CRITERIA FOR ASSESSMENT OF TRAINEES
Qualification Document: Machine Operator & Programmer – CNC Milling
Sector: Petrochemical
Assessment Guidelines:
1. Criteria for assessment for each Qualification Document will be created by CIPET.
2. Each Performance Criteria (PC) will be assigned marks proportional to its importance in
Learning Outcome and few performance criteria may be allotted marks in combine.
3. Each Learning Outcome will be assessed both for theoretical knowledge and practical
which is being proportionately demonstrated in the table below.
4. The assessment for the theory part will be based on knowledge bank of questions
created by CIPET which will contain multiple choice theory questions and Practical
question database with mark allotment criteria.
5. To pass the Qualification Pack, every trainee should score a minimum of 50 % in
Functional and all Generic Learning Outcome’s.
6. In case of successfully passing only certain number of Learning Outcome’s, the trainee is
eligible to take Subsequent assessment on the balance Learning Outcome’s to pass the
Qualification Document.
Title of the Component: Machine Operator & Programmer – CNC Milling
Assessable Outcome
LO
CPC/ N 7119
Perform
machining
operations on
metal or plastic
material using
Conventional
Centre Milling
machine
Performance Criterion Description
PC1. understand and comply with safety,
environmental & other relevant regulations
and guidelines
PC2. wear personal protective equipment
(PPE) like safety glasses, apron, no loose
cloths/ hair, safety shoes while performing
milling
operations
regulations
while
performing CNC turning operations
PC3. ensure work area is clean and safe
PC4. ensure that machine safety guards
are in place and are in correctly working
condition
PC5. ensure that all tools, equipments are
in a safe and usable conditions
PC6. ensure availability of job specification
i.e. approved drawings, sketches, instructions
from the supervisor, job instruction sheet/ job
card.
PC7. read and understand the Job
Assessment Criteria for the
outcome
Theory Practical
Total
0.5
2
2.5
0.5
2
2.5
1
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3
1
2
3
1
2
3
1
2
3
1
2
3
requirements from the job specifications and
attention shall be given to the geometric
tolerances
PC8. check the work piece material for the
dimensions and ensure that it is free from
foreign objects, dirt or other contamination
and is within the required size
PC9. plan to perform the turning or other
machining operations and sequence of
operations as per required job specifications
PC10. obtain all the appropriate tools and
measuring instruments/ gauges required for the
job
PC11. check the milling machine for its
functioning and ensure that it is ready for
operation
PC12. prepare the Milling machine for the
operations by mounting and setting the
required work holding devices and cutting tools
PC13. clarify any doubt, if any and see
necessary instruction /training on the operation
of the machine whenever required
PC14. hold the work piece securely and
correctly, without distortion
PC15. adjust the machine settings as per job
requirement to maintain desired accuracy
PC16. adjust and set the speed and feed of the
Milling machine to achieve
the job
specifications
PC17. Operate the machine tool controls
safely & correctly, in line with operational
procedures both in manual & power modes.
PC18. stop the Milling machine, both in
normal and emergency situations correctly by
following the right procedure and should be
able to restart the machine after and
emergency
PC19. should be able to use the Milling
machine accessories and attachments such as
steady and follower rests, tail stock, taper
turning attachments, profile attachments etc.
PC20. perform various Milling operations
using different tools to produce components
with various features.
Tool: H.S.S, tools, brazed carbide tip tools,
interchangeable carbide insert tools, drills,
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3
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3
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1
2
3
1
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2
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1
2
3
reamers, boring tool, threading tool.
Component Feature: flat faces, outer diameter
parallel, stepped, eccentric and taper,
chambers, grooves, undercuts, holes – drilled,
reamed, bored, tapered, internal and external
threads, internal and external threads, parting
off, knurling or special profiles
PC21. produce components as per required
quality standards and free from burrs & sharp
edges
PC22. shall achieve given production targets
PC23. shall be able to apply roughing and
finishing cuts, considering the effect on tool life,
surface finish and dimensional accuracy
PC24. shall be able to use coolants/ cutting
fluids for different combinations of work piece
and tool as per different locations
PC25. shall be able to observe and report any
difficulties/ discrepancies that may arise during
the machine operation and carry out the
corrective actions as per instructions
PC26. correctly shutting down the machine on
completion of the machining operations,
removing and disposing of the chips/ waste and
critical parameters different locations
PC27. use of measuring instruments/ gauges
to check the critical parameters
Range of checking equipment: e.g external
micrometers, vernier/digital/dial calipers, dial
test indicators (DTI), surface finish equipment
(eg. comparison plates), steel rules,
micrometers (internal, depth), depth verniers,
gauges (slip, bore/hole), thread gauges (eg. ring,
plug, profile), gauges (plug, ring, radius/profile),
protractors, etc
Critical parameters: diameters (external,
internal, eccentricity), parallelism, bore/hole
size/fit, angle/taper, surface finish, linear
dimensions
(eg.
lengths,
depths),
grooves/undercuts (eg. position, width, depth),
concentricity, ovality, thread fit, straightness,
squareness
PC28. shall be able to carry out the corrective
action, in the case of deviation from the
required specifications
PC29. report the problem to the supervisor, if
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LO
CPC/ N 7120
Perform
machining
operations on
metal or plastic
work pieces
using Computer
Numerically
Controlled
Milling
machines
it cannot be resolved
PC30. seek guidance from the supervisor/
specialist of the problem is outside his/her
area of competence
Sub total
Performance Criterion Description
PC1.
understand and comply with safety,
environmental & other relevant regulations
and guidelines
PC2. wear personal protective equipment
(PPE) like safety glasses, apron, no loose
cloths/ hair, safety shoes while performing
milling operations
PC3. ensure work area is clean and safe
PC4. ensure that machine safety guards are
in place and are in correctly working condition
PC5. ensure that all tools, equipments are in
a safe and usable conditions
PC6. ensure availability of job specification i.e.
approved drawings, sketches, instructions from
the supervisor, job instruction sheet/ job card.
PC7. read and understand the Job
requirements from the job specifications and
attention shall be given to the geometric
tolerances
PC8. check the work piece material for the
dimensions and ensure that it is free from
foreign objects, dirt or other contamination &is
within the required size
PC9. plan to perform the turning or other
Millilng operations and the sequence of
operations as per required job specifications on
CNC Milling machine
PC10. obtain all the appropriate tools and
measuring instruments/ gauges required for the
job
PC11. check the CNC Milling machine for its
functioning and ensure that it is ready for
operation
PC12. prepare the CNC Milling machine for the
operations by mounting and setting the
required workholding devices and cutting tools
PC13. clarify any doubt, if any & see necessary
instruction / training on operation of CNC
Milling machine whenever required
PC14. hold the work piece securely and
1
2
3
29
Theory
60
Practical
89
Total
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1
1
3
3
4
4
1
3
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1
3
4
1
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4
correctly, without distortion
PC15. adjust the CNC Milling machine settings
as per job requirement to maintain desired
accuracy
PC16. perform daily maintenance of machine
according to defined checklist, at the beginning
of day's shifts.
Basic maintenance activities: replenish
coolant; ensure all parts are clean; perform
housekeeping tasks on the machine; remove
and dispose swarf
PC17. use and extract information from
engineering drawings, dimensioning and
tolerances
Drawings, dimensioning and tolerances:
projections (orthographic [first angle, third
angle]; isometric [including exploded],
sectional view); reference points, lines, edges
and surfaces
PC18. use and extract information from
reference charts, tables, graphs and
Engineering standards
Information pertaining to: e.g. thread sizes;
feeds and speeds; machining symbols and
tolerances; surface finish symbols; etc.
PC19. load and unload component(s) using
pre-determined fixtures or work holding
devices as per work instructions
Work-holding devices to position and secure
work-pieces: chucks with hard jaws, chucks
with soft jaws, fixtures, drive centres, collet
chucks, faceplates, magnetic/pneumatic
devices and other work-holding devices
PC20.
make basic program and check
correctness of program through dry run and
single block check
PC21. adjust and set the speed and feed of
the CNC Milling machine to achieve the job
specifications
PC22. operate the machine tool controls
safely and correctly, in line with operational
procedures.
PC23. stop the CNC Milling machine, both in
normal and emergency situations correctly by
following the right procedure and should be
able to restart the machine after the
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1
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1
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1
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1
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1
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1
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4
emergency
PC24. do first part cutting trial by setting tool
offsets to get oversize part
PC25. measure the critical parameters of the
machined component on the machine
(without removing from the machine ), after
the trial run Critical parameters: linear
dimensions (such as lengths, depths), slots
(position, width, depth), flatness, surface
finish, squareness, parallelism, hole size/fit,
angles, recesses, thread fit, runout and
roundness
PC26. correct the offsets based on the
measurements by accessing program edit
facility in order to enter tooling data
Tooling data: offset compensation, radius
compensation
PC27.
measure the component after
unloading to check for accuracy in the critical
parameters as per job specifications
PC28. produce machined components that
combine different turning operations and
have a range of features
Features of machined components: facing,
slotting, pocket milling, circular pocket, drilling,
reaming, boring, counter boring, profile milling
keyways, grooves, slots, gear cutting, helical
milling or special profiles etc.
PC29.
follow the specified machining
sequence and procedure as per job
specifications
PC30. interpret in-built machine alarms &
respond to same as per operating manual or
specified instructions
PC31.
observe for inconsistency in
dimensions due to tool wear and correct the
offsets accordingly
PC32. ensure that machine settings are
adjusted as and when required, either by self
or the setter, to maintain the required
accuracy
PC33. identify when tools need replacement
and replace worn tool with new tool
PC34. produce components as per required
standards
Produce component standards: components
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LO
CPC/ N 7121
Programming of
Computer
Numerically
Controlled
(CNC) Milling
Machines
to be free from false tool cuts, burrs and
sharp edges; general dimensional tolerance
+/- 0.02mm; specific dimensional tolerances
within +/- 0.1mm; surface finish within
1.6μm; reamed holes within H8; screw
threads 6G/6H; angles/tapers within +/- 15
sec; flatness and squareness 0.025mm
PC35. report problems and seek appropriate
assistance in a timely manner
PC36. complete documentation during and
post operations as per organizational
procedures and applicable quality
management system
PC37. return the machine and all tools and
equipment to the correct location on
completion of activities
PC38. leave the work area in a safe and tidy
condition on completion of job activities as
per 5S practices
Safe conditions: correctly isolated; operating
programs closed or removed; cleaning the
machine; ensuring that any spilt cutting fluids
are correctly dealt with; disposing of metal
and other waste
PC39. report the problem to the supervisor, if
it cannot be resolved
PC40. seek guidance from the supervisor/
specialist of the problem is outside his/her
area of competence
Sub total
Performance Criterion Description
PC1.
comply with health and safety,
environmental and other relevant regulations
and guidelines at work
PC2. adhere to procedures and guidelines for
personal protective equipment (PPE) and
other relevant safety regulations while
programming CNC Milling machines
PC3. work following laid down procedures
and instructions
PC4. ensure that machine guards are in place
and are correctly adjusted
PC5. read
and
understand
safety
instructions, warning signs on the machine
PC6. ensure work area is clean and safe
from hazards
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1
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1
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1
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40
Theory
120
Practical
160
Total
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1
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1
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1
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1
3
4
1
3
4
PC7. ensure that all tools, equipment,
power tool cables, extension leads are in a
safe and usable condition
PC8. ensure availability of job specification i.e.
approved drawings, sketches, instructions
from the supervisor, job instruction sheet/ job
card.
PC9. read and establish job requirements
from the job specification documentaccurately
Job specification documents: detailed
component
drawings;
approved
sketches/illustrations; national, international
and organizational standards; reference tables
and charts; fabrication/casting drawings;
operational
diagrams;
contractual
specifications
Job requirements: raw materials or
components required (type, quality, quantity);
dimensions; limits & tolerances; surface finish
requirements; profiles to be generated;
instruments & tools to be used; form
tolerances (flatness, concentricity, etc.); cycle
time, production rate; projections orthographic
(first angle, third angle), isometric (including
exploded, oblique); reference points, lines,
edges & surfaces; dimensions (baseline,
continuous); workholding devices.
PC10.
follow job instructions, assembly
drawings and laid down procedures at all times
PC11.report and rectify incorrect and
inconsistent information in job specification
documents as per organization procedures
PC12.
use and extract information from
reference charts, tables, graphs and standards
Information pertaining to: tapping sizes and
threads; cutting parameters – feeds, speed,
depth of cut; machining symbols and
tolerances
PC13. prepare the work area as per procedure
or operational specification
PC14. conduct a preliminary check of the
readiness of the program so that the CNC
machine operates correctly
CNC machines: 2-axis CNC machine, 3-axis
machining centers (VMC, HMC), > 3 axes
machining centers(3.5/4/5 axes)
Checks: ensure that all tool tool length / wear
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/ radius offsets are correctly entered; for
finishing operations, adjust offsets to get
slightly oversize/undersize dimensions to
ensure that the part does not get rejected; run
the program in dry run mode to ensure that
there are no collisions between the tool and
workpiece / work holding devices; check tool
change positions are safe and clear of the
workpiece and work holding devices; ensure
that correct tools are selected at the
appropriate points in the program; check if the
tool paths are executed safely and correctly;
ensure that the auxiliary functions operate at
the correct point in the program(spindle
start/stop, coolant flow, program optional
stop); run the program, in single block mode
wherever necessary; measure the dimensions
of the component on the machine and make
necessary corrections in tool offsets; inspect
the component for all dimensions and record
findings in specified formats; make necessary
changes in tool length / wear / radius offsets
to correct dimension errors; run the next
component; ensure that all dimensions are
within specifications; if dimensions are not
within
specifications,
correct
using
appropriate actions; repeat this till parts come
within specifications without any correction
requirement
PC15. determine what operational objectives
and targets need to be achieved and how
best the machine needs to be programmed
to achieve this
CNC programming operations: preparing,
loading, storing in appropriate format, proving
the part program, trial runs
PC16. extract and use information from
engineering
drawings
and
related
specifications in relation to work undertaken
PC17. identify tool requirements from tooling
layout and assess their suitability
PC18. identify suitable workholding or fixturing
device as per the job requirement
PC19. ensure the correct and latest partprogram is uploaded onto the CNC system
PC20. make CNC program with commands for
tool
motions,
spindle
motions,
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miscellaneous functions & tool change,
in syntax corresponding to machine and
control system on which the component
will be machined.
PC21. various ways to make CNC program are
by writing it on paper or in computer's
text editor, or using CAM software or
controllers on machine Ways: written,
directly entered into machine controller,
using computer software- CAM software
PC22. ensure that part program is efficient &
results in minimal cycle time, with
optimal cutting parameters and no
unnecessary tool motions
PC23. use subprograms and canned cycles, to
reduce program size and input time and
avoid memory overflow on the machine
PC24. transfer the program to the machine by
entering it at the console or transmitting
it through a wired link or through a data
transfer device
PC25. follow the correct procedures for calling
up the program and dealing with any
error messages or faults
PC26. handle the typical problems that can
occur with the programming, loading
and editing activities effectively using
approved procedures
PC27.
save the proven program in the
appropriate storage medium – paper,
computer hard disk, etc. and location
PC28. complete relevant documentation as
per organizational procedure
PC29. leave the work area in a safe and tidy
condition on completion of the activities
PC30. obtain appropriate equipment or
tools needed as per job requirements
PC31. ensure that all measuring equipment
is calibrated and approved for usage
PC32. ensure that the tools and fixtures are
in usable condition(eg. free from breakage,
damage, calibration, etc.)
