable materials and fire hazards

manual handling of materials and equipment

waste management and disposal

variations in lighting levels a range of floor surfaces and water hazards

accidents and a range of storage areas

Risk controlmeasures

May include:

isolation procedures

guard and safety devices

inspection and housekeeping

Personalprotectiveequipment

May include:

goggles or face shields

respirators, air-supplied or self-contained helmets

safety boots, gloves and appropriate clothes/garments.

Tools,equipment andmaterials

May include:

digital balance; stirrer and mixer; tanker and pump

titrater, pH meter and glass wares

OHS practices May relate to:

manual handling techniques

standard operating procedures

personal protective equipment

safe materials handling and safe storage of equipment

housekeeping, reporting accidents and incidents


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Evidence Guide

Critical Aspectsof Competence

Demonstrates skills and knowledge to:

prepare chemicals and other substances use for textile processing

handle chemicals and substances use for textile processing

recognize and report hazards to designated personnel

accurately follow workplace procedures relevant to handling andpreparing substances in the workplace

maintain accurate records

UnderpinningKnowledge andAttitudes

Demonstrates knowledge of:

different substances use in textile chemical processing

location of materials, equipment and designated work areas forworking with substances

workplace emergency and evacuation procedures

the meaning of OHS signs and symbols workplace reporting procedures in regard to risks, hazards and

accidents

quality standards and practices

location and use of necessary safety equipment, includingpersonal protective equipment

OHS practices, including hazard identification and controlmeasures and workplace practices

recording and reporting practices

Underpinning

Skills

Demonstrates skills to:

carry out measurements production processes and procedures for using substances

identify and apply risk control measures

identify and report workplace hazards

follow OHS practices for accidents and emergency situations

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


sequence operations and meet specifications

clarify and check task-related information

carry out work according to OHS practicesResourceImplications

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

Methods ofAssessment

Competence may be assessed through:

Interview / Written exam

Demonstration / Observation

Context ofAssessment

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


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Unit Title Produce Textile Designs for Commercial Production


Unit DescriptorThis unit covers the knowledge, attitudes and skills to create andproduce textile design for commercial production. It includesdevelopment of product design and production of textile productsample.


1. Develop designconcepts

1.1 Information from market analysis is applied to development ofcommercial product ideas

1.2 Consultation with design team is undertaken to analyze andrefine product ideas and develop a design brief

1.3 Testing of design brief is conducted with appropriate personneland market research activities.

1.4 Design brief and specifications for product development areconfirmed and documented

1.5 Design concepts are developed in- line with design brief

2. Evaluatecommercialproductionfactors

2.1 Scope of commercial production is determined and means ofproductionresearched and evaluated

2.2 Appropriate personnel are consulted to determine productionrequirements

2.3 Costsassociated with commercial production are estimatedand compared

2.4 Commercial production variables are compared and analyzed toinform final product design

3. Present textiledesigns forapproval

3.1 Textile product designs are drafted in line with brief andproduction estimates

3.2 Designs are presented to appropriate personnelusing a rangeof presentation tools

3.3 Textile designs are reviewed and modifications made

accordingly3.4 Final textile design is accepted and confirmed and relevant

documentation is completed

4. Produce textiledesign sample

4.1 Components and resources required for sample production areobtained and tested

4.2 Technical aspects of production are described

4.3 Specification sheet is completed to guide production.

4.4 Production plan is developed to guide production.

4.5 Textile sample is produced according to plan and OHSpractices


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5. Test productsample toevaluate designand productionprocesses

5.1. Textile sample is evaluated against design specifications anddesign brief.

5.2. Textile sample is tested to ensure quality and performancestandards are met

5.3. Design is evaluated to determine necessary modifications.5.4. Production process is evaluated to determine necessary

improvements

5.5. Overall evaluation of design and process is confirmed andprocess and improvements documented

6. Finalize textiledesign

6.1 Evaluation of textile sample design and process is discussedwith design team and production personnel

6.2 Modifications to design and production process are incorporatedinto design

6.3 Final design is confirmed and documented

Variable Range

Means ofcommercialproduction

May include:

off-shore production

on-shore production

large or long runs

one-off runs

Cost Include:

labor

overheads

materials

tooling

equipment

yarns

dyes

other chemicals or materials

Appropriatepersonnel

May include:

managers, directors

design team

production staff

business development staff

marketing and sales staff

clients

Presentation tools Include:

story boards

models

computer aided drawings

textile or yarn samples


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UnderpinningSkills


apply principles and elements of design

communicate and promote design concepts

produce a textile product sample

test sample

evaluate design and production process and make improvements

document and transfer information



sequence operations and meet specifications

carry out work according to OHS practices

ResourcesImplication

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



Interview/ Written Test

Observation/Demonstration with Oral Questioning


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


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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.

