By Dr. Olaniyi Opanuga PhD, FNIPM, FCIAM

NIPM Production Operatives Certification Exam (POCE)and relatedjob skills training helps manufacturing companies to build competent, efficient and productive workforce. Organizations expect their employees to demonstrate professional skills and behaviours.   

In factory work you are required to apply technical, operational and human relations knowledge, skills and attitude (KSA). You need expertise, a set of talents and skills with the right behaviour and attitude. Production and manufacturing workers are supposed to be professionals who should demonstrate capacity for critical thinking, problem solving, decision making and effective job performance. Let us review the required skillset.

1. Machine Operations

Knowledge of basic mechanics and electricity, mechatronics and ability to operate and control equipment. It involves both mental and physicals activity. The use of computer-aided technologies (e.g. computer-aided design (CAD), computer-aided manufacturing (CAM) increases efficiency. The need to ensure proper uptime and reduce factory downtime is crucial. It is also important to evaluate machine wastages impact on production and the entire business and explore ways to prevent factory wastages in the factory. Downtime may be planned or unplanned. Machine wastages may be due to poor product design, operator error, machine maintenance lapses, ineffective communication and others to be taught. However wastage reduction can be delivered through:

• Work Standards
• Layout and Process Flow
• Planned preventive Maintenance
• Total Preventive Maintenance (TPM)   
• Understand and Flow of Instructions  
• Follow the Standard Operating Procedures (SOPs)
• Perform tasks with greater care and completeness
• Pay attention to details
• Speed does not mean “rush”
• Work  load balancing
• Improved Ergonomics    

Impact of Factory Downtime and Machine Wastages 

Unplanned downtime and machine wastage arising from lateness to work, delayed set up time, aging and usage, inattentive to warnings, poor quality material, machine break down, poor monitoring and control, unstable power improper operation, lack of concentration, poor communication and lack of team work and so on have implication for:

• Reduced profitability due to uncompetitiveness and low sales
• Higher environmental impact
• Staff wages and salaries will be affected
• Not meeting market demand
• It may lead to workers lay-off
• It will stifle  company growth
• Employee welfare may suffer neglect
• Therefore adequate knowledge of manufacturing production processes and strict adherence of SOPs is very important.

• Material Handling and Work Flow

Apart from operating and maintaining machines production and technical personnel also use of power tools, receive materials from the store, unload, organize and stock shipments, process and pack  products etc.    

Downtime and wastages can occur due to poor material handling as a result of internal storage, transportation, security, stock control, space utilization, unit loads, ergonomic and allied issues.

Materials handling – movement and utilization through manual or mechanical or electro-mechanical processes should be efficient and safe.  

We cannot harp enough on the need to follow instructions and production schedules or daily work sheet while responding to equipment fault or product defects on the assembly line.

Acting fast when a problem arises is important. Fix it right away if it is your responsibility to do so. Report immediately to your team leader or supervisor if not.

3     Good Housekeeping and 5S Checklist

Maintaining a clean, tidy and safe workplace help in getting rid of hazards that may cause incidents and accidents. Properly stacked or arranged goods will prevent workers being hit by falling objects, Properly stored tools and a well-organized work station will reduce delays while shipping or triping  on wet floors, stairs or dirty surfaces will be avoided through regular and proper cleaning.

Adequate lighting, proper use of signage and warning signs, right storage and disposal of waste and removal of clutters which may cause fire outbreak are all ways to prevent factory accident.

5S is a five-step methodology designed to create a better workplace organization which allows for waste elimination, greater efficiency, improved safety and higher productivity. 5S derived from the Japanese words-seiri (sort), seiton (set in order), seiso (clean), seiketsu (standardize) and shitsuke (sustain).

5S is another way of describing housekeeping principles. To upgrade 7S we can add “safety’’ and “self-discipline”.

NIPM 5S housekeeping training features 5S Audit checklist that can help manufacturers to evaluate their 5S implementation-related processes and procedures, optimize space utilization, improve safety and quality standards, boost workers morale, improve maintenance, promote a culture of continuous improvement, reduce waste, remove inefficient operations, streamline processes, improve productivity and profitability. 

• 4 Factory Level Productivity And Output Efficiency

Effective employees are known by their worker output efficiency– from the way they operate machines, equipment and tools, raw materials, intermediate materials, finished goods and the entire production process.

Efficiency = Output X 100%

                       Input

Output efficiency is not only computed in terms of volume or quantity but also in terms of quality and safety. Speed is good but consistent quality is vital. Other elements of output efficiency include:

• Setup time and Run time
• Just-in-time (J.I.T) inventory, production and 
• Zero Waste, Zero Reduction and Spoilage or Scrap reduction
• Physical strength is not enough. Use approved methods

 To ascertain whether maximum production capacity has been achieved we can use the formula below: 

Production Efficiency =       Actual Output X 100%

                                               Standard Output

Our goal in the factory should be to increase productivity by producing more quality products at lower cost by using fewer resources. Production workers should focus on production target on a daily basis. Accountability for results is sacrosanct.

• 5 Occupational Health and Safety 

There are laws and regulatory requirements with which organizations need to comply. Government agencies carry out investigations and insect factories with a view to enforcing compliance. On their own part companies are expected to put in place health, safety and environmental (HSE) policy, strategy, rules and regulations as well as carry out risk management and hazard control programme. Employees need to prevent diseases, injuries and fatalities adhere to and continuously learn safe work practices, permit systems, permit to work, working in specific circumstances such as “at height” and ‘’confined space’’ working with electricity and lifting heavy objects, housekeeping, physical and chemical exposure, fire precautions, medical emergencies, first aid, incident reporting etc.

The need to eradicate substance abuse or more precisely alcohol and drug abuse is a critical element of an effective HSE programme. 

Drug Abuse

Drugs are used to treat specific disease and may be chemical agent with health risks or undesirable effects when used without doctor’s prescription. They may serious impact on human life and workplace safety, quality and productivity.

Personal Protective Equipment (PPE)

A part of safety protocol it is mandatory that employees use the personal protection equipment (PPE) given to them as instructed. Depending on the hazards associated with their work employees are provided with uniforms, safety boots, hand gloves, respirator, goggles, ear muffs, helmet, nose mask etc.

• 6 Troubleshooting Skills

Technical employees need to monitor equipment and machinery, fix any problems detected.

• 7 Ethics Skills – Work Ethics and Positive Work Attitude

Strong work ethics. Sharing ethical values enhance employee commitment, loyalty, ability to work with others for team results etc.

• 8 Communication Skills

Oral and Written communication skills for effective interactions, record keeping and report writing

• 9 Team Work

Team spirit, interpersonal relations, collaboration and co-operation at work help workers to complete tasks successfully and achieve unit, sectional and departmental objectives.   

• 10 Punctuality and Time Management Skills

• 11 Quality Inspection Skills

Inspecting assembly line to ensure that products meet quality and safety specifications. Full concentration, focus and patience are required.

12 Innovation and General Skills

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