Curriculum Machinist with Green Skills. (Cooperative Vocational Training-CVT)

Transcription

1 National Vocational & Technical Training Commission (NAVTTC) Curriculum for Machinist with Green Skills (Cooperative Vocational Training-CVT) December, 2015 Curriculum Machinist with Green Skills NVQF Level2

2 Validated on December 14, 2015 by Validated by; 1. Faisal Naveed Siddiqui, Project Manager, TUSDEC-NIDA 2. Muhammad Farooq, CEO, ESS 3. M. Usman Ghani, ESS 4. Mohammad Ali, Professor, UET KICS 5. Muhammad Tahir Izhar, Professor, UET KICS 6. Hamza Bajwa, Director, Pesticides Formulation Industry 7. M. Shahid Iqbal, Deputy Manager Works, Pesticides Formulation Industry 8. Nausheen Mohiyddin, Director, NAVTTC Moderated by: 1. Ammara Mukhtar, Management Assistant, sequa ggmbh

3 Contents 1 INTRODUCTION Course Title Description of the Structure of the Course Duration of the course: Purpose of the training programme: Specific characteristics of this training programme: Main objectives of the training programme Skill development by action orientation: Entry level of trainees Minimum qualification for instructors Medium of instruction Laws and Regulations Competencies gained after completion of the course Worker Traits Opportunities for employment and advancement Overview of the Curriculum TEACHING AND LEARNING GUIDE FOR MACHINIST MODULE-1: BASIC BENCH WORK MODULE-2: PERFORM DRILLING MACHINE OPERATIONS MODULE-3: APPLY OCCUPATIONAL HEALTH & SAFETY PROCEDURES AT WORKPLACE MODULE-4: CARRY OUT MAINTENANCE OF TOOLS AND MACHINES MODULE-5: PERFORM LATHE MACHINE OPERATIONS MODULE-6: PERFORM MILLING MACHINE OPERATIONS MODULE-7: CARRY OUT COMPUTERIZED NUMERICAL CONTROL (CNC) MACHINE OPERATIONS MODULE-8: PERFORM GRINDING MACHINE OPERATIONS MODULE-9: PERFORM SHAPER MACHINE OPERATIONS MODULE-10: IMPLEMENT ENERGY MANAGEMENT MEASURES MODULE-11: APPLY NOISE PREVENTION MEASURES MODULE-12: IMPLEMENT WASTE MANAGEMENT MEASURES MODULE- 13. DEVLOP PROFESSIONALISM Module 14: COMPUTER SKILLS-I Curriculum Machinist with Green Skills NVQF Level2

4 2.15 Module 15: COMPUTER SKILLS-II Module 16: ENGLISH SKILLS-I Module 17: ENGLISH SKILLS II Module 18: SECONDARY SKILLS & ACTIVITIES Module 19: SECONDARY SKILLS & ACTIVITIES Module 20: ON-THE-JOB TRAINING- I Module 21: ON-THE-JOB TRAINING-II ASSESSMENT GUIDANCE Differences between sessional and final assessments Methods of assessment Direct assessment: Indirect assessment Principles of assessment Assessment strategy for Machinist Curriculum Suggestions for sessional assessment Suggestions of final assessment Final assessment: Structure of the assessment team Planning for assessment LIST OF MACHINERY/ EQUIPMENT/ TOOLS ETC List of Consumable Supplies

5 1 INTRODUCTION 1.1 Course Title GPATI training scheme has been developed in such a way that training sequences will be in a training center (vocational institute), complimented by on the job training (OJT) phases in the premises of the employers, the training course split between training at the institute and OJT is Half of the course time will be spent at the Vocational Training Institute and the other half will be spent doing OJT. After completion of vocational training the graduates will have a good balance of technical knowledge, skills, attitude and work experiences, which are the essential elements of any industry. Further, as GPATI is simultaneously integrating work experience through on-the-job training, the graduates will be able to use the latest technologies to achieve new levels of expertise. Machinist with Green Skills 1.2 Description of the Structure of the Course Sequence of Modules; Training in Training Center-12 Months Phase-I; Basic Phase-III: Advanced Institutional Learning Institutional Learning On the Job Training (OJT) in a company-12 months Phase-II: Basic OJT Phase-IV: advanced OJT Revision in Training (2-3 weeks) 5 P a g e