Element Performance Criteria

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. Conductsample or trialruns 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 productstandards and further adjustment is made until sample

meets 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. Communicate

information

6.1 Records and other documentation of setting and

maintenance 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

superwash

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 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 ofCompetence


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 specifications

needed for machine setting and maintenance


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perform normal testing, setting, and maintenance ofmachines

investigate improper operation of machines and identify andrectify operating problems

conduct sample runs of machines and check products

against required standards perform operator maintenance ofwork area

document and communicate work related informationincluding 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

OHS practices, including hazard identification and controlmeasures

quality practices

workplace practices practices for recording and reporting

UnderpinningSkills


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


communicate within the workplace

sequence operations

meet specifications




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


Competency may be accessed through:

Interview / Written Test

Observation / Demonstration and Oral Questioning


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


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Unit Title Monitor Work Activities


Unit Descriptor This unit covers the knowledge, skills and attitudes required tomonitor work activities to ensure efficient production.


1. Monitorprocess

1.1 Job specificationsare checked for requirements includingquantity, quality and special requirement.

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

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/processproblems

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 team members.

3.2 Work allocation requirements are monitored and addressedin order to maintain optimum production efficiency.

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

4. Checkperformanceefficiency

4.1 Regular checks of process operation are undertaken andresults 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:

customers orders

pattern diagrams

color charts formula

written and verbal instructions

drawings

Performanceparameters

May include:

processing time

acceptable error rate

wastage

dimensions of color

color matching

selecting the correct linings, buttons, zips and thread to exactly match the garment

Productionprocesses

May include:

pre-treatment

dyeing

printing

finishing

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



Tools andequipment

May include:

color wheel

acrylic paints

paint brushes

cartridge paper

crayons

watercolors

pencils

color software and painting programs, including color

features of CAD programs

computers


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Evidence Guide



identify the major processes to be monitored at work location

identify manufacturing system and quality requirements to be

monitored identify major faults and out of specification performance

address faults or problems

conduct regular performance checks



yarn manufacturing processes used in an enterprise

range of problems and their solutions associated with yarnmanufacturing operations


OH&S practices, including hazard identification and control

measures workplace practices


characteristics of fabrics used for garment construction

sequence of operations

UnderpinningSkills


interpret technical data

monitor manufacturing system


maintain accurate records sequence operations

meet specifications





Methods of

Assessment


Observation/Demonstration Written Test/ Interview/Oral Questioning


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


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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 to

ensure 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 withmachineoperation

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 manufacturerinstructions.

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


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required.

4.4 Machine is cleaned in accordance with manufacturercleaning instructions.

5. Perform

preventativemaintenanceprocedures

5.1 Inspection of parts is conducted according to operating

procedures and manufacturer instructions.5.2 Service and production records are maintained to assist

with 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 with

operational 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 ecurrent 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

Immediatesolution may

Include:

decommission machine

change settings

adjust operation

perform temporary fix

refer to textile mechanic


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Parts andconsumables mayinclude:

items that require periodic replacement as a result of

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

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:








housekeeping


environmental practices

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

apply OHS practices in work operations



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












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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. Implementcorrectiveactions

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 improvement3.2 Take action to make improvements in accordance with

procedures

Variable Range

Performance Performance may be thought of as the rate of output of the plantcompared to the rate required to meet demand. Performancemight also be thought of in terms of task where task time is theallowable time to produce one product at the rate customers is

demanding it. This is NOT the same as cycle time, which is thenormal time to complete an operation on a product (whichshould be less than or equal to task time).

Procedures All work instructions, standard operating procedures,formulas/recipes, batch sheets, temporary instructions andsimilar instructions provided for the smooth running of the plant.They may be written, verbal, computer based or in some otherform. For the purposes of this Training Package, 'procedures'also includes good operating practice as may be defined byindustry codes of practice (e.g. Good Manufacturing Practice

(GMP), Responsible Care) and government regulations.


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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 being

prevented, is usually met with a warning signal of some sort; theterm 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.


Demonstrate knowledge of:

production techniques and procedures

existing procedures

modified procedures

sourcing and updating latest technology

improvement process

UnderpinningSkills

Demonstrates skills of:

technical competence to perform job

problem solving

teamwork

communication

ResourcesImplication Access to a workplace implementing competitive manufacturingstrategies or appropriate simulated environment.








