quality controller...quality control through the workshop manager and supervisors/ service advisors...

Quality Controller

Model Curriculum

Quality Controller

SECTOR: SUB-SECTOR: OCCUPATION:

REF ID: NSQF LEVEL:

Automotive Automotive vehicle service Workshop operations ASC/Q1605, v1.0 6

Quality Controller

Quality Controller

TABLE OF CONTENTS

1. Curriculum 01

2. Trainer Prerequisites 06

3. Annexure: Assessment Criteria 07

Quality Controller 1

Quality Controller CURRICULUM / SYLLABUS

This program is aimed at training candidates for the job of a “Quality Controller”, in the “Automotive” Sector/Industry and aims at building the following key competencies amongst the learner.

Program Name Quality Controller

Qualification Pack Name & Reference ID.

ASC/Q1605, v1.0

Version No. 1.0 Version Update Date 22/10/2018

Pre-requisites to Training

ITI or diploma in Mechanical /Automobile/ Electrical engineering. B.E./ B. Tech in Mechanical/ Electrical/ Automobile engineering. On the job training:

• Desirable for ASDC Quality Controller Level 6 certificate or graduate degree / diploma in any discipline.

• Compulsory for all other qualifications.

Training Outcomes After completing this programme, participants will be able to:

• Perform quality control checks.

• Plan and organise work to meet expected outcomes.

• Work effectively in a team.

• Maintain a healthy, safe and secure working environment.


This course encompasses 4 out of 4 National Occupational Standards (NOS) of “Quality Controller”

Qualification Pack issued by “Automotive Skill Development Council (ASDC)”.

Sr. No.

Module Key learning outcomes Equipment Required

1 Introduction Theory Duration (hh:mm) 04:00 Practical Duration (hh:mm) 00:00 Corresponding NOS Code Bridge Module

• Describe the role and responsibilities of a Quality Controller.

• Explain the organisation structure of the service department in a dealership.

• Explain the importance of quality checks.

• Describe terms and conditions of quality check.

• Explain the importance of audit process in providing quality product to the customer.

• Interpret standard operating procedure (SOP) to implement quality culture at the organisation.

• Describe safety requirements for equipment, auto components and aggregates.

• Explain professional code of conduct.

• Describe safety, health policies and regulations at the workplace.

Training Kit (Presentations, Trainer Guide).

2 Performing quality control check Theory Duration (hh:mm) 96:00 Practical Duration (hh:mm) 260:00 Corresponding NOS Code ASC/N1607

• Interpret OEM technical specifications of vehicular products.

• Describe basic technology and functioning of various components and aggregates.

• Describe various ISO and environmental certifications like ISO/TS16949, ISO 9000, ISO 10002 and ISO 14001.

• Evaluate various quality control tools

• Describe the importance of ‘Kaizen’ in the quality control.

• Access and interpret OEM guidelines to gather technical and quality aspects.

• Perform visual inspection under the hood as a part of quality check for:

o Loose tools. o Proper installation of caps and

covers. o Fluid levels. o Any leaks. o Proper connection of wires and

hoses. o Proper fitment of air filter

housing.

• Perform visual inspection inside the vehicle as a part of quality check for:

o Finger prints, grease, and foot prints.

Training Kit (Presentations, Trainer Guide), vehicle, precision gauges, OEM service manuals and guidelines, quality control check sheets, sample job cards, literature on ISO/TS 16949, ISO 9000, ISO 10002, ISO 14001, personal protective equipment (PPE).


Sr. No.


o Cleanliness of steering wheels and door handles.

o Cleanliness of floor mats and seat covers.

• Perform visual inspection of the entire vehicle for cleanliness after the wash.

• Assess the need and required specifications for wheel balancing and alignment by checking the job card.

• Assess proper functioning of the odometer by calculating in and out mileage.

• Check the job card for completeness of the service as per the standard check sheet.

• Document the observations accurately with required detail, in relevant forms and formats and inform relevant authority for any shortcomings.

• Use precision tools and gauges to inspect auto parts, components and materials.

• Identify key factors and actions that will ensure effectiveness of overall supervision.

• Plan and execute supervisory schedules of activities for effective overall supervision.

• Describe the importance of quality control programs.

• Develop and implement quality control programs to improve the efficiency of daily operations.

• Communicate any updates in maintenance and service bulletins to the team and technicians.

• Notify to the concerned authority regarding incomplete or repeated work.

• Provide relevant and accurate information in the required detail to technical support team for resolving quality issues with auto components manufacturers.

• Communicate to the concerned personnel of the latest circulars received from OEM or component manufacturers.

• Differentiate between the original and spurious auto parts, components and materials along with precision tools and gauges.

3 Planning and organising work to

• Interpret Standard Operating Procedures (SOP) and plan sequence

Training kit (Trainer guide,


Sr. No.


meet expected outcomes Theory Duration (hh:mm) 30:00 Practical Duration (hh:mm) 50:00 Corresponding NOS Code ASC/N0001

of operations correctly.