6 Module 1 - Perform Basic Bench work Module 2 - Drilling Machine Operations Module 3 - Apply Occupational Health & Safety Procedures at Workplace Module 4 - Carry Out Maintenance of Tools and Machines Module 5 - Perform Lathe Machine Operations Module 6 - Perform Milling Machine Operations Module 11- Apply Noise Prevention Measures Module 7- Apply Carry Out Basic CNC Machine Operations. Module 8 - Perform Grinding Machine Operations Module 9 - Perform Shaper Machine operations Module-10: Implement Energy Management Measures Module 12: Apply waste management measures Module 13 - Develop Professionalism Module 20: OJT-I Giving details of the OJT process as per OJT module Module 21: OJT-II Giving details of the OJT process as per OJT module Review & Preparation for final Examination Module 15- Computer Skills-II Module 14: Computer Skills-I Module 16 -English Language Skills-I Module 17 - English Language Skills-II Module 18 - Secondary Skills Activities I Module 19 - Secondary Skills Activities II 2 P a g e

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8 1.3 Duration of the course: The proposed curriculum is composed of 21 modules that will be covered in the distribution of contact hours is given below: Total 3226 Hours. Institute Training 1594 Hours {Theory 432 Hours (27%) Practical 1162 Hours (73%} OJT Training 1600 Hours 1.4 Purpose of the training programme: The purpose of this training is to develop a range of skills and techniques, personal skills and attributes essential for successful performance in machinist in accordance with industry requirements.it also enables the student to pursue a machinist career path with greater employment and entrepreneurial skills progress to related general and/or vocational qualifications. 1.5 Specific characteristics of this training programme: The training programme shall be organized in an institute where the Machinist labs are available for trainees. The training program shall enable the student to pursue a Machinist career path with greater employment skills The training program shall give the opportunity to become entrepreneur in machinist field. 4 P a g e

9 The training program will be more effective and beneficial who may already have experience or knowledge of basic machine shop. The training program will be also be beneficial for them who want to focus on only one area and make their future in the same field The training program shall be good guidance on inside tips and tricks on techniques like bench work, drilling, lathe work, milling work, shaping work, grinding work and CNC machining etc. The training program shall be more focused that how to finalize the workpiece on lathe or milling machine. This training programme will be more creative on how to create special workpiece on CNC milling/lathe. 1.6 Main objectives of the training programme Following are the main objectives of the training programme: To produce capable & skillful workforce as required by the prevailing market demands To produce work safely, effectively and hygienically To develop characteristics among the trainees such as self-reliance, reliability, responsibility and ability to lead the program in the field To give competency in the field of machinist and its associated elements To develop excellent workpiece on milling, lathe, shaper and CNC machines. To develop ability among the trainees to work in a team environment To develop knowledge of sterilization and sanitation rules and explain their importance To define personal and public hygiene & demonstrate good grooming principles 1.7 Skill development by action orientation: 5 P a g e

10 The student must have the following skills after action orientation: Collaborate and lead to a positive community change and improvement in the system Consult with instructor and other trainees to determine their ideas and requirements. Give a positive impression of yourself whenever any task given by instructor. Develop a sense of duty, patience and a desire to be helpful. Ensure personal and machine safety practices at work. Ensure personal & occupational health and safety precautions. Perform basic bench work operations sawing, filling, threading and reaming. Define and practice housekeeping. Adopt preventive maintenance of machine and tools. Control tools and equipment to minimize the risk of damage. Cut thread (internal & external) on lathe machine. Mill Gears on milling machine. 1.8 Entry level of trainees Matriculation 6 P a g e

11 1.9 Minimum qualification for instructors Two years Machinist certificate with four years experience DAE in Mechanical with relevant experience of two years B. Tech. with one year relevant experience Computer literate 1.10 Medium of instruction English & Urdu 1.11 Laws and Regulations Deal with hazards in accordance with workplace instructions and legal requirements Report to the people responsible for health and safety in their workplace those hazards which present the highest risk Check which of the potentially harmful working practices and aspects of the workplace present the highest risks to them and others Students are led to appreciate the importance of environmental issues as they engage in a range of activities relating to Machinist. Impact on the environment of the wrongful disposal of rough material and scrap. Health and safety, fire, accident and emergency reporting and procedures, first aid provision, use, storage tools and attachments. First aid provision and fire safety, the requirements regarding personal health, safety and hygiene and the broad provisions of the Health and Safety at Work Act 1974 Workplace Regulations 1992, Manual Handling Operations Regulations 1992, 7 P a g e

12 Personal Protective Equipment at Work Regulations 1992, Provision and use of Equipment Regulations 1992, Control of Substances Hazardous to Health (COSHH)Regulations 1992, (Students must use, store and dispose of chemicals correctly and have an awareness of the hazards/risks from substances), Electricity at Work Regulations 1989, Reporting of Injuries, Diseases and Dangerous Occurrences Regulations (RIDDOR) 1985, (Accidents must be reported and the appropriate documentation completed). The Management of Health and Safety at Work Regulations 1992 (dermatitis and asthma) Environment protection agency Occupational Health and Safety Act (OHSA) regulations Workplace Hazardous Materials Information Systems (WHIMIS) regulations Competencies gained after completion of the course After completion of the course, the trainees will be able to: Explain the bench work relating to safety precautions, hand tools, perception of filing, Polishing, tapping, threading, and reaming. Ensure personal and machine safety practices at work. Explain and use of Basic Bench work and Machine Operations and using appropriate techniques of Health & Safety Procedures at Workplace. Explain Sawing filling threading reaming techniques and methods. Explain and demonstrate the use of drill machine operations. Explain and demonstrate the use of grinding machines for different operations 8 P a g e