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Variable Range

Managing impactof change

All Elements may be undertaken individually or as part of a teamand may require assistance from the team leader for areasoutside the employee's range of responsibility and authority.

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, Manufacturing ResourcePlanning (MRP), and proprietary systems such as SAP

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

Competitive manufacturing should be interpreted so as to takeinto account the stage of implementation of competitivemanufacturing approaches, the enterprise's size and work

organization, culture, regulatory environment and manufacturingsector

Procedures Procedures include all work instructions, standard operatingprocedures, formulas/recipes, batch sheets, temporaryinstructions and similar instructions provided for the smoothrunning of the plant. They may be written, verbal, computerbased or in some other form. For the purposes of this TrainingPackage, 'procedures' also includes good operating practice asmay be defined by industry codes of practice (eg GoodManufacturing Practice (GMP), Responsible Care) andgovernment regulations.

Continuousimprovement

Continuous improvement (also called kaizen) - the philosophy ofcontinual improvement, that every process can and should becontinually evaluated and improved in terms of time required,resources used, resultant quality, and other aspects relevant tothe process.


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Value chain Competitive manufacturing organizations encompass the entireproduction system, beginning with the customer, and include theproduct sales outlet, the final assembler, product design, rawmaterial mining and processing and all tiers of the value chain(sometimes called the supply chain). Any truly 'competitive'

system is highly dependent on the demands of its customersand the reliability of its suppliers. No implementation ofcompetitive 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 andAttitude

Demonstrate knowledge of: current process and principles of operation

sources of data on the process/plant and possible applicationsto information

methods of determining own skill needs and developing skillsrequired

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

basic continuous improvement principles

Underpinning

Skills

Demonstrates skills of:

analysis communication

problem solving

reading and interpreting

teamwork


Access to a workplace implementing competitive manufacturingstrategies or appropriate simulated environment.






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


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Unit Title Make Prototype


Unit Descriptor This unit covers the skills and knowledge to design processesleading to the making of a prototype for marketing purposes.


1. Set upworkstation

1.1 Workstation is set up in accordance with specificationsand workplace procedures

2. Design ormodify existingmodel

2.1 Specification of customer requirements are interpreted

2.2 Components are designed, to conform with model, using

CAD or manual technique with reference to all relevantoperations

2.3 Materials, trims and colours are selected

2.4 Models are produced from appropriate materials

2.5 Ongoing liaison occurs with relevant departments inworkplace to ensure workability and marketability ofdesign, and availability of materials and resourcesincluding workforce skills

3. Produceprototype

3.1 Existing model is modified, or model is designed, totranslate design concept into 3D

3.2 Making of prototype is coordinated using samplepatterns, relevant designed components and all relevantmanufacturing processes

4. Test prototype 4.1 Liaison occurs with other relevant departments in relationto practicality of design and cost of production, andpredicted commercial success

4.2 Prototype is reviewed with customer specifications, andcustomer as appropriate

4.3 Corrections are made as necessary

5. Make samples 5.1 Samples are made for marketing or testing

5.2 Work is conducted according to OHS practices

6. Producepatterns

6.1 Standard or master pattern is created from the meanform

6.2 Standard is dissected to produce all working patterns,making adjustments for enterprise procedures andmaterials used to create patterns

6.3 Patterns are derived from the past pattern, allowing foradjustments as required


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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 must include hazard identification and control,

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









housekeeping reporting accidents and incidents

other OHS practices relevant to the job and enterprise

Evidence Guide



plan and coordinate complicated design and prototypeoperations

check work against work specifications and workplace

standards prepare equipment and work prior to commencing operations

apply complex techniques over the full range of operations

check work against specifications

apply workplace health and safety policies in work operations




manufacturing focus of the enterprise

manufacturing capacity, skill capacity, and tool or equipmentbase of workplace

materials and properties and their reaction to manufacturingprocesses

pattern design and prototype construction

quality standards and handling procedures

safety and environmental aspects of relevant processes

workplace operations and reporting procedures


practices for recording and reporting

Underpinning

Skills


interpret work specifications for complicated operations


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create standard patterns to specifications

select appropriate materials

produce prototypes using appropriate manufacturingprocesses

make samples and correct as necessary

meet work specifications communicate effectively with other relevant departments in

the workplace

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


sequence operations




Assessment may occur on the job or in an appropriatelysimulated environment and requires access to work areas,materials and equipment and to information on workplacepractices and OHS practices




