Agricultural Implements Manufacturing Sector
Lead Resource Person for
Welding Operations

Relevant Experience: 

• Bachelor degree in Mechanical Engineering, Metallurgical Engineering or Diploma of Associate Engineer (DAE) or Certification in Welding
• For Bachelor degree holders at least eight years, for DAE holders ten years, and for certified welders 15 years professional experience is required 
• 8 years of experience working in an industry where arc welding operations are extensively performed is a prerequisite.
• Experience conducting apprenticeship / on-job training is essential
• Good writing and communication skills in Urdu and English

Job Description:

The performance of the agricultural implements manufacturing sector of Pakistan is far below its potential. The major constraint is a capacity issue for manufacturers who lack expertise and skills in numerous areas including technical, engineering and management. Absence of standardized products and process parameters, coupled with missing quality systems, process optimization techniques and total ignorance of industrial engineering principles results in an exceptionally higher rework and wastage rate with greater consumption of material and energy. Overdesigned implements, underdeveloped workers’ skills, technology upgrading requirements and inefficient energy consumption are some of the other major challenges the sector is facing. All these are rendering the manufacturers cost inefficient and with poor quality of products. Such poor quality implements also consume more tractor fuel and lead to high repair/maintenance costs. 

In terms of volume of work and frequency, welding is one of the major manufacturing operations of this sector. Manufacturing units are using obsolete welding which are extremely inefficient with respect to electricity consumption and the quality of welding joints. Efficient welding using new technology that can provide better performance and quality are available in the local market. This new technology can reduce the electricity cost by one third and can improve the quality of work. 

Most of the welders working in these manufacturing units have not acquired skills from any formal training program but have learnt it by trial and error. Therefore, they do not have basic knowledge of metallurgy, nature and types of joints, welding techniques, correct method of welding, and other related information and skills. As a result, due to lack of knowledge and lack of technical skills, a welder takes more time for any given job, uses more electricity, and consumes more welding rods while still producing weaker welded joints. 

The USAID Firms Project intends to provide assistance in welding operations to 11 selected manufacturing units by providing them in-kind technology upgrading assistance and training for the welders to develop their skills, thereby increasing their labor productivity. 

For these interventions, the USAID Firms Project requires a consultant to provide detailed specifications (including but not limited to type, make, current rating, power rating etc.,) for purchase of new arc welding plants that are locally available and to act as the lead resource person for the project’s Welding Operations. The lead resource person will develop training content, supervise and provide guidance and supervision to the skills upgrades program administered to welders in the  selected 11 manufacturing units. 

B.  Principal Duties & Responsibilities. The specific duties of the consultancy would include: 

a)      Visit and analyze the current needs of the welding operations of each agricultural implements manufacturing unit and outline the technical specifications of efficient arc welding plants with better welding quality (such as low wastage, less deposits and stronger joints as compared to current welding plants at the manufacturing units). The consultant should provide the approximate price of at least 5 available brands in Pakistan’s local market and provide a comparison of their technical performance and features.

b)      Conduct a capacity needs assessment for each of the selected manufacturing units taking into account the requirements of the welding operations of the signatory manufacturing units, evaluate the current knowledge, skills and expertise level of welders working in the manufacturing units and identify the skills gaps to be addressed through training. 

c)      In consultation with the manufacturing units and the USAID Firms Project team, the consultant will, utilizing the results of the needs assessment conducted in section 3.b, develop and produce the training materials for the skills upgrades program including but not limited to: types of joints, selection of welding rods, uses of fluxes, parts of joints, welding process, expansion and contraction of joints, precautionary measures etc.  

d)     All training materials developed by the consultant will be provided in Urdu language and include supportive pictures embedded in the content and be in line with the units’ requirements and education level of workers. 

e)      Visit the 11 manufacturing units as per given schedule below to provide overall guidance and technical supervision where needed to the welding instructors deployed by the USAID Firms Project and supervise the overall provision of the training program to the welding workers. The lead resource will ensure that the instructors are imparting theoretical knowledge as well as practical skills applicable to welding workers per the requirements of the program. 

 Training Plan 

f)       Under this consultancy, the consultant shall be responsible to perform all of the tasks and activities, clearly mentioned or implied in this document.

Deliverables.  The substance of, findings on, and recommendations with respect to the above mentioned tasks shall be delivered by Consultant(s) in a written deliverable in the format presented to the Consultant by the Team Lead. This includes:

1. Detailed specifications of efficient arc welding plants, based on the requirements of the manufacturing units including a description and comparison of at least 5 locally available brands who can meet the required specification (i.e.  features, performance and energy consumption etc.).
2. One comprehensive report of 8 to 10 pages, summarizing the findings from 11 units and addresses the capacity need assessment. The report will describe the existing and desired level of welders working in manufacturing units, identify skills gaps and highlight training areas needed.
3. A training manual with 24 sections or topics with detailed content under each section provided in Urdu.
4. Supervision of the training program given by instructors to the welders in 11 manufacturing units by visiting Daska and Faisalabad clusters for two days each week (i.e. 1 day in Daska and 1 day in Faisalabad).
5. A comprehensive final report on the USAID Firms Project template.

Applications can also be sent on [email protected]. Please mention the position applied for in the subject line. Last date for applications is August 9,2012.