13 Define the use of lathe machine. Explain and demonstrate the use of milling machines. Explain and demonstrate the use of surface and cylindrical grinding machine Explain and demonstrate the setting of CNC lathe and Milling machine Explain and demonstrate the use of shaper machines. Define and apply the personal tool and Machine safely hazards properly Define and practice housekeeping and preventive maintenance of machines and tools 1.13 Worker Traits Physically fit Personal hygiene Devoted/motivated Honest Attentive Punctual Organized Communication skills Knowledge Friendly Interpersonal skills Creative Hard worker Team worker Collaborative Confident Competent Innovative 1.14 Opportunities for employment and advancement 9 P a g e

14 Fertilizer plants. Engineering industry Chemical plants. Pharmaceutical industry. Cement plants. Oil refineries. Automobile industry. Sugar plants. Power plants. Papers and board industry. Packaging industry. Private & government workshops. Own workshop Page 10

15 1.15 Overview of the Curriculum Module Title and Aim Learning Units Theory 1 Days/hours Workplace 2 Days/hours Timeframe of modules Module 1:Perform Basic Bench LU-1: Carry out Sawing 03 hours 08 hours 11 hours Work LU-2: File the Work Piece to Produce required 10 hours 28 hours 38 hours Aim: Be able to prepare the sawing, Smoothness filling, threading (internal +external) 04 hours 16 hours 20 hours Reaming. LU-3: Produce Threads on Work Piece 03 hours 08 hours 11hours LU-4: Perform Hand Reaming Module 2: Perform Drilling Machine Operations Aim: Be able to prepare drilling, Counter Boring, Counter Sinking and machine reaming. LU-1: Produce Holes using Drilling Machine LU-2: Perform Counter Boring and Counter Sinking LU-3: Perform Machine Reaming 04 hours 02 hours 04 hours 10 hours 10 hours 10hours 14 hours 12 hours 14hours Module 3: Apply Occupational LU-1: Identify hazards in workplace environment 04 hours 04 hours 08 hours Health & Safety Procedures at Workplace LU-2: Comply with Occupational Health and Safety 04 hours 04 hours 08 hours Precautions Aim: Be able to prepare Occupational Health & Safety LU-3: Apply Personal Protective and Safety 04 hours 04 hours 08 hours Procedures at Workplace Equipment LU-4: Practice safe work habits to ensure safety at workplace. 03 hours 03 hours 06 hours Module 4: Carry Out Maintenance of Tools and Machines Aim: Be able to prepare Maintenance of Tools and Machines housekeeping. LU-1: Perform Preventive Maintenance of Machines and Tools LU-2: Perform General Housekeeping and Maintenance of Machines and Tools 08 hours 07 hours 08 hours 07 hours 16 hours 14 hours Page 11

16 Module 5: Perform Lathe Machine LU-1: Perform Facing Operations 08 hours 15 hours 23 hours Operations LU-2: Perform Turning Operations 05 hours 30 hours 35 hours Aim: Be able to perform all common +complex.lathe operation using LU-3: Perform Drilling / Boring Operations 05 hours 30 hours 35 hours Conventional lathe machine. LU-4: Perform Taper Turning Operations 03 hours 30 hours 33 hours LU-5: Perform Knurling Operations 03 hours 20 hours 23 hours LU-6: Perform Threading Operations 16 hours 55 hours 71 hours Module 6:Perform Milling Machine LU-1: Produce a Squared Shape Work Piece 15 hours 20 hours 35 hours Operations LU-2: Perform Spur Gear Cutting 15 hours 60 hours 75 hours Aim: Be able to perform common milling operation and produce LU-3: Perform helical gear cutting 10hours 60hours 70hours commonly used square, slotting, drilling, boring and gears. LU-4:Perform Slotting / Grooving on Work Piece 10 hours 20 hours 30 hours Module 7: Carry Out Computerized Numerical Control (CNC) Machine Operations Aim: Be able to set &perform on computer numerical control (CNC) Lathe (CNC) and milling.machine LU-5: Perform Drilling / Boring using Milling Machine 10 hours 20 hours 30 hours LU-1: Set CNC Machine according to Job 15 hours 60 hours 75 hours Requirements LU-2: Perform Milling Operations Using CNC Machine LU-3: Perform Turning Operations Using CNC Machