| Manufacturing Process Design and Development Research and design manufacturing systems from conceptualization to implementation and optimization. |
| Sub-competency · Technical Drawings and Schematics |
| Topic · Computer Aided Design (CAD) Drawing and Drafting |
| Knowledge of CAD standards and practices and familiarity with Augmented Reality shop-aides. | Knowledge | Not critical | Not critical | Curriculum |
| Skill in accessing and analyzing 2D and 3D CAD models using software like AutoCAD, SolidWorks, or CATIA V5 while using spatial reasoning. | Skill | Not critical | Not critical | Curriculum |
| Ability to translate design concepts and specifications into detailed CAD drawings and schematics while adhering to established standards. | Ability | Not critical | Not critical | Curriculum |
| Topic · Tolerancing |
| Knowledge of Geometric Dimensioning and Tolerancing (GD&T) and general tolerancing principles and standards for parts manufacturing. | Knowledge | Medium | Not critical | Curriculum |
| Skill in applying GD&T and general tolerancing concepts to engineering drawings. | Skill | Medium | Not critical | Curriculum |
| Ability to ensure accurate designs that meet GD&T and general tolerancing requirements. | Ability | Not critical | Medium | Curriculum |
| Topic · Blueprint and Print Reading |
| Knowledge of engineering drawings, blueprints, schematics, and technical specifications. | Knowledge | Medium | Not critical | Curriculum |
| Skill in translating drawings into actionable manufacturing instructions. | Skill | Medium | Not critical | On-the-job |
| Ability to identify potential design or manufacturing issues through detailed print reading and provide valuable input to enhance product quality and manufacturability. | Ability | Low | Medium | On-the-job |
| Topic · Electric Schematics (e.g. wiring and circuitry) |
| Knowledge of electrical circuit principles, symbols, and terminology. | Knowledge | Medium | High | Curriculum |
| Knowledge of digital circuits and their components including number systems (binary/decimal), counters, memory, digital bus, pulsers, logic gates, etc.). | Knowledge | Not critical | Medium | Curriculum |
| Skill in reading and interpreting electrical schematics, including wiring diagrams, circuit layouts, connection types and control panel drawings. | Skill | Medium | Not critical | Curriculum |
| Skill in reading and interpreting schematics and codes for digital circuits. | Skill | High | Not critical | Curriculum |
| Ability to design, modify, connect components, and troubleshoot electrical and digital circuits and systems based on schematics. | Ability | Not critical | Not critical | Curriculum |
| Sub-competency · Design Lifecycle and Concepts |
| Topic · Design Thinking |
| Knowledge of design thinking principles and methodologies. | Knowledge | High | Not critical | Curriculum |
| Skill in applying user-centered design principles to prototypes and iteratively improving. | Skill | Not critical | Medium | Curriculum |
| Ability to brainstorm and innovative on all aspects of the design lifecycle. | Ability | Not critical | Medium | Curriculum |
| Topic · Prototype Development and Testing |
| Knowledge of prototyping techniques, materials, and technologies relevant to advanced manufacturing (e.g., rapid prototyping). | Knowledge | Medium | Not critical | Curriculum |
| Skill in creating functional prototypes to validate design concepts and manufacturing processes. | Skill | Not critical | Medium | Curriculum |
| Ability to adapt and refine prototypes with changing requirements. | Ability | Not critical | Medium | Curriculum |
| Topic · Material Selection & Compatibility |
| Knowledge of materials (e.g., polymers, metals, ceramics, composites, nanomaterials) relevant to advanced manufacturing, including material properties and compatibilities. | Knowledge | Not critical | Medium | Curriculum |
| Skill in reviewing material selection. | Skill | Not critical | Not critical | Curriculum |
| Ability to provide input on material selection. | Ability | Not critical | Not critical | Curriculum |
| Topic · Technology Applications |
| Knowledge of both existing and emerging technologies and their applications in advanced manufacturing (e.g., industry 4.0, automation, robotics, IoT). | Knowledge | Not critical | Medium | Curriculum |
| Skill in assessing the feasibility of implementing technologies in advanced manufacturing processes. | Skill | Not critical | Medium | Curriculum |
| Ability to integrate technologies into manufacturing operations to optimize the process. | Ability | Not critical | High | Curriculum |
| Topic · Systems Thinking |
| Knowledge of the interdependencies and interactions within complex manufacturing systems. | Knowledge | Not critical | Medium | Curriculum |
| Skill in analyzing and modeling complex manufacturing systems. | Skill | Not critical | Not critical | Curriculum |
| Ability to apply systems thinking to troubleshoot and improve overall system performance. | Ability | Not critical | High | Curriculum |
| Sub-competency · Continuous Improvement |
| Topic · Lean Thinking |
| Knowledge of lean principles, methodologies, philosophies, and tools and techniques for waste reduction. | Knowledge | High | Not critical | Curriculum |
| Skill in applying lean principles to identify and eliminate waste, improve process efficiency, and optimize resource utilization. | Skill | Low | High | Curriculum |
| Topic · Root Cause Analysis (RCA) |
| Knowledge of root cause analysis (RCA) methodologies, such as failure mode, effects analysis, and fishbone diagrams. | Knowledge | High | Not critical | Curriculum |
| Skill in conducting systematic root cause analysis (RCA) for quality, product, or equipment issues. | Skill | High | Not critical | Curriculum |
| Ability to use RCA tools and methodologies to identify and communicate underlying causes. | Ability | Not critical | Medium | Curriculum |
| Topic · Manufacturing Process Optimization |
| Knowledge of manufacturing process optimization techniques, such as mixed model line balancing, process mapping, plant layout analysis, reduction of waste and value stream analysis. | Knowledge | Not critical | Medium | Curriculum |
| Skill in analyzing production processes, identifying bottlenecks, and reconfiguring workflows to improve efficiency. | Skill | Low | Medium | Curriculum |
| Ability to identify and communicate methods to streamline manufacturing processes, like reducing lead times or maximizing resource utilization. | Ability | Not critical | Medium | Curriculum |
| Topic · Process Simulation Tools (e.g., die press lines, manufacturing lines) |
| Knowledge of the benefits of process simulation tools and their applicability throughout the E2E product lifecycle such as die press lines and manufacturing lines. | Knowledge | Medium | Medium | Curriculum |
| Skill in contributing to testing procedures under simulated conditions. | Skill | Not critical | Medium | Curriculum |