PC33. pre-set tooling appropriately using
setting jigs/ fixtures
PC34.
seek
any
necessary
instruction/training on operation of the
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machine where required
PC35. mount tools in the correct positions in
the tool turret or magazine
PC36. check that the tools have been
mounted in positions corresponding to tool
numbers in the part program
PC37. mount the part on machine firmly in
the specified work holding devices, with the
appropriate clamping forces.
PC38. enter work offset and tool data on the
machine – X and Z offsets, tool orientation
and LOe radius for lathes; length offsets and
tool radius for machining centers.
PC39. ensure that tool data has been
entered in offset number corresponding to
tool offset numbers in part program
PC40. deal with error messages and faults
on the program or equipment
PC41. cut a trial part using single block run,
dry run and feed and speed override
controls
PC42. edit the program and adjust tool and
wear offsets to correct any dimensional
errors on the part
PC43. ensure that trial part conforms to
drawing specifi-cations in terms of
dimensions, surface finishes & geometrical
parameters like concentricity, parallelism,
runout, etc.
PC44 correct the tool wear offsets whenever
required, based on the results of the period
inspection
PC45. change worn out tools and indexable
inserts whenever required
PC46. after every change of a worn out tool
or insert, cut a trial part and correct any
dimensional inaccuracies by adjusting the
tool offsets or wear offsets
PC47.
return worn out cutting tools,
workholding device / fixtures / instruments /
drawings to store
PC48. ensure that there is no damage to the
tool/fixture while doing the prove-out
PC49. shut down the equipment to a safe
condition on conclusion of the activities
PC50. deal promptly and effectively with
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LO
CPC/ N 7122
Maintain
healthy and
safe work
practices
problems within span of responsibility and
control and report those that cannot be
solved
Sub total
Performance Criterion Description
PC1. understand potential dangers/ risks and
their causes at the workplace
Dangers: Heated & sharp metal chips, sharp
edged objects, heavy tools, loose rotating
parts, loud noise, welding radiations, gas
cylinders, fume, dust, chemical coolant,
hazardous surfaces – slippery, broken, uneven
etc., working at heights, intense light, electrical
hazards- loose & naked cables, power supply
and points, loose contacts etc.
Causes: physical actions, inattention, mental
sickness, drumpedness, health issues, other
peoples mistake, faulty equipment, natural
disaster.
PC2. use protective clothing/equipment for
specific tasks and work conditions as per work
environment
Protective clothing: leather or asbestos gloves,
flame proof aprons, flame proof overalls
buttoned to neck, cuffless (without folds),
trousers, industrial footwear, safety helmets,
cap & shoulder covers, ear defenders/plugs,
knee pads, glasses/ goggles/visors
Equipment: hand shields, machine guards,
residual current devices, dust sheets,
respirator
PC3. know the location of general health &
safety equipments at the workplace
PC4. shall know the name and location of
people responsible for health and safety in the
workplace
PC5. shall have complete knowledge of the
names and location of documents that refer to
health and safety in the workplace
Documents: fire notices, accident reports,
safety instructions for equipment and
procedures, company notices and documents,
legal documents (eg government notices)
PC6. carry out safe working practices to
ensure the safety of self and others
Safe working practices: using protective
clothing and equipment; putting up and
50
Theory
150
Practical
200
Total
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
reading safety signs; handle tools in correct
manner and store and maintain them properly;
keep work area clear of clutter, spillage and
unsafe object lying casually; while working
with electricity take all electrical precautions
like insulated clothing, adequate equipment
insulation, use of control equipment, dry work
area, switch off the power supply when not
required, etc.; safe lifting and carrying
practices; use equipment that is working
properly and is well maintained
PC7. understand methods of accident
prevention at the workplace
Methods of accident prevention: training in