• Adhere to 5S practices and keep the work area clean and tidy.

• Organise required tools and equipment for the task to be carried out.

• Maintain information confidentiality and share the information with the concerned authority only.

• Seek guidance from the appropriate authority as per the policy.

• Interpret the work correctly and agree on the timelines to complete the work accurately.

• Manage time, resources and cost effectively to achieve better results.

Presentations).

4 Working effectively in a team Theory Duration (hh:mm) 30:00 Practical Duration (hh:mm) 50:00 Corresponding NOS Code ASC/N0002

• State the importance of communication.

• Describe various communication methods.

• Explain the importance of listening skills in day-to-day activities.

• Describe the importance of non- verbal communication.

• State characteristics of an aligned team

• Pass on the information to colleagues as per the policy.

• Respect colleagues and customers at all times.

• Adhere to commitments made to complete the work timely and accurately.

• Demonstrate problem solving and decision making abilities.

• Collaborate with team members to achieve the task.

• Carry out required documentation as per the policy.

• Communicate effectively with colleagues and customers.

• Read instructions and applicable guidelines accurately.

• Seek clarification or advice from the concerned authority.

• Check the quality of work and ensure that the work is complete in all respects.

Training kit (Trainer guide, Presentations).

5 Maintaining a healthy, safe and secure working environment Theory Duration (hh:mm) 30:00

• Describe organization’s policy regarding health, safety and security.

• Identify potential hazards at the workplace and take necessary actions to avoid such hazards.

• Report any identified safety breaches to the concerned authority.

• Identify the components of a first aid kit.

Training Kit (Presentations, Trainer Guide) first aid kit, different types of fire extinguishers, personal protective equipment (PPE).


Sr. No.


Practical Duration (hh:mm) 50:00 Corresponding NOS Code ASC/N0003

• Provide first aid to minor injuries at the workplace.

• Explain the term ‘Fire Triangle’.

• Identify various types of fire extinguishers and state their application.

• Operate a fire extinguisher to extinguish the fire.

• Read and interpret various safety symbols.

Total Duration Theory Duration 190:00 Practical Duration 410:00

Unique equipment required: Training Kit (Presentations, Trainer Guide), Vehicle, precision gauges, Personal Protective Equipment (PPE), First Aid Kit, Different types of Fire Extinguishers. Training Aids: OEM service manuals and guidelines, quality control check sheets, sample job cards, literature on ISO/TS 16949, ISO 9000, ISO 10002, ISO 14001.

Grand Total Course Duration: 600 Hours, 0 Minutes

(This syllabus/ curriculum has been approved by Automotive Skill Development Council)


Trainer Prerequisites for Job role: “Quality Controller” mapped to Qualification Pack: “ASC/Q1605v1.0” Sr. No.

Area Details

1 Description A Trainer of ‘Quality Controller’ is responsible for training candidates in proper monitoring, testing and inspecting all systems and processes at the dealership. The Quality Controller should be able to ensure that quality standards are met as specified by the various components/ aggregate manufacturers of the OEM product or service provided by an organisation.

2 Personal Attributes

An individual on this job must have good communication and interpersonal skills in addition to being a team player, as the job requires coordination with various internal and external stakeholders to ensure maximum quality is maintained. The individual must have a technical bend of mind to understand the technical aspects of various aggregates/ components in the vehicle. The individual should be methodological and systematic in his way of working to ensure various systems and processes quality related aspects in the workshop.

3 Minimum Educational Qualifications

Diploma /Degree in Automotive Engineering.

4a Domain Certification

Certified for Job Role: “Quality Controller” mapped to QP: “ASC/Q1605, v1.0”. Minimum accepted score is 80%

4b Platform Certification

Recommended that the Trainer is certified for the Job Role: “Trainer”, mapped to the Qualification Pack: “MEP/Q0102”. Minimum accepted as per respective SSC guidelines is 80%.

5 Experience • 3-4 years of experience as a Quality Controller in big dealerships

• 1-2 years of teaching experience


Guidelines for Assessment 1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of marks for Theory and Skills Practical for each PC. 2. The assessment for the theory part will be based on knowledge bank of questions created by the SSC. 3. Assessment will be conducted for all compulsory NOS, and where applicable, on the selected elective/option NOS/set of NOS. 4. Individual assessment agencies will create unique question papers for theory part for each candidate at each examination/training center (as per assessment criteria below). 5. Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/training center based on this criterion. 6. To pass the Qualification Pack, every trainee should score a minimum of 70% of aggregate marks to successfully clear the assessment. 7. In case of unsuccessful completion, the trainee may seek reassessment on the Qualification Pack.