| Ability to use simulation software (e.g., CAMEO) and other tools to model and analyze simple manufacturing processes and communicate findings. | Ability | Not critical | Medium | Curriculum |
| Production Operations Execute processes for transforming raw materials into finished products. |
| Sub-competency · Pre-Production Operations |
| Topic · Machine Preparation |
| Knowledge of machine preparation activities such as lubrication, restocking of materials, understanding operation and safety. | Knowledge | High | Not critical | Curriculum |
| Skill in preparing the machine for operation, including cleaning, tool setup, and material loading. | Skill | High | Not critical | On-the-job |
| Ability to ensure that the machine is ready for production, minimizing the risk of errors and accidents during operation. | Ability | Not critical | Medium | On-the-job |
| Topic · Machine Calibration |
| Knowledge of calibration procedures, precision measurement tools, and equipment accuracy requirements. | Knowledge | High | Not critical | Curriculum |
| Skill in calibrating machine settings and sensors to meet the desired specifications and tolerances. | Skill | Not critical | Medium | Curriculum |
| Ability to maintain accurate and consistent machine performance through proper calibration, ensuring product quality and process reliability. | Ability | Not critical | Medium | Curriculum |
| Topic · Workstation Layout |
| Knowledge of workstation layout best practices such as workflow optimization and anti-fatigue tactics. | Knowledge | High | Not critical | Curriculum |
| Skill in identifying opportunities for improved ergonomic workstation layouts. | Skill | Not critical | Medium | Curriculum |
| Ability to communicate ineffective, unsafe, or nonoptimal workspace conditions. | Ability | High | Not critical | Curriculum |
| Topic · Machine Safeguarding |
| Knowledge of various machine safeguarding equipment such as strings, pulls, and curtains. | Knowledge | High | Not critical | Curriculum |
| Skill in identification of appropriate safeguarding equipment. | Skill | Not critical | Medium | Curriculum |
| Ability to ensure a safe working environment by effectively safeguarding machines and conducting safety assessments as needed. | Ability | Not critical | Medium | Curriculum |
| Topic · Changeover Procedures |
| Knowledge of changeover processes, including tool changes, material swaps, and adjustments required for different product runs. | Knowledge | High | Not critical | On-the-job |
| Skill in performing changeovers efficiently and accurately, minimizing downtime and waste during transitions. | Skill | Not critical | High | On-the-job |
| Ability to streamline changeover procedures, reducing production interruptions and ensuring rapid adaptation to new manufacturing requirements. | Ability | Not critical | Medium | On-the-job |
| Topic · Startup and Testing |
| Knowledge of machine startup sequences, testing protocols, and diagnostic procedures. | Knowledge | Medium | Not critical | On-the-job |
| Skill in safely starting up machines, conducting pre-production tests, and verifying that all components are functioning as expected. | Skill | Medium | Not critical | On-the-job |
| Ability to ensure a smooth and reliable startup, troubleshoot any issues that arise, and verify that the machine is ready for full-scale production. | Ability | Not critical | High | On-the-job |
| Topic · Programming Operations |
| Knowledge of basic building blocks of manufacturing programming language for machines such as CNC. | Knowledge | Medium | Not critical | Curriculum |
| Skill in executing CNC, robotics, machine programs, including software upgrades. | Skill | Not critical | High | Curriculum |
| Ability to analyze CNC, robotics, machine, and machine programs, including software upgrades. | Ability | Not critical | Not critical | Curriculum |
| Topic · Measurement and Mathematics |
| Knowledge of hands-on measurement techniques and instruments (tools such as metric/decimal/fractional rulers, calibers, micrometers, and scales). | Knowledge | High | Not critical | Curriculum |
| Knowledge of common methods used for parts tolerancing measurement and impact that tolerance deviations have on part production and quality. | Knowledge | Medium | Not critical | Curriculum |
| Skill in taking accurate measurements of materials, components, and finished products using appropriate measuring tools and equipment to verify dimensions and adhere to specified tolerances. | Skill | High | Not critical | Curriculum |
| Skill in manufacturing-relevant mathematics, such as fraction to decimal conversions and calculations including fractions, decimals, and order of operations. | Skill | High | Not critical | Curriculum |
| Topic · Production Materials (e.g. metals, plastics, composites) |
| Knowledge of the properties, characteristics, and applications of production materials, including metals, plastics, and composites. | Knowledge | Medium | Not critical | Curriculum |
| Skill in handling, storing, and preparing production materials, including material selection and cutting or shaping as needed. | Skill | Medium | Not critical | On-the-job |
| Ability to identify defects in production materials and communicate them to a supervisor. | Ability | Medium | Not critical | On-the-job |
| Topic · Machine Adjustments and Impacts |
| Knowledge of how machine adjustments can impact product quality, efficiency, and safety. | Knowledge | Medium | Not critical | Curriculum |
| Skill in making precise machine adjustments to align with production requirements. | Skill | Medium | Not critical | On-the-job |
| Ability to troubleshoot and address issues related to machine adjustments to maintain smooth operations. | Ability | Not critical | Medium | On-the-job |
| Topic · Work Center Organization |
| Knowledge of work center layouts, organization principles, and efficiency considerations. | Knowledge | High | Not critical | Curriculum |
| Skill in implementing 5S principles (Sort, Set in order, Shine, Standardize, Sustain) and visual management techniques. | Skill | Medium | Not critical | On-the-job |
| Sub-competency · Manufacturing Processes |
| Topic · Work Orders |
| Knowledge of work order submission process and work order interpretation. | Knowledge | Low | Not critical | On-the-job |
| Skill in identifying when a work order needs to be submitted. | Skill | Not critical | Medium | On-the-job |
| Ability to effectively communicate work order requirements to the appropriate departments or individuals, ensuring that work orders are processed promptly and accurately. | Ability | Not critical | Not critical | On-the-job |
| Topic · Raw Material Input (e.g. feeding and loading) |
| Knowledge of raw material input requirements, including material specifications, quantity, and handling procedures. | Knowledge | Low | Not critical | On-the-job |
| Skill in loading and inputting raw materials into machines, ensuring proper feeding and alignment. | Skill | Not critical | Medium | On-the-job |
| Ability to optimize the raw material input process to minimize waste, enhance efficiency, and maintain continuous machine operations. | Ability | Not critical | Not critical | On-the-job |
| Topic · Waste/Scrap Removal |
| Knowledge of effective waste/scrap removal protocols and ways to reduce waste. | Knowledge | Medium | Not critical | On-the-job |
| Skill in identifying, separating, and properly disposing of waste and scrap materials according to protocols. | Skill | Low | Medium | On-the-job |
| Topic · Machinery Oversight |
| Knowledge of machine operations, standard operating procedures (SOPs), safety, and basic troubleshooting practices. | Knowledge | High | Not critical | Curriculum |
| Skill in operating machines based on standard operating procedures (SOPs) and monitoring machine operations to ensure proper functioning. | Skill | Medium | Not critical | On-the-job |
| Ability to identify deviations from standard operating procedures (SOPs) and appropriately escalate issue to the proper teams as needed. | Ability | Not critical | High | On-the-job |
| Topic · Process Variables |
| Knowledge of machine output reading symbols, icons, colors, and standards (e.g. gauges, machinery screens, analog clock). | Knowledge | High | Not critical | On-the-job |
| Skill in reading gauges, meters, and indicators to assess various parameters, such as pressure, temperature, or fluid levels. | Skill | Medium | Not critical | Curriculum |
| Ability to interpret readings from gauges, meters, etc. and take corrective action if out of normal range. | Ability | High | Not critical | Curriculum |
| Topic · Fabrication Processes |
| Knowledge of metal and non-metal fabrication techniques, such as welding, cutting, and bending. | Knowledge | Not critical | Medium | Curriculum |
| Skill in selecting the appropriate fabrication method for a given material and product. | Skill | Not critical | Not critical | Curriculum |
| Ability to identify and communicate issues during the fabrication processes. | Ability | Not critical | Not critical | Curriculum |
| Topic · Hot and cold forming processes |
| Knowledge of hot and cold forming techniques, including forging and rolling. | Knowledge | Not critical | Not critical | Curriculum |
| Skill in controlling forming processes for desired shapes and properties. | Skill | Not critical | Not critical | Curriculum |
| Ability to identify and communicate issues during the hot and cold forming processes. | Ability | Not critical | Not critical | Curriculum |
| Topic · Assembly Processes |
| Knowledge of various assembly methods and tools, including manual and automated assembly and threaded fasteners. | Knowledge | High | Not critical | Curriculum |
| Skill in operating assembly lines, such as workstations and packaging/labeling stations. | Skill | High | Not critical | On-the-job |
| Topic · Soldering and Welding |
| Knowledge of the soldering and welding processes and different types. | Knowledge | Medium | Not critical | Curriculum |
| Skill in soldering and welding techniques. | Skill | High | Not critical | Curriculum |
| Ability to perform high-quality soldering and welding operations, choosing the appropriate welding process based on product specifications. | Ability | Not critical | High | Curriculum |
| Topic · Treatment and Coating |
| Knowledge of surface treatment, coating, and preparation techniques (plating, anodizing, powder coating, and chem treatments). | Knowledge | Not critical | Medium | Curriculum |
| Skill in applying surface treatments and coatings to products to enhance product durability, appearance, and provide corrosion resistance. | Skill | Not critical | Medium | Curriculum |
| Topic · Casting, molding, and stamping processes |
| Knowledge of casting, molding, and stamping methods for metal and plastic manufacturing and understanding of mold design and material flow. | Knowledge | Not critical | Medium | Curriculum |
| Skill in mold setup and operation. | Skill | Low | Medium | On-the-job |
| Ability to adapt processes to ensure the quality and consistency of cast, molded, and stamped products. | Ability | Not critical | Medium | On-the-job |
| Topic · Power and Hand Tool Operations |
| Knowledge of power and hand tools, including screwdrivers, wrenches, and drills, and their relevant techniques for use. | Knowledge | High | High | Curriculum |
| Skill in operating power and hand tools correctly and safely. | Skill | High | High | Curriculum |
| Ability to assess the most proficient power and hand tools for specific tasks. | Ability | High | High | Curriculum |
| Topic · Finishing processes (e.g. painting, sanding) |
| Knowledge of finishing processes such as painting, coating, and surface treatment. | Knowledge | Not critical | Medium | Curriculum |
| Skill in achieving desired surface finishes (e.g., improve appearance, adhesion, solderability). | Skill | Not critical | Medium | Curriculum |
| Ability to determine desired finish and proper finishing process to achieve product aesthetics and functionality. | Ability | Not critical | Not critical | Curriculum |
| Topic · Production Methods |
| Knowledge of production methods, including batch, push, pull, and flow. | Knowledge | Medium | Not critical | Curriculum |
| Skill in executing production processes based on the designated method. | Skill | Not critical | Not critical | Curriculum |
| Ability to align the production method with the manufacturing requirements and switch between production methods when necessary. | Ability | Not critical | Not critical | Curriculum |
| Topic · Parts Handling |
| Knowledge of proper handling techniques to prevent damage or contamination. | Knowledge | High | Not critical | Curriculum |
| Skill in safely and efficiently handling parts or materials, including loading, unloading, transporting, and positioning components within the manufacturing process. | Skill | High | Not critical | On-the-job |
| Ability to provide input on efficient part flow through the facility and various manufacturing processes. | Ability | High | Not critical | On-the-job |
| Topic · Error Recovery |
| Knowledge of error recovery procedures, including identification and analysis of manufacturing errors or deviations from standards. | Knowledge | Medium | Not critical | Curriculum |
| Skill in recognizing and diagnosing errors or discrepancies in manufacturing processes, products, or components. | Skill | Medium | High | On-the-job |
| Ability to respond effectively and proactively to errors and deviations. | Ability | High | High | On-the-job |
| Topic · Machine Tooling |
| Knowledge of cutting, milling, drilling, boring, turning terms and techniques. | Knowledge | Medium | Not critical | Curriculum |
| Skill in selecting appropriate tooling, and adjusting machine settings as directed. | Skill | High | High | Curriculum |
| Ability to follow procedures and guidelines for safe and precise operation of machine tools. | Ability | High | High | On-the-job |
| Sub-competency · Manufacturing Systems |
| Topic · Open/Closed Loop Systems |
