Manufacturing Team Challenge - irantvto.irskill.irantvto.ir/uploads/91_258_TD03_40CA_EN_v2.0.pdf ·...

international© WorldSkills International

TD03 v2.0 - WSC2009

Technical Description

Manufacturing Team Challenge

WorldSkills International, by a resolution of the Technical Committee and in accordance with the Constitution, the Standing Orders and the Competition Rules, has adopted the following minimum requirements for this skill for the WorldSkills Competition. The Technical Description consists of the following: 1. INTRODUCTION ........................................................................................................2

2. COMPETENCY AND SCOPE OF WORK ..................................................................2

3. THE TEST PROJECT.................................................................................................3

4. SKILL MANAGEMENT AND COMMUNICATION......................................................6

5. ASSESSMENT ...........................................................................................................6

6. SKILL-SPECIFIC SAFETY REQUIREMENTS...........................................................8

7. MATERIALS & EQUIPMENT .....................................................................................8

8. MARKETING THE SKILL TO VISITORS AND MEDIA............................................11 Effective 30.12.08

Liam Corcoran Technical Committee Chair

TD03_40CA_EN Date: 30.12.08 – v2.0

© WorldSkills International – Technical Description Manufacturing Team Challenge

1 of 11

TD03_40CA_EN Date: 30.12.08 – v2.0


2 of 11

1. INTRODUCTION

1.1 Name and description of skill

1.1.1 The name of the skill is Manufacturing Team Challenge.

1.1.2 Description of skill • MTC is a team event. • There will be three (3) Competitors per MTC team. • Competitors are not to exceed 25 years of age in the year of the Competition. • Teams need a team identification (such as coloured shirts) or armbands that indicate your

country (such as country flag). Competitors may work in large manufacturing concerns such as automobile plants or be individuals in small or family businesses specialising in components of a design and manufacturing process. MTC covers designing and manufacturing equipment assemblies. Each team has three members who are issued with a project specification one year prior to the competition. The teams will then design their individual assemblies in advance and build them during the competition. At the beginning of the event, teams are given another surprise task. Comprehensive project documentation must also be produced.

1.2 Scope of application

1.2.1 Every Expert and Competitor must know this Technical Description.

1.2.2 In the event of any conflict within the different languages of the Technical Descriptions, the English version takes precedence.

1.3 Associated documents

1.3.1 As this Technical Description contains only skill-specific information it must be used in association with the following: • WSI - Competition Rules • WSI - Competition Manual • WSI - Online resources as indicated in this document • Host Country - Health and Safety regulations

2. COMPETENCY AND SCOPE OF WORK

The Competition is a demonstration and assessment of the competencies associated with this skill. The Test Project consists of practical work only.

2.1 Competency specification The Competitors must be able to: • Effectively manage a team for optimum performance. • Analyse and control production costs within the set guidelines. • Comply with occupational health and safety procedures. • Organise skill improvement through training sessions. • Design any jigs fixtures and processes to complete the allotted task(s). • Generate any automation programs needed to complete the allotted task(s). • Machine the designated part(s), jigs, and/or fixtures using conventional or CNC methods to the

required tolerances.

TD03_40CA_EN Date: 30.12.08 – v2.0


3 of 11

• Carry out assembly of any designated components using automated methods. • Utilise modern problem solving techniques in achieving the desired result. • Optimise the complete process in order that cycle times are minimised. • Compile a dossier of the complete process. • Join processes.

2.2 Theoretical knowledge

2.2.1 Theoretical knowledge is required but not tested explicitly. Design Ability to interpret, construct, and modify engineering CAD drawings, to work with 3D modelling, and to convert both to CAM. Use CAM to generate toolpaths using a suitable postprocessor. Drawing standard will be ISO-A or ISO-E depending on country involved. Machining A good knowledge of machining to drawings on conventional machine tools and setting up, loading, and running CNC machines from a CAM generated toolpath including the ability to modify that toolpath manually to meet the specification of the finished product. It is expected that knowledge be required for machining steel (400-550 N/sq. mm.) or aluminium, plastics or whatever material it is made of. Fitting As required to complete the assembly of jigs, fixtures, or the project. Mechatronics A sound knowledge of Mechatronics and robotics as required by the design of the project.

2.2.2 Knowledge of rules and regulations is not examined.

2.3 Practical work Note: The task(s) should be designed in the year preceding the Competition so that the team composition, selection, and training may proceed and the major equipment list compiled. The theoretical and practical training for the MTC should be defined 8 months prior to each WorldSkills Competition so that the composition of the teams is aligned to the proposed task(s). General description of task work • To carry out a CAD/CAM exercise in preparation for the manufacturing task • To design and make any jigs, fixtures, adaptors, and attachments required for the task. • To set up and machine all components required for the project. • To carry out an assembly process required by the project. • To work as a team in optimising the manufacturing process so that cycle times and costs are

minimised. This would involve looking at design, toolpaths, assembly procedures, as well as jigs, fixtures, and machining techniques.

• To run a full optimised cycle of at least 10 components.

3. THE TEST PROJECT

3.1 Format / structure of the Test Project The format of the Test Project is a main Test Project, a surprise project and a portfolio. Main Test Project The Main Test Project involves the manufacture of a team’s solution to a manufacturing challenge and would include skill areas such as design, planning, manufacturing and documenting the manufacturing process.

TD03_40CA_EN Date: 30.12.08 – v2.0


4 of 11

The manufacturing challenge will detail the project brief and the evaluation procedure and will be made freely available to MTC teams prior to the Competition. Surprise project The surprise project represents the 30% of change. See 3.9 Test Project change at the Competition. Portfolio The portfolio will include the documentation involving the main project and will include 2D mechanical drawings, electronic solid model, electrical drawings, manufacturing plans, design calculations and manufacturing costs. Some sections of portfolio documentation may be done prior to the Competition.

3.2 Test Project design requirements The total working time for the project will be between 18 and 22 hours. Design The task is to have all design work including process parts, jigs, and fixtures carried out in accordance with the instructions, specifications, drawings, parts, and samples provided by the project designer(s). Program generation Generate all programs required for the automated sections of the task including those for any CNC machines, robots, PCs and PLCs. Manufacture Make any parts nominated by the Experts as well as those needed for the working of those manufactured parts such as jigs, fixtures, adaptors, and process attachments to the required tolerances. Assembly Assemble the various components either manufactured previously or supplied as part of the task by outside sources using automated methods where nominated as part of the task. Optimisation Revise the manufacturing and assembly process to optimise cycle times and reduce the process cost. Documentation Document the process including header page, index, and descriptive overview of the task, hard copy of any programs, instructions for setting up and assembly, and any relevant drawings.

3.3 Test Project development The Test Project MUST be submitted using the templates provided by WorldSkills International (http://www.worldskills.org/competitionpreparation). Use the Word template for text documents and DWG template for drawings.

3.3.1 Who develops the Test Project / modules The Test Project / modules are developed independently by each Expert.

3.3.2 How and where is the Test Project / modules developed The Test Project / modules are developed prior to the current Competition and then brought to the Competition for selection by all the Experts.

3.3.3 When is the Test Project developed The Test Project/modules are developed prior to the current Competition.

http://www.worldskills.org/competitionpreparation

TD03_40CA_EN Date: 30.12.08 – v2.0


5 of 11

The various Technical Delegates are to be advised of the team skills required and appropriate descriptive material is to be forwarded in advance for team preparation. Main Project information including assessment weightings and assessment procedure to be included in current Competition MTC Information Pack

3.4 Test Project marking scheme Each Test Project must be accompanied by a marking scheme proposal based on the assessment criteria defined in Section 5.

3.4.1 The marking scheme proposal is developed by the person(s) developing the Test Project. The detailed and final marking scheme is developed and agreed by all Experts at the Competition.

3.4.2 Marking schemes should be entered into the CIS prior to the Competition.

3.5 Test Project validation The Test Projects are validated as follows: • Main Project – specifications to be developed with performance outcomes – explanations and

clarifications including assessment procedure to be available in current Competition MTC Information Pack – skills must be outlined in MTC TD.

• Surprise Project – sample project to be supplied as well as all required documentation to be examined by Experts to conform with skills outlined in MTC TD.

3.6 Test Project selection The Test Project is selected as follows: • By vote of Experts at the previous Competition.

3.7 Test Project circulation The Test Project is circulated via WorldSkills International website as follows: • 9 months before the current Competition.

3.8 Test Project coordination (preparation for Competition) Coordination of the Test Project will be undertaken by the Chief Expert.

3.9 Test Project change at the Competition The surprise project represents the 30% of change and the contents of this project will not be released to the teams prior to the start of the Competition. Each Expert will present a surprise project proposal and a vote of these proposals at the pre-competition meeting of Experts will determine the surprise project for that Competition. Editing of the surprise project is permitted and encouraged at this meeting of Experts to vary the content and evaluation procedure. Selection of the Surprise Project The Surprise Project must be complete and checked for accuracy before it can be considered for the ballot. The Surprise Project should be challenging and involve as many skills identified in the MTC Technical Description as possible. The duration of the Surprise Project should take 30% of competition time. Proposals not requiring this time will not be considered for the ballot. Ideally, the Surprise Project should relate to the main Test Project.

3.10 Material or manufacturer specifications All software including that required for CNC and Robotics must be available to each team at least 6 months prior to the Competition in the form in which it will be used at the Competition.

TD03_40CA_EN Date: 30.12.08 – v2.0


6 of 11

4. SKILL MANAGEMENT AND COMMUNICATION

4.1 Discussion Forum Prior to the Competition, all discussion, communication, collaboration and decision making regarding the skill must take place on the skill-specific Discussion Forum (http://www.worldskills.org/forums). All skill-related decisions and communication are only valid if they take place on the forum. The Chief Expert (or an Expert nominated by the Chief Expert) will be moderator for this forum. Refer to Competition Rules for the timeline of communication and competition development requirements.

4.2 Competitor information All information for registered Competitors is available from the Competitor Centre (http://www.worldskills.org/competitorcentre).

This information includes: • Competition Rules • Technical Descriptions • Test Projects • Other Competition-related information

4.3 Test Projects Circulated Test Projects will be available from worldskills.org (http://www.worldskills.org/testprojects) and the Competitor Centre (http://www.worldskills.org/competitorcentre).

4.4 Day-to-day management The day-to-day management is defined in the Skill Management Plan that is created by the Skill Management Team led by the Chief Expert. The Skill Management Team comprises the Jury President, Chief Expert and Deputy Chief Expert. The Skill Management Plan is progressively developed in the six months prior to the Competition and finalised at the Competition (agreed by Experts and submitted to the Chair/Vice Chair of the Technical Committee). The Chief Expert is to regularly share updates of the Skill Management Plan via the Forum.

5. ASSESSMENT

This section describes how the Experts will assess the Test Project / modules. It also specifies the assessment specifications and procedures and requirements for marking.

5.1 Assessment criteria This section defines the assessment criteria and the number of marks (subjective and objective) awarded. The total number of marks for all assessment criteria must be 100. Section Criterion Marks

Subjective (if applicable)

Objective Total

A Main project performance 50 50B Main project cost 15 15C Portfolio 5 5D Surprise project 30 30

Total = 100 100

5.2 Subjective marking Not applicable.

http://www.worldskills.org/forums

http://www.worldskills.org/competitorcentre

http://www.worldskills.org/testprojects

http://www.worldskills.org/competitorcentre

TD03_40CA_EN Date: 30.12.08 – v2.0


7 of 11

5.3 Skill assessment specification Main Test Project Recording and calculation of some marks for the main project may be done on a spreadsheet with pre-programmed formulae. Any spreadsheets used must be verified by a nominee of the Technical Committee and locked by password prior to the Competition. The main project marks will be calculated by comparing team’s build cost and compliance to project specifications. Marking will be on the basis of product cost and will include such things as Competitors’ time, materials used, parts used, any consulting fees, training required, and machine tool and tooling costs. Required tolerances must be met for a result to be valid. Each team member must record the time they start and finish each shift and clearly indicate whether they are working on the main project, surprise project or the portfolio. Competitors not working must remain in central position. Lunch time excepted. There may be other forms of assessment for sub-categories of the main project such as cycle time where applicable which may also translate to cost per product item made and inclusion of specific items of documentation Multiple awards may be made. Main project labour hours and machine usage hours will be costed at an hourly rate. This hourly rate will be in the currency of the host country. Typical hourly rates are: • Each Competitor’s work time @ €25.00/person/hour • CNC machine @ €25.00/hour • Consultant and training @ €40.00/hour Portfolio Sections of the portfolio must be done during the Competition and will be costed. The portfolio has to contain: • 2D drawings • Design calculations • Manufacturing plan • Wiring diagrams • 2D assembly • Project documents (such as Maintenance manual).

5.4 Skill assessment procedures Time-keeping system Machines are to be allocated in 15-minute increments. Working hours and actual machine usage hours to be calculated to the accuracy of the time-keeping system. The minimum increment for consultant is 15 minutes. For the main project, raw materials such as steel and aluminium in pipe, sheet and bar form will be costed on a price per kilogram rate. Rate to be decided by Experts prior to the Competition. All other components of the main project will require current catalogue prices – a printout of a current e-catalogue is acceptable as long as the printout has the website and date printed on it. The accuracy of these catalogues will be checked by Experts. Prices quoted must indicate whether or not they are inclusive of taxes. Currency conversion rates will be set by Experts at pre-competition meeting. Work schedule Teams will present a work schedule by the end of the first day of the Competition, showing a schedule of their planned activities, people and machines, for the duration of the Competition in

TD03_40CA_EN Date: 30.12.08 – v2.0


8 of 11

progressive timelines on electronic project management software (such as MS Project). The schedule is to be updated daily. Pre-competition coloured poster The teams need to provide a pre-competition coloured poster (size: 600x1000) with: • 3D drawing of the design • Names and photographs of the Competitors • Description of main project Progressive marking for all sections of the Competition Main project performance C4 (Day 4 of Competition) Main project cost C4 (Day 4 of Competition) Portfolio - section A Portfolio – Section B

C1 (Day 1 of Competition) C4 (Day 4 of Competition)

Surprise Project C3 (Day 3 of Competition) Security If any suspect items are identified during a toolbox check, the compatriot Expert is to be informed immediately. At no time should an Expert dismantle any components, but these Experts may ask that a team member be present and assist. The compatriot Expert must be present during this process. The compatriot Expert is to remain in the skill area while the team is having lunch.

6. SKILL-SPECIFIC SAFETY REQUIREMENTS

Refer to Host Country Health & Safety documentation for Host Country regulations. • All Competitors must use safety glasses when using any hand, power or machine tools or

equipment likely to cause or create chips or fragments that may injure the eyes. • A first-aid kit must be available throughout the Competition. • Experts will use the appropriate personal safety equipment when inspecting, checking or working

with a Competitor's project.

7. MATERIALS & EQUIPMENT

7.1 Infrastructure List The Infrastructure List lists all equipment, materials and facilities provided by the Host Country. The Infrastructure List is online (http://www.worldskills.org/infrastructure/). The Infrastructure List specifies the items & quantities requested by the Experts for the next Competition. The Host Country will progressively update the Infrastructure List specifying the actual quantity, type, brand/model of the items. Host Country supplied items are shown in a separate column. At each Competition, the Experts must review and update the Infrastructure List in preparation for the next Competition. Experts must advise the Secretary General of any increases in space and/or equipment. At each Competition, the Technical Observer must audit the Infrastructure List that was used at that Competition. The Infrastructure List does not include items that Competitors and/or Experts are required to bring and items that Competitors are not allowed to bring – they are specified below.

http://www.worldskills.org/infrastructure/

TD03_40CA_EN Date: 30.12.08 – v2.0


9 of 11

7.2 Materials, equipment and tools supplied by Competitors in their toolbox Teams have to submit a list of the parts that they bring to the Competition and present these parts for inspection to the Experts before the commencement of the Competition. The Expert will then determine what security arrangements will apply for these items.

7.3 Materials, equipment and tools supplied by Experts Not applicable.

7.4 Materials & equipment prohibited in the skill area Digital storage devices including: • Laptop or portable computers • PDAs such as Palm, IPAQ etc • Mobile phones • Digital or film cameras • Memory sticks/MP3 players • Walkman radio/CD players • Electronic organisers/diaries • Wireless communication devices • Non-approved CDs or floppy discs – approval by Chief Expert or delegate • Any additional software not supplied by organisers unless approved by majority of Experts • Purchased items are not to be modified in any way prior to the Competition. • Teams will be controlled for components of the unit that they are not allowed to bring into the

Competition. In other words, bringing purchased and self–made items that have to be made at the Competition will be banned. A toolbox inspection will be conducted before the Competition and any suspect components will be quarantined and banned from use during the Competition.

• During the Competition, no tools, equipment, stationary, components, manuals, drawings or digital storage devices may be removed from the Competition venue, unless approved by Chief Expert.

7.5 Sample workshop and workstation layouts Workshop and workstation layouts from Shizuoka are available at: http://www.worldskills.org/index.php?option=com_halls&Itemid=318 Workshop layout from previous Competition:

http://www.worldskills.org/index.php?option=com_halls&Itemid=318

TD03_40CA_EN Date: 30.12.08 – v2.0


10 of 11

Workstation layout from previous Competition:

TD03_40CA_EN Date: 30.12.08 – v2.0


11 of 11

8. MARKETING THE SKILL TO VISITORS AND MEDIA

8.1 Maximising visitor and media engagement To maximise visitor and media engagement for MTC the following ideas will be considered: • Utilise MTC Media Liaison Person (previous competitor is ideal) at Competition site to explain

MTC concept and escort media on site. • Display screens with head cam showing live images. • Test Project descriptions. • Enhanced understanding of Competitor activity. • Site layout to enable public and media to get close to competitors – have access bays. • Display screen with Competitor profiles. • Daily reporting of competition status including marks, costs and times. • Active assessment involving timed and active tasks – use announcer to inform public of what is

happening.

8.2 Sustainability • Selection of projects to be related to sustainability and energy conservation e.g. wind generator,

solar powered water pump and inner city rechargeable electric vehicle • Main project ideally be of benefit to developing countries. • Use of ‘green’ materials. • All swarf and scrap materials to be collected for recycling. • Use of completed Test Projects after the Competition.

Manufacturing Team Challenge - irantvto.irskill.irantvto.ir/uploads/91_258_TD03_40CA_EN_v2.0.pdf ·...

Documents

Transcript of Manufacturing Team Challenge - irantvto.irskill.irantvto.ir/uploads/91_258_TD03_40CA_EN_v2.0.pdf ·...