Observation / Demonstration with Oral Questioning




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Occupational Standard: Textile and Chemical Processing Level III

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. Assess qualityof work andproductdelivered

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

2.2 Work outputs and performance delivered are evaluatedusing the appropriate evaluation parametersand inaccordance with 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

Quality standards materials component parts

final product

production process

conformity to specifications

Quality parameters finish

size

durability

product variations

materials

alignment color

damage and imperfections

Evidence Guide


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 againststandard

recommended suitable preventive actions

UnderpinningKnowledge


relevant quality standards, policies and procedures

characteristics of products/outputs

safety environment aspects of production processes relevant evaluation techniques and quality checking

procedures

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 withprocedures

meet work specifications and requirements


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communicate effectively within defined workplace procedures

ResourceImplications

The following resources should be provided:

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

Methods ofAssessment Competence may be accessed through: Interview / Written Test


Context forAssessment



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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 arecommunicated to 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 tothe skills, knowledge and aptitude required to properlyundertake the assigned task and according to companypolicy

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

3. Set

performanceexpectations forteam members

3.1 Performance expectations are established based on client

needs and according to assignment requirements3.2 Performance expectations are based on individual team

members duties and area of responsibility

3.3 Performance expectations are discussed and disseminatedto 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

support and advice on strategies to overcome anydeficiencies

4.3.Performance issueswhich cannot be rectified or addressedwithin 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/client needs and requirements are met

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


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4.7. All relevant documentation is completed in accordance withcompany procedures

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 performancegiven a variety of possible scenario

Assessed and monitored team and individual performanceagainst set criteria

Represented concerns of a team and individual to next levelof management or appropriate specialist and to negotiate ontheir behalf

Allocated duties and responsibilities, having regard toindividuals knowledge, skills and aptitude and the needs ofthe tasks 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


Competence may be assessed through: 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. Benchmark thebusiness

2.1 Sources of relevant benchmarking data are identified

2.2 Key indicatorsfor benchmarking are selected inconsultation with key stakeholders

2.3 Like indicators of own practice are compared withbenchmark indicators

2.4 Areas for improvement are identified

3. Develop plansto improvebusiness

performance

3.1 A consolidated list of required improvements is developed

3.2 Cost-benefit ratios for required improvements aredetermined

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 improvementsis developed and agreed

3.6 Organizational structuresare checked to ensure they aresuitable

4. Developmarketing andpromotionalplans

4.1 The practice vision statement is reviewed4.2 Practice objectivesare developed/reviewed

4.3 Target markets are identified/refined

4.4 Market research datais obtained

4.5 Competitor analysisis obtained

4.6 Market positionis developed/reviewed

4.7 Practice brandis developed

4.8 Benefitsof practice/practice products/services are

identified


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4.9 Promotion toolsare selected/developed

5. Developbusinessgrowth plans

5.1 Plans to increase yield per existing clientare developed

5.2 Plans to add new clients are developed

5.3 Proposed plans are ranked according to agreed criteria5.4 An action plan to implement the top ranked plans is

developed and agreed

5.5 Practice work practices are reviewed to ensure they supportgrowth plans

6. Implement andmonitor plans

6.1 Implementation plan is developed in consultation with allrelevant stakeholders

6.2 Indicators of success of the plan are agreed

6.3 Implementation is monitored against agreed indicators

6.4 Implementation is adjusted as required

Variable Range

Data requiredincludes:

organization capability

appropriate business structure

level of client service which can be provided

internal policies, procedures and practices

staff levels, capabilities and structure

market, market definition market changes/market segmentation

market consolidation/fragmentation

revenue

level of commercial activity

expected revenue levels, short and long term

revenue growth rate

break even data

pricing policy

revenue assumptions

business environment economic conditions

social factors

demographic factors

technological impacts

political/legislative/regulative impacts

competitors, competitor pricing and response to pricing

competitor marketing/branding

competitor productsCompetitive

advantage

services/products

fees


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includes: location

timeframeObjectives shouldbe 'SMART' , that

Specific

Measurable

Achievable

Realistic

Time definedMarket researchdata includes:

data about existing clients

data about possible new clients

data from internal sources

data from external sources such as:

trade associations/journals

Yellow Pages small business surveys

libraries

Internet

Chamber of Commerce client surveys

industry reports

secondary market research

primary market research such as:

telephone surveys

personal interviews

mail surveysCompetitoranalysis

competitor offerings

competitor promotion strategies and activities

competitor profile in the market placeSWOT analysisincludes:

internal strengths such as staff capability, recognized

quality

internal weaknesses such as poor morale,

under-capitalization, poor technology

external opportunities such as changing market and

economic conditions

external threats such as industry fee structures, strategic

alliances, competitor marketingKey indicators may

include:

salary cost and staffing

personnel productivity (particularly of principals) profitability

fee structure

client base

size staff/principal

overhead/overhead controlOrganizationalstructures include:

legal structure (partnership, limited liability company, etc.)