| Knowledge of open-loop and closed-loop control systems and their components used in manufacturing processes (e.g. sensors, transmitters, controllers, actuators). | Knowledge | Medium | Not critical | Curriculum |
| Skill in configuring and monitoring control systems to maintain process stability and meet product specifications. | Skill | Not critical | Medium | Curriculum |
| Ability to adjust and fine-tune control parameters in open and closed-loop systems to optimize manufacturing processes and product quality. | Ability | Not critical | Medium | Curriculum |
| Topic · Electrical and Electronic Systems |
| Knowledge of electrical and electronic systems, such as high voltage/utility systems and industrial equipment, optics/x-rays, and electromechanical components, and their properties. | Knowledge | Not critical | Medium | Curriculum |
| Knowledge of units of measurements for voltage, current, power, and resistance. | Knowledge | High | Not critical | Curriculum |
| Knowledge of electrical and circuitry components such as resistors, transistors, diodes LEDs, etc. | Knowledge | Medium | Not critical | Curriculum |
| Skill in identifying specific electronic components such as different resistor types based on color. | Skill | Low | Not critical | Curriculum |
| Skill in identifying and integrating electronic components into a circuit or system. | Skill | Not critical | Medium | Curriculum |
| Ability to operate electrical and electronic systems end-to-end, adapt to changing system configurations and requirements, and protect systems from electrostatic discharge (ESD). | Ability | High | Not critical | On-the-job |
| Topic · Additive and Subtractive Systems |
| Knowledge of various subtractive manufacturing techniques, such as milling, turning, grinding, drilling and CNC machine use. | Knowledge | Medium | Not critical | Curriculum |
| Knowledge of various additive manufacturing techniques such as 3D printing, jetting, and extrusion. | Knowledge | Medium | Not critical | Curriculum |
| Skill in 3D printing, jetting and extrusion setup and operation. | Skill | Not critical | Low | Curriculum |
| Skill in performing additive and subtractive manufacturing for rapid prototyping and customization. | Skill | Not critical | Low | Curriculum |
| Topic · Robotics and Mechatronics Systems |
| Knowledge of robotics and mechatronics systems, including selective compliant assembly robot arms (SCARA) and AC/DC electricity principles. | Knowledge | Medium | High | Curriculum |
| Skill in programming, maintaining, and operating robotics and mechatronics systems. | Skill | Medium | High | Curriculum |
| Ability to adapt to changing robotics and mechatronics systems end-to-end configurations and requirements. | Ability | Not critical | Low | Curriculum |
| Topic · Other Manufacturing Systems (e.g. thermal, energy, hydraulic, pneumatic) |
| Knowledge of specialized manufacturing systems, such as thermal systems (e.g., furnaces), energy systems (e.g., HVAC), hydraulic systems, pneumatic systems, and pump systems. | Knowledge | Low | Medium | Curriculum |
| Skill in operating and maintaining these systems, including temperature control, energy management, fluid dynamics, and flow and pressure control. | Skill | Not critical | Medium | Curriculum |
| Ability to ensure the proper functioning of specialized manufacturing systems, contributing to overall process efficiency and product quality. | Ability | Not critical | Medium | Curriculum |
| Topic · Control Systems |
| Knowledge of control systems, including programmable logic controllers (PLCs) and other automation technologies. | Knowledge | Medium | Not critical | Curriculum |
| Skill in programming and operating control systems to automate manufacturing processes and monitor equipment performance. | Skill | Not critical | Medium | Curriculum |
| Ability to configure and troubleshoot control systems, ensuring safe and communicate any issues. | Ability | Not critical | Not critical | Curriculum |
| Maintenance, Installation, and Repair Set up, perform upkeep, and fix equipment and machinery to ensure continuous, efficient, and safe processes. |
| Sub-competency · Preventative and Predictive Maintenance |
| Topic · Field and Input/Output (IO) Installation Checks |
| Knowledge of installation procedures and IO checks. | Knowledge | High | Not critical | Curriculum |
| Skill in conducting thorough field installation checks and verifying the proper functioning of input/output components. | Skill | High | Not critical | On-the-job |
| Ability to troubleshoot and repair components that fail installation checks. | Ability | Not critical | High | On-the-job |
| Topic · Condition Monitoring |
| Knowledge of inspection techniques (i.e. visual checks), equipment, equipment specifications and maintenance requirements. | Knowledge | Medium | Not critical | Curriculum |
| Skill in ensuring equipment integrity, preventing potential failures, and contributing to maintenance planning. | Skill | Not critical | High | Curriculum |
| Ability to conduct thorough machinery inspections, check electrical connections, identify wear and damage, and report findings. | Ability | High | Not critical | On-the-job |
| Topic · Safety Monitoring (e.g. safety hazards) |
| Knowledge of safety regulations, hazard identification, and safety protocols relevant to manufacturing equipment and processes. | Knowledge | High | High | Curriculum |
| Skill in monitoring and assessing safety conditions, recognizing potential hazards, and taking appropriate safety precautions. | Skill | High | High | On-the-job |
| Ability to conduct safety inspections and report violations and other findings to a supervisor. | Ability | High | High | On-the-job |
| Topic · Equipment Upkeep and Maintenance (e.g. changing saw blades) |
| Knowledge of and technical maintenance operations such as exchanging of parts. | Knowledge | Medium | Not critical | On-the-job |
| Skill in performing basic routine equipment maintenance tasks, such changing saw blades, filter replacement, lock replacement, and shaft alignment. | Skill | High | Not critical | On-the-job |
| Topic · Floor upkeep and cleaning |
| Knowledge of cleanliness and organization standards for the manufacturing floor. | Knowledge | Medium | Not critical | On-the-job |
| Skill in cleaning and maintaining the manufacturing floor. | Skill | High | Not critical | On-the-job |
| Ability to identify areas of opportunity to improve floor cleanliness. | Ability | High | Not critical | On-the-job |
| Topic · Installation Concepts |
| Knowledge of machine and part installation processes and concepts for various systems including manufacturing machinery, power supplies, and power transmission systems. | Knowledge | Medium | Not critical | Curriculum |
| Skill in installation of parts and assemblies into existing machines/systems. | Skill | High | Not critical | On-the-job |
| Topic · Maintenance Workshop Operations (e.g., tool check-out, work benches, machine materials, manuals) |
| Knowledge of workshop operations, including tool and equipment inventory, maintenance scheduling, and spare parts management. | Knowledge | Medium | Not critical | On-the-job |
| Skill in operating maintenance workshops, including the use of tools, equipment, and facilities for repair and maintenance tasks. | Skill | Medium | Not critical | On-the-job |
| Sub-competency · Maintenance Planning |
| Topic · Spare Parts Inventory |
| Knowledge of various spare parts needed in manufacturing processes and spare parts inventory management practices, such as usage tracking and lead times. | Knowledge | Medium | Medium | On-the-job |
| Skill in maintaining an organized spare parts inventory, tracking usage, and optimizing stock levels. | Skill | Low | Not critical | On-the-job |
| Ability to ensure availability of critical parts, minimizing downtime. | Ability | Not critical | High | On-the-job |
| Topic · Maintenance Supply Inventory |
| Knowledge of maintenance supply inventory activities such as recording stock and placing orders. | Knowledge | Low | Not critical | On-the-job |
| Skill in maintaining an organized and efficient maintenance supply inventory, tracking stock levels, and ordering supplies as needed. | Skill | Not critical | Low | On-the-job |
| Topic · Maintenance Documentation (e.g. work orders, SOPs, etc.) |
| Knowledge of maintenance documentation practices, including work orders, standard operating procedures (SOPs), equipment manuals, bill of materials, and documentation requirements for regulatory compliance. | Knowledge | Medium | Not critical | Curriculum |
| Skill in creating, updating, and maintaining maintenance documentation, ensuring accuracy and completeness. | Skill | Medium | High | On-the-job |
| Ability to use maintenance documentation to plan and execute maintenance tasks efficiently. | Ability | Not critical | Medium | On-the-job |
| Topic · Maintenance Scheduling |
| Knowledge of equipment maintenance schedules, manufacturer's recommendations, and maintenance scheduling techniques. | Knowledge | Low | Not critical | On-the-job |
| Skill in organization of a maintenance schedule that minimizes equipment downtime. | Skill | Not critical | Not critical | On-the-job |
| Ability to create and follow an efficient maintenance schedule. | Ability | Not critical | Medium | On-the-job |
| Sub-competency · Troubleshooting & Monitoring |
| Topic · Alarm and Event Analysis |
| Knowledge of alarm systems and event logs in manufacturing equipment, alarm prioritization and critical event handling (e.g., IoT alarms). | Knowledge | High | Medium | On-the-job |
| Skill in analyzing alarm and event data, investigating anomalies, and taking appropriate actions to resolve issues. | Skill | High | Medium | On-the-job |
| Ability to respond quickly to changes in machine status. | Ability | Not critical | High | On-the-job |
| Topic · Basic Equipment Troubleshooting |
| Knowledge of equipment operation, system components, common failure modes and troubleshooting techniques. | Knowledge | High | Medium | On-the-job |
| Skill in diagnosing equipment issues, using technical manuals and diagrams, and conducting root cause analysis. | Skill | High | Medium | On-the-job |
| Ability to quickly identify and resolve equipment problems to minimize downtime and maintain production efficiency. | Ability | High | Medium | On-the-job |
| Logistics Plan, monitor, move, and store materials and products in coordination with suppliers, internal systems, and customers. |
| Sub-competency · Material Flow |
| Topic · Heavy Machinery Operations |
| Knowledge of forklift and heavy machinery operations, including load handling, rigging, and safety principles. | Knowledge | High | Not critical | On-the-job |
| Skill in operating forklifts and other heavy machinery safely. | Skill | High | Not critical | On-the-job |
| Ability to operate and inform others on how to operate heavy machinery safely. | Ability | High | High | On-the-job |
| Topic · Material Handling |
| Knowledge of product flow within the manufacturing plant and rejection procedures. | Knowledge | Medium | Not critical | Curriculum |
| Skill in safely and efficiently moving materials within the manufacturing facility using various handling equipment. | Skill | High | Not critical | Curriculum |
| Ability to plan and execute material handling tasks, optimize material flow, prevent material damage or loss, and ensure that materials are delivered to the right locations in a timely manner. | Ability | Not critical | Not critical | Curriculum |
| Topic · Material Storage / Racking and Shelving |
| Knowledge of storage and shelving systems, including rack design, load capacity, and storage space optimization. | Knowledge | Medium | Not critical | Curriculum |
| Skill in organizing and storing materials efficiently on racks and shelves, including proper labeling and inventory tracking. | Skill | Medium | Not critical | On-the-job |
| Ability to facilitate quick retrieval of materials when needed to support manufacturing processes. | Ability | High | Not critical | On-the-job |
| Sub-competency · Inventory Control |
| Topic · Warehouse Organization |
| Knowledge of warehouse layout and organization principles, including storage zones, shelving arrangements, and aisle configurations. | Knowledge | Low | Not critical | Curriculum |
| Skill in optimizing warehouse space, arranging materials logically for efficient retrieval, and ensuring proper traffic flow within the warehouse. | Skill | Medium | Not critical | On-the-job |
| Topic · Inventory Labeling |
| Knowledge of labeling standards, barcoding systems, and identification methods used for inventory items. | Knowledge | Medium | Not critical | Curriculum |
| Skill in labeling inventory items accurately, ensuring that labels contain relevant information such as part numbers, quantities, and expiration dates. | Skill | High | High | On-the-job |
| Ability to enhance inventory tracking and accuracy by implementing effective labeling practices, minimizing errors in material identification and usage. | Ability | High | Not critical | On-the-job |
| Topic · Material Receiving |
| Knowledge of material receiving procedures, quality inspections, and documentation requirements. | Knowledge | Medium | Not critical | Curriculum |
| Skill in receiving materials, inspecting them for quality and quantity, and ensuring accurate documentation and reporting. | Skill | Medium | Not critical | On-the-job |
| Ability to ensure the smooth flow of materials into the inventory system, verify material quality, and address any discrepancies or issues promptly. | Ability | Not critical | Medium | On-the-job |
| Topic · Material Tracking |
| Knowledge of tracking systems, inventory management software (such as kanban), and real-time tracking technologies. | Knowledge | Medium | Not critical | Curriculum |
| Skill in using tracking tools to monitor material movement, quantities, and locations. | Skill | Not critical | Medium | Curriculum |
| Ability to maintain accurate real-time visibility of inventory levels and respond to changes in demand or supply effectively. | Ability | Not critical | Medium | Curriculum |
| Topic · Material Issuing |
| Knowledge of material issuing procedures, priority allocation, and documentation for material usage. | Knowledge | Not critical | Low | Curriculum |
| Skill in issuing materials according to established protocols, ensuring that the right materials are provided to production as needed. | Skill | Not critical | Medium | Curriculum |
| Topic · Material Identification |
| Knowledge of part identification systems, including part numbering, naming conventions, and categorization methods. | Knowledge | High | High | Curriculum |
| Skill in identifying materials accurately based on their characteristics, labels, or identification codes. | Skill | High | High | Curriculum |
| Ability to facilitate easy material retrieval through effective identification practices. | Ability | High | High | On-the-job |
| Topic · Storage Systems |
| Knowledge of various storage systems, including rack systems, shelving, automated storage, and climate-controlled storage. | Knowledge | Low | Not critical | Curriculum |
| Skill in selecting and optimizing storage systems to accommodate different material types, sizes, and storage requirements. | Skill | Not critical | Medium | Curriculum |
| Ability to make informed decisions about storage solutions, improve space utilization, and protect sensitive materials through appropriate storage methods. | Ability | Not critical | Not critical | Curriculum |
| Topic · Raw Material & Finished Product Inventory Management |
| Knowledge of inventory management principles, including ABC analysis, reorder points, and safety stock calculations. | Knowledge | Low | Not critical | Curriculum |
| Skill in managing raw material and finished product inventory levels, conducting regular audits, assessing inventory turnover/rotation, and implementing inventory control measures. | Skill | Not critical | Medium | Curriculum |
| Ability to maintain optimal inventory levels, minimize carrying costs, and ensure that materials are available when needed while preventing excess or obsolete inventory. | Ability | Not critical | Not critical | Curriculum |
| Sub-competency · Packaging and Shipping |
| Topic · Reverse Logistics |
| Knowledge of environmental regulations and reverse logistics processes, including returns management, recycling, and disposal. | Knowledge | Low | Low | Curriculum |
| Skill in managing the reverse flow of goods, minimizing returns-related costs, and implementing sustainable disposal practices. | Skill | Not critical | Medium | Curriculum |
| Ability to efficiently handle returned products, reduce waste, and support environmentally responsible supply chain practices. | Ability | Not critical | Medium | Curriculum |
| Topic · Recordkeeping |
| Knowledge of recordkeeping requirements, data security, document retention policies, and legal and regulatory compliance. | Knowledge | Medium | Not critical | Curriculum |
| Skill in maintaining accurate records of supply chain transactions, contracts, and quality documentation. | Skill | Not critical | Medium | Curriculum |
| Ability to ensure compliance with recordkeeping regulations, facilitate audits, and provide essential documentation for decision-making and reporting. | Ability | Not critical | Medium | Curriculum |
| Topic · Packaging |
| Knowledge of packaging materials, methods, and standards. | Knowledge | Medium | Not critical | Curriculum |
| Skill in selecting appropriate packaging materials, packing products securely to prevent damage during transit, and ensuring proper labeling and documentation. | Skill | Medium | Not critical | On-the-job |
| Ability to optimize packaging processes to minimize material waste, reduce shipping costs, and maintain product quality during transportation. | Ability | Not critical | Medium | On-the-job |
| Topic · Picking |
| Knowledge of order picking processes, inventory management systems, and order fulfillment requirements. | Knowledge | Low | Not critical | On-the-job |
| Skill in accurately picking the right products or materials from inventory based on customer orders or production requirements. | Skill | High | High | On-the-job |
| Topic · Loading |
| Knowledge of loading procedures, safety regulations, and load distribution principles. | Knowledge | High | Not critical | On-the-job |
| Skill in loading products or materials onto shipping vehicles, securing loads, and optimizing space utilization to ensure safe transport. | Skill | High | Not critical | On-the-job |
| Quality Assurance Utilize processes to ensure products meet quality, reliability, and performance standards and customer requirements. |
| Sub-competency · Operations Excellence and Maintenance |
| Topic · Total Quality Management (TQM) principles |
| Knowledge of TQM principles, methodologies, and quality improvement philosophies. | Knowledge | Medium | Medium | Curriculum |
| Skill in implementing TQM practices, conducting process improvement projects, and using quality management techniques to enhance product and process quality. | Skill | Not critical | Medium | Curriculum |
| Ability to foster a culture of quality, drive continuous improvement initiatives, and lead cross-functional teams to achieve quality objectives. | Ability | Not critical | Not critical | Curriculum |
| Topic · Quality Assurance Audits and Procedures |
| Knowledge of quality assurance standards, audit processes, and industry-specific quality requirements. | Knowledge | Medium | Not critical | Curriculum |
| Skills in planning, conducting, and reporting on quality assurance audits. | Skill | Not critical | Not critical | Curriculum |
| Ability to identify non-conformities, and recommend corrective actions. | Ability | Not critical | Not critical | Curriculum |
| Topic · Asset Integrity Management Systems (AIMS) |
| Knowledge of AIMS principles, reliability engineering, risk-based inspection (RBI) practices and equipment integrity assessment methods. | Knowledge | Not critical | Medium | Curriculum |
| Skill in implementing AIMS strategies, conducting asset reliability assessments, and optimizing maintenance plans for critical equipment. | Skill | Not critical | Not critical | Curriculum |
| Ability to ensure the integrity and reliability of manufacturing assets, reduce downtime, and enhance safety and operational performance. | Ability | Not critical | Not critical | Curriculum |
| Topic · Computerized Maintenance Management Systems (CMMS) |
| Knowledge of CMMS software, maintenance planning, and data management. | Knowledge | Not critical | Low | Curriculum |
| Skills in utilizing CMMS tools for maintenance scheduling, work order management, equipment history tracking, and maintenance cost analysis. | Skill | Not critical | Medium | Curriculum |
| Ability to improve maintenance efficiency, optimize equipment utilization, and reduce maintenance costs through effective CMMS utilization. | Ability | Not critical | Not critical | Curriculum |