health and safety procedures; using health and
safety procedures; use of equipment and
working practices (such as safe carrying
procedures); safety notices, advice; instruction
from colleagues and supervisors
PC8. identify common danger signs displayed
in various areas
Various areas: on chemical containers;
equipment; packages; inside buildings; in open
areas and public spaces, machine, electrical
panels etc
PC9. apply good housekeeping practices at all
times
Good housekeeping practices: clean/tidy
work areas, removal/ disposal of waste
products, protect surfaces, 5S practices
PC10. understand the application and use the
various appropriate fire extinguishers on
different types of fires correctly
Types of fires: Class A: eg. ordinary solid
combustibles, such as wood, paper, cloth,
plastic, charcoal, etc.; Class B: flammable
liquids and gases, such as gasoline, propane,
diesel fuel, tar, cooking oil, and similar
substances; Class C: eg. electrical equipment
such as appliances, wiring, breaker panels, etc.;
Class D: combustible metals such as
magnesium, titanium, and sodium (These fires
burn at extremely high temperatures and
require special suppression agents)
PC11. understand and follow rescue
techniques practices during fire hazard
PC12. follow good housekeeping in order to
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
LO
CPC/ N 7123
Effective
working with
others
prevent fire hazards
PC13. participate in emergency procedures
Emergency procedures: raising alarm, notifying
authorities, contacting emergency numbers,
safe/efficient, evacuation, correct means of
escape, correct assembly point, roll call, correct
return to work
PC14. respond promptly and appropriately to
an accident situation or medical emergency
PC15. demonstrate correct method to move
injured people and others during an emergency
PC16. Provide appropriate first aid to victims
where required eg. in case of bleeding, burns,
choking, electric shock, poisoning etc.
PC17. demonstrate how to free a person from
electrocution
PC18. complete a written accident/incident
report or dictate a report to another person,
and send report to person responsible
Incident Report includes details of: name,
date/time of incident, date/time of report,
location, environment conditions, persons
involved, sequence of events, injuries
sustained, damage sustained, actions taken,
witnesses, supervisor/manager notified
Sub total
Performance Criterion Description
PC1. display appropriate communication
etiquette while working Communication
etiquette: use appropriate tone, pitch and
language to convey politeness, assertiveness,
care and professionalism, use appropriate
titles and terms of respect; do not use
abusive language
PC2.
display active listening skills while
interacting with others at work
PC3.
demonstrate responsible and
disciplined behaviors at the workplace
Disciplined behaviors: e.g. punctuality;
completing tasks as per given time and
standards; not gossiping and idling time;
eliminating waste, observing honesty, etc
General health and safety equipment: fire
extinguishers; first aid equipment; safety
instruments and clothing; safety
installations(eg fire exits, emergency door)
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
9
Theory
36
Practical
45
Total
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
LO
CPC/ N 7124
Basics of
computer and
data entry
LO
CPC/ N 7125
Soft Skills
PC4.
accurately receive information and
instructions from the supervisor and fellow
workers, getting clarification where required
PC5. accurately pass on information to
authorized persons who require it and within
agreed timescale & confirm its receipt
PC6. display helpful behavior by assisting
others in performing tasks in a positive
manner, where required and possible
PC7. Consult with & assist others to
maximize effectiveness and efficiency in
carrying out tasks
PC8. escalate grievances and problems to
appropriate authority as per procedure to
resolve them & avoid conflict.
Sub total
Performance Criterion Description
PC1. Fill and process mandated forms for
receiving, processing, or tracking data, enter
data from source documents in to Computer
application having MS OFFICE software
PC2. Verify data entered with source
documents, checks for compliance and
corrects all typographical errors and missing
or repeated data.
PC3.
Maintain files of source documents
or other information related to data
entered.
PC4. Update database information to
reflect most current source information
PC5.
Assist in the filing and storage of
security and back up data files
PC6. Respond to requests for information and
access relevant files
Sub total
Performance Criterion Description
PC1.
Able to effectively understand the
verbal instructions in English or any
vernacular language
PC2. Able to communicate effectively with
the supervisor and fellow colleagues to carry
out day to day activities.
Able to read the reports either in
PC3.
English or any vernacular language
PC4. Understand the meaning of these
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
4
Theory
16
Practical
20
Total
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
3
Theory
12
Practical
15
Total
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
1
1.5
LO
CPC/ N 7126
Understanding
and
Implementation
of 5S
reports and its importance.
PC5. Filing of the reports and formats in
proper location.
PC6. Retrieval and producing the specific
reports/files to the supervisor as and when
required.
PC7. Numbering and orderliness maintenance
of files in safe locations
Sub total
Performance Criterion Description
PC1. Follow the sorting process and check
that the tools, fixtures & jigs that are lying on
workstations are the ones in use and unnecessary items are not cluttering the
workbenches or work surfaces.
PC2.
Ensure segregation of waste in
hazardous/ non Hazardous waste as per the
sorting work instructions
PC3.
Follow the technique of waste disposal
and waste storage in the proper bins as per
SOP
PC4. Segregate the items which are labelled
as red tag items for the process area and keep
them in the correct places
PC5.
Sort
the
tools/
equipment/
fasteners/ spare
parts
as
per
specifications/ utility into proper trays,
8 cabinets, lockers as mentioned in the 5S
guidelines/ work instructions
PC6. Ensure that areas of material storage
areas are not overflowing PC7. Properly stack
the various types of boxes and containers as
per the size/ utility to avoid any fall of items/
breakage and also enable easy sorting when
required
PC8. Return the extra material and tools to
the designated sections and make sure that no
additional material/ tool is lying near the work
area
PC9.
Follow the floor markings/ area
markings used for demarcating the various
sections in the plant as per the prescribed
instructions and standards
PC10. Follow proper labeling mechanism of
instruments/
boxes/ containers and
maintaining reference files/ documents with
0.5
1
1.5
0.5
1
1.5
0.5
1
1.5
3.5
Theory
10
Practical
13.5
Total
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
the codes and the lists
PC11. Check that the items in the respective
areas have been identified as broken or
damaged
PC12. Follow the given instructions and check
for labeling of fluids, oils. Lubricants, solvents,
chemicals etc. and proper storage of the same
to avoid spillage, leakage, fire etc.
PC13. Make sure that all material and tools are
stored in the designated places and in manner
indicated in 5S instructions
PC14. Check whether safety glasses are
clean and in good condition
PC15. Keep all outside surfaces of recycling
containers are clean
PC16. Ensure that the area has floors swept,
machinery clean and Generally clean. In case
of cleaning, ensure that proper displays are
maintained on the floor which indicate
potential safety hazards
PC17. Check whether all hoses, cabling & wires
are clean, in good condition and clamped to
avoid any mishap or mix up
PC18. Ensure workbenches and work surfaces
are clean and in good condition
PC19. Follow the daily cleaning standards and
schedules to create a clean working
environment
PC20. Attend all training programs for
employees on 5 S
PC21. Support the team during the audit of 5 S
PC22. Participate actively in employee work
groups on 5S and encourage team members
for active participation
PC23. Follow the guidelines for What to do
and What not to do to build sustainability in
5S as mentioned in the 5S check lists/ work
instructions
Sub total
Total
Means of Assessment 1:
The assessment comprise of :
 Theory
 Viva-voce
 Practical assessment
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
0.5
2
2.5
11.5
150
46
450
57.5
600
Means of Assessment 2:
Pass/Fail –
The Pass mark of theory written assessment is 40% and for viva and practical assessment is 50%.
The candidate has to pass separately in Theory and Practical.