organizational structure/hierarchy

reward schemesMarket position

shouldinclude data on:

product

the good or service provided


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product mix

the core product - what is bought

the tangible product - what is perceived

the augmented product - total package of consumer

features/benefits

product differentiation from competitive products

new/changed products

price and pricing strategies (cost plus, supply/demand, abilityto pay, etc.)

pricing objectives (profit, market penetration, etc.)

cost components

market position

distribution strategies

marketing channels

promotion

promotional strategies target audience

communication

promotion budgetPractice brandmay include:

practice image

practice logo/letter head/signage

phone answering protocol

facility decor

slogans

templates for communication/invoicing

style guide writing style

AIDA (attention, interest, desire, action)Benefits mayinclude:

features as perceived by the client

benefits as perceived by the clientPromotion toolsinclude:

networking and referrals

seminars

advertising

press releases

publicity and sponsorship

brochures newsletters (print and/or electronic)

websites

direct mail

telemarketing/cold callingYield per existingclient may beincreased by:

raising charge out rates/fees

packaging fees

reduce discounts

sell more services to existing clients


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Evidence Guide


The candidate must be able to demonstrate:

ability to identify the key indicators of business performance

ability to identify the key market data for the business

knowledge of a wide range of available information sources ability to acquire information not readily available within a

business

ability to analyze data and determine areas of improvement

ability to negotiate required improvements to ensureimplementation

ability to evaluate systems against practice requirements

and form recommendations and/or make recommendations

ability to assess the accuracy and relevance of information

Underpinning

Knowledge andAttitudes


data analysis communication skills

computer skills to manipulate data and present information

negotiation skills and problem solving

planning skills

marketing principles

ability to acquire and interpret relevant data

current product and marketing mix

use of market intelligence

development and implementation strategies of promotion

and growth plansUnderpinning Skills data analysis and manipulation

ability to acquire and interpret required data

current practice systems and structures

sources of relevant benchmarking data

methods of selecting relevant key benchmarking indicators

communication skills

working and consulting with others when developing plansfor the business

negotiation skills and problem solving

using computers to manipulate, present and distributeinformation

planning skills






Observation / Demonstration

Context of

Assessment

Competence may be assessed in the work place or in a

simulated work place setting


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NTQF Level II


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Occupational Standard: Textile Chemical Processing Level II

Unit Title Weigh and Check Textile Materials and Products


Unit Descriptor This unit covers the skills and knowledge to weigh and checktextile materials and products.


1. Prepare forweighing

1.1 Fibre, yarns, other materials and productsto be weighedare identified and samples are taken.

1.2 Appropriate weighing or measuring equipmentisorganized.

1.3 Calibration is checked as required.

2. Weighmaterials andproducts

2.1 Fibre, yarns, raw materials and products are weighedaccurately.

2.2 Weighing is conducted according to materials handling andOHS practices.

2.3 Weights are correctly recorded and documented.

3. Checkmaterials andproducts

3.1 Yarns, raw materials and products are correctly checked forcolour, blend and number if appropriate.

3.2 The weight of the fibres, yarns, raw materials and textileproducts is checked against production order.

4. Confirmdocumentation

4.1 Fibres, yarn, raw materials and product weight, colour andorder details are checked against relevant documentation.

Variable Range

Legislative/regulatoryrequirements

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

Materials andproducts mayinclude:

yarns for tufting spun cotton, worsted and woollen yarns

finished knitted garments

finished hosiery garments

non-woven raw materials and fabrics

finished fabrics used in textile printing

fabrics used in weaving, dyeing, knitting, tufting and

finishing

Equipment mayinclude:

weighing, measuring and mixing equipment which are usedaccording to manufacturer specifications and workplace

practices


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housekeeping



Documentationmay include:

production order

delivery documentation tickets or labels

specification sheet

Evidence Guide



correctly weigh and measure

record and document weight and measurement readings

check results against specifications apply OHS practices in workplace operations




operation of weighing and measuring machines andequipment

requirements for recording and documenting equipmentreadings

care and maintenance of equipment

technical specifications manuals


stores and procurement procedures


workplace practices


UnderpinningSkills


use machines and measuring equipment

calibrate equipment

confirm compliance to operational specifications

interpret technical data

recognize fault conditions


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test and adjust equipment

check products against specifications

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




Access is required to real or appropriately simulated situations,

including work areas, materials and equipment, and to

information on workplace practices and OHS practices.








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Occupational Standard: Textile Chemical Processing Level II

Unit Title Use Specialized Machinery to Assist Textile Production


Unit Descriptor This unit covers the skills and knowledge to use specializedmachinery to assist in the production of textile products.


1. Prepare forspecializedmachineoperation

1.1 Work pieces or materials are laid out in sequence.

1.2 Work area, bench or seating are set up or preparedaccording to OHS practices.

1.3 Specialized machine is prepared and adjusted according tothe specifications for the work.

1.4 Problems are reported and recorded.

2. Operatespecializedmachine

2.1 Specialized machine is operated.

2.2 OHS practices are followed.

2.3 Work is assessed for compliance with quality standards andproduction specifications.

2.4 Specialized machine is checked during production andadjusted to ensure optimum performance.

3. Dispatch

completed work

3.1 Production outputs are checked against quality standards.

3.2 Any machine or product faults identified are reported andrecorded.

3.3 Outputs are directed to the next operation.

3.4 Work documentation is completed as required.

Variable Range

Legislative/regulatory requirements

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

Specialist machinemay include

stud machine fusing or gluing or backing

machine

labeling machine beveling machine

cutting machine








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housekeeping


environmental practicesEvidence Guide



check work against job specifications and workplacestandards

prepare workstation and work before commencing operations

apply machine operation techniques

carry out minor machine maintenance according to workplace

practices understand and use workplace fault reporting practices





operating procedures for specialized machinery



workplace practices

recording and reporting practicesUnderpinningSkills


perform production tasks

carry out specialized machine operation

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 informationon workplace practices and OHS practices.








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Occupational Standard: Textile Chemical Processing level II

Unit Title Perform Minor Maintenance


Unit Descriptor This unit covers the skills and knowledge to provide minormaintenance of production machines.


1. Operatemachine andassessperformance

1.1 Machine is started and stopped according to manufacturerrequirements.

1.2 Machine operation is monitored to ensure correctprocedures are assessed and product meets qualitystandards.

1.3 Problem with machine is identified and reported.

2. Rectify minormachine fault

2.1 Minor machine and associated equipment and tool faultsare identified and addressed where necessary to meetspecified requirements, and are reported.

2.2 Major machine or product faults are identified anddocumented, and appropriate personnel informed.

2.3 Machine maintenance records and other documentationare accurately completed.

3. Clean andlubricatemachine

3.1 Machine is cleaned according to OHS practicesandschedules, and manufacturer cleaning instructions.

3.2 Machine is lubricated according to workplace requirementsand schedules, and manufacturer lubricating instructions.

4. Check machineoperation

4.1 Machine is checked to ensure correct operation.

Variable Range

OHS 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:









housekeeping


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Evidence Guide

Critical Aspects ofCompetence Demonstrates skills and knowledge to: operate machines correctly

monitor machine performance against machine specifications

make minor adjustments

complete records accurately and completely




procedures and guidelines for safe operation of machines

typical fault conditions and related fault finding procedures

basic machine maintenance and repair techniques

technical specifications manuals quality standards and practices


workplace practices


UnderpinningSkills


assess operating performance of machine

start and stop machines according to specifications

monitor machine operations, including machine production

readings recognize fault conditions

rectify minor machine faults or problems as required

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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Occupational Standard: Textile Chemical Processing level II

Unit Title Apply Cost Factors to Work Practices


Unit Descriptor This unit covers the knowledge and skills needed for an individualto identify cost components and to be able to determine in generalterms the cost impacts of alternative actions.


1. Identify in ownwork areamajor costcomponents of

product orprocess

1.1 Identify cost componentsin the product or processinown work area

1.2 Recognize the impact of current or alternative actions oncosts

2. Identifyconstraints tocost efficiency

2.1 Identify required production/process rate and major costs

2.2 Identify costs factors under the control of the individual orteam

2.3 Relate identified costs factors to impact on overall costofproduction/process

2.4 I

tesfay os textile chemical processing l3 & l2

Documents