| Topic · Field Service Management |
| Knowledge of field service management principles, field service technologies, service level agreements (SLAs), and customer support strategies. | Knowledge | Medium | Not critical | Curriculum |
| Skill in coordinating field service teams, optimizing service routes, and ensuring timely response to customer service requests. | Skill | Not critical | Not critical | Curriculum |
| Ability to enhance customer satisfaction, minimize service downtime, and manage field service operations efficiently. | Ability | Not critical | Not critical | Curriculum |
| Topic · Product Inspection & Testing |
| Knowledge of product inspection and testing methods, such as batch testing. | Knowledge | Medium | Not critical | Curriculum |
| Skills in conducting product inspections, interpreting inspection results, and identifying defects or deviations from quality standards. | Skill | Not critical | Medium | Curriculum |
| Ability to ensure product quality, implement quality control measures, and communicate deviations. | Ability | Not critical | High | Curriculum |
| Topic · Statistical Process Control Methods |
| Knowledge of statistical process control (SPC) methods and techniques, and additional quality control tools such as Process Flow Diagram, Cause-and-effect diagram, Check sheet, Control chart (Run chart), Histogram, Pareto Chart, Scatter diagrams. | Knowledge | High | Not critical | Curriculum |
| Skill in applying SPC methods and quality control tools to monitor and control manufacturing processes. | Skill | Not critical | Medium | Curriculum |
| Ability to use SPC and quality control tools to detect and address variations in manufacturing processes. | Ability | Not critical | Not critical | Curriculum |
| Topic · Document Control and Revision Methods |
| Knowledge of document control principles and practices, including document management systems, version control, and regulatory requirements. | Knowledge | Medium | Not critical | Curriculum |
| Skill in managing, organizing, and maintaining a comprehensive set of manufacturing documents, including procedures, work instructions, and equipment manuals. | Skill | Not critical | Not critical | Curriculum |
| Ability to establish and maintain a robust document control system that ensures document accuracy, accessibility, and traceability. | Ability | Not critical | Not critical | Curriculum |
| Topic · Calibration of Instruments |
| Knowledge of measurement principles, calibration standards, various measuring instruments and their accuracy requirements. | Knowledge | Medium | Not critical | Curriculum |
| Knowledge of use and care of gauges and other calibration devices. | Knowledge | High | Not critical | Curriculum |
| Skill in calibrating instruments accurately, following calibration procedures, and documenting calibration records. | Skill | High | Not critical | On-the-job |
| Topic · Six Sigma |
| Knowledge of six sigma principles including DMAIC (Define, Measure, Analyze, Improve, Control) for variability reduction. | Knowledge | High | Not critical | Curriculum |
| Skill in applying six sigma methodologies to identify and solve problems within manufacturing processes. | Skill | Not critical | High | Curriculum |
| Ability collaborate with cross-functional teams to implement six sigma principles and replicate solutions across teams. | Ability | Not critical | High | Curriculum |
| Sub-competency · Data Analytics |
| Topic · Query-based computer Skill |
| Knowledge of query languages and database management systems, such as SQL. | Knowledge | Medium | Not critical | Curriculum |
| Skill in crafting and executing SQL queries to retrieve specific manufacturing data. | Skill | Not critical | Medium | Curriculum |
| Ability to extract relevant information from complex databases. | Ability | Not critical | Medium | Curriculum |
| Topic · Multiple source data targeting, retrieval, validation |
| Knowledge of various data sources within advanced manufacturing environments. | Knowledge | Not critical | Low | Curriculum |
| Skill in identifying and targeting data sources from multiple platforms and systems. | Skill | Not critical | Not critical | Curriculum |
| Ability to identify and communicate data quality issues. | Ability | Not critical | Not critical | Curriculum |
| Topic · Data Visualization |
| Knowledge of data visualization tools and techniques. | Knowledge | Medium | Medium | Curriculum |
| Skill in creating clear and informative data visualizations and developing predictive models. | Skill | Not critical | Medium | Curriculum |
| Ability to choose appropriate visualization methods for different types of data and turn information into actionable insights to support business decisions. | Ability | Not critical | Not critical | Curriculum |
| Workplace Safety and Standards Adhere to policies and procedures that ensure a safe working environment. |
| Sub-competency · Process & Equipment Standards |
| Topic · Electrical Standards |
| Knowledge of electrical standards, codes, and regulations relevant to manufacturing equipment and electrical systems (e.g., High Voltage Standards, NEC,NFPA). | Knowledge | Medium | Not critical | Curriculum |
| Knowledge of electrical grounding and bonding practices and importance. | Knowledge | Medium | Not critical | Curriculum |
| Skill in designing, installing, and maintaining electrical systems in compliance with standards, like electrostatic discharge (ESD) protocols. | Skill | Not critical | High | Curriculum |
| Ability to ensure electrical equipment and systems meet safety and compliance requirements and report violations. | Ability | Not critical | High | Curriculum |
| Topic · Information Security Standards (e.g. cybersecurity and Intellectual property protection) |
| Knowledge of information security standards and protocols, including cybersecurity measures and intellectual property protection strategies. | Knowledge | Medium | Not critical | Curriculum |
| Skill in maintaining robust security practices, mitigate cybersecurity risk, and protect sensitive manufacturing information and intellectual property from unauthorized access or theft. | Skill | High | High | On-the-job |
| Topic · Control and Automation Standards |
| Knowledge of control and automation standards, including industry-specific protocols (e.g., OPC, Modbus) and automation best practices. | Knowledge | Medium | Not critical | Curriculum |
| Skill in configuring, programming, and maintaining control and automation systems in compliance with standards. | Skill | Not critical | Medium | Curriculum |
| Ability to ensure that control and automation systems operate reliably and efficiently, adhering to established standards. | Ability | Not critical | Medium | Curriculum |
| Sub-competency · EHS Standards |
| Topic · Environmental (e.g. ISO, CAA, CWA) |
| Knowledge of environmental standards, regulations, and compliance requirements, such as ISO 14001 (Environmental Management System), Clean Air Act (CAA), and Clean Water Act (CWA). | Knowledge | Low | Not critical | Curriculum |
| Skill in implementing environmental management systems, conducting environmental audits, and ensuring compliance with regulations. | Skill | Not critical | Medium | Curriculum |
| Ability to minimize the environmental footprint of manufacturing processes, monitor and report environmental performance, and develop strategies for sustainable resource use and environmental protection. | Ability | Not critical | Not critical | Curriculum |
| Topic · Safety (e.g. HAZCOM, OSHA) |
| Knowledge of safety standards and regulations, including Hazard Communication (HAZCOM) and Occupational Safety and Health Administration (OSHA) requirements (e.g., Working at Heights, Confined Space, PPE). | Knowledge | High | High | Curriculum |
| Skill in following implemented safety programs, safety training, and identifying and mitigating workplace hazards. | Skill | High | High | Curriculum |
| Ability to maintain a safe working environment, enforce safety policies and procedures, and report non-compliance with safety regulations. | Ability | High | High | On-the-job |
| Topic · Workplace Health |
| Knowledge of workplace health principles, including ergonomics, occupational health, and wellness programs. | Knowledge | Medium | Not critical | Curriculum |
| Skill in maintaining health and well-being through ergonomics and employer-provided health assessments and wellness initiatives. | Skill | Medium | Not critical | On-the-job |
| Ability to minimize occupational health risks, and seek support for physical and mental well-being as needed. | Ability | Not critical | Medium | On-the-job |
| Sub-competency · Preventative Health, Safety, Security and Environmental Procedures |
| Topic · Security Clearance Management |
| Knowledge of security clearance levels, including Secret, Top Secret (TS) and Top Secret with Sensitive Compartmented Information (TS-SCI) with Polygraph. | Knowledge | Not critical | Medium | Curriculum |
| Skill in completing and submitting security clearance applications in accordance with guidelines. | Skill | Not critical | Medium | Curriculum |
| Ability to assess security risks and proactively identify potential threats to classified information. | Ability | Not critical | Medium | Curriculum |
| Topic · Clean Room Protocols |
| Knowledge of clean room standards and classifications. | Knowledge | Medium | Not critical | Curriculum |
| Skill in following clean room protocols and procedures. | Skill | Medium | Not critical | On-the-job |
| Ability to ensure clean room compliance with industry standards and regulations and address clean room incidents. | Ability | Not critical | Not critical | On-the-job |
| Topic · Emergency Response Preparedness |
| Knowledge of emergency response planning and procedures, contents of safety data sheets, and potential emergencies like chemical spills or equipment malfunctions. | Knowledge | High | Not critical | On-the-job |
| Skill in developing and implementing emergency response plans and conducting emergency drills and exercises. | Skill | Not critical | Medium | On-the-job |
| Ability to respond effectively to manufacturing-related emergencies and adapt response plans. | Ability | Not critical | Not critical | On-the-job |
| Topic · Risk Management |
| Knowledge of risk identification, evaluation, and mitigation strategies. | Knowledge | Medium | Not critical | Curriculum |
| Skill in conducting risk assessments for manufacturing processes and facilities. | Skill | Not critical | Medium | Curriculum |
| Ability to develop risk management strategies and contingency plans. | Ability | Not critical | Not critical | Curriculum |
| Topic · Situational Awareness |
| Knowledge of situational awareness principles, including the ability to perceive, comprehend, and predict potential safety or security risks in a manufacturing environment. | Knowledge | High | High | Curriculum |
| Skill in continuously monitoring the manufacturing environment for changes or hazards, identifying potential safety or security concerns, and assessing their significance. | Skill | High | High | On-the-job |
| Ability to maintain a high level of situational awareness, stay vigilant, and respond promptly to emerging safety, security, or environmental risks. | Ability | High | High | On-the-job |
| Topic · Regular Inspection Scheduling |
| Knowledge of inspection criteria and regulatory requirements. | Knowledge | Medium | Not critical | Curriculum |
| Skill in planning and scheduling regular inspections of equipment and facilities. | Skill | Not critical | Medium | Curriculum |
| Ability to conduct thorough inspections and identify maintenance needs. | Ability | Not critical | Medium | Curriculum |
| Topic · Lockout/Tagout procedures |
| Knowledge of lockout/tagout regulations and practices. | Knowledge | High | Not critical | Curriculum |
| Skill in following lockout/tagout procedures. | Skill | High | Not critical | On-the-job |
| Ability to understand to lockout/tagout incidents and identify violations. | Ability | High | Not critical | On-the-job |
| Topic · Violation Reporting and Documentation |
| Knowledge of incident reporting procedures and documentation requirements. | Knowledge | High | Not critical | On-the-job |
| Skill in developing and implementing violation reporting processes. | Skill | Not critical | Not critical | On-the-job |
| Ability to investigate violations, assess root causes, and implement corrective actions. | Ability | Not critical | Not critical | On-the-job |
| Topic · Pre-task Analysis |
| Knowledge of pre-task analysis (PTA) procedures and the importance of PTA in preventing accidents and incidents. | Knowledge | High | High | Curriculum |
| Skill in conducting thorough pre-task analyses, which involves identifying potential hazards, evaluating risks, and developing mitigation strategies before starting a task. | Skill | High | High | Curriculum |
| Ability to systematically analyze tasks for safety, security, and environmental risks, communicate findings to the team, and ensure that necessary safety measures and equipment are in place before task execution. | Ability | Not critical | High | On-the-job |
| Topic · Safe Raw and Finished Goods Handling |
| Knowledge of material properties, potential hazards, and safe handling protocols. | Knowledge | High | Not critical | On-the-job |
| Skill in safely and efficiently handling raw materials during receipt, storage, and transport, as well as finished goods during packaging and shipping. | Skill | High | Not critical | On-the-job |
| Topic · Ergonomic |
| Knowledge of proper body mechanics and ergonomics principles, including the importance of body posture, positioning, and movement to prevent musculoskeletal disorders and injuries. | Knowledge | High | Not critical | Curriculum |
| Skill in maintaining correct body posture and using ergonomic techniques while performing manufacturing tasks, such as lifting, bending, and repetitive motions. | Skill | High | Not critical | Curriculum |