Annexure: Assessment Criteria

Criteria For Assessment Of Trainees

Job Role: Quality Controller

Qualification Pack: ASC/Q1605

Sector Skill Council: Automotive Skill Development Council

Assessable

Outcomes

Assessment criteria Marks Allocation

Theory Viva Practical

ASC/ N 1607

Perform quality

control check

PC1. plan, organise and schedule work to

quality control through the workshop

manager and supervisors/ service advisors

300 10 20

PC2. determine inspection criteria and

work methods for verifying quality of repairs

9 18


PC3. check the following parameters while

performing the quality check:

visual inspection under hood:

· visual inspection inside vehicle:

· complete car wash

· 2 wheel alignment

· 4 Wheel Alignment

· in and out mileage

· completed service procedures & used

parts checked off

· procedures sheet correctly documented

· recommended services checked or

crossed

· cause, correction (parts & labour), and

repair

· visual maintenance inspection

12 24

PC4. ensure overall supervision of quality

control process through regular:

· inspection of various equipment’s and

tools (including special tools)

· inspection of work methods for verifying

quality of repairs carried out

· monitoring of the deviations between

what is mentioned on the job card and what

is actually carried out

· check of whether the overall system for

service, repair and routine maintained is

followed as per the OEM guidelines

10 24

PC5. supervise inspection of auto parts,

components and material with precision

tools and gauges to avoid spurious or

duplicate parts

8 16

PC6. develop and implement quality

control programs to improve efficiency of the

daily operations

8 20

PC7. ensure that maintenance & service

bulletin books are up-to-date and the same

has been communicated to all the

employees of the workshop

9 18

PC8. determine and inform managers and

supervisors in case the repair is not done

appropriately and further rework is required

8 16

PC9. provide information to technical

support team for resolving quality issues

with auto components manufacturers

10 12

PC10. evaluate and recommend the use of

reconditioned aggregate, new part or repair

or an existing part needs to be done as per

8 16


the OEM guidelines

PC11. understand the various ISO and

other environmental certifications (both

mandatory by the OEM or optional for a few

workshops) including:

· ISO/TS 16949 - specifies the quality

system requirements for the

design/development, production, installation

and servicing of automotive-related products

· ISO 9000 series - series of quality

management system standards for

delivering quality products/services to the

customers

· ISO 10002 - relevant to any organization

that wishes to exceed customer

expectations

· ISO 14001 – criteria for an effective EMS

(environment management system)

· Or any other certification as may be

desired from time to time to ensure quality

aspects in the workshop like Kaizen

8 16

Subtotal 100 200

ASC/ N 0001

Plan and

organise work

to meet

expected

outcomes

PC1. keep immediate work area clean

and tidy

60 3 6

PC2. treat confidential information as per

the organisation’s guidelines

2 4

PC3. work in line with organisation’s

policies and procedures

2 4

PC4. work within the limits of job role 2 4

PC5. obtain guidance from appropriate

people, where necessary

2 4

PC6. ensure work meets the agreed

requirements

2 4

PC7. establish and agree on work

requirements with appropriate people

2 4

PC8. manage time, materials and cost

effectively

3 6

PC9. use resources in a responsible

manner

2 4

Subtotal 20 40

ASC/ N 0002

Work

effectively in a

PC1. maintain clear communication with

colleagues (by all means including face-to-

face, telephonic as well as written)

60 3 6


team PC2. work with colleagues to integrate

work

2 4

PC3. pass on information to colleagues

in line with organisational requirements both

through verbal as well as non-verbal means

3 6

PC4. work in ways that show respect for

colleagues

2 4

PC5. carry out commitments made to

colleagues

2 4

PC6. let colleagues know in good time if

cannot carry out commitments, explaining

the reasons

2 4

PC7. identify problems in working with

colleagues and take the initiative to solve

these problems

3 6

PC8. follow the organisation’s policies

and procedures for working with colleagues

3 6

Subtotal 20 40

ASC/ N 0003

Maintain a

healthy, safe

and secure

working

environment

PC1. comply with organisation’s current

health, safety and security policies and

procedures

60 2 4

PC2. report any identified breaches in

health, safety, and security policies and

procedures to the designated person

3 6

PC3. coordinate with other resources at

the workplace to achieve the healthy, safe

and secure environment for all incorporating

all government norms esp. for emergency

situations like fires, earthquakes etc.

3 6

PC4. identify and correct any hazards

like illness, accidents, fires or any other

natural calamity safely and within the limits

of individual’s authority

2 4

PC5. report any hazards outside the

individual’s authority to the relevant person

in line with organisational procedures and

warn other people who may be affected

2 4

PC6. follow organisation’s emergency

procedures for accidents, fires or any other

natural calamity

2 4

PC7. identify and recommend

opportunities for improving health, safety,

and security to the designated person

3 6


PC8. complete all health and safety

records are updates and procedures well

defined

3 6

Subtotal 20 40

TOTAL 480 160 320

quality controller...quality control through the workshop manager and supervisors/ service advisors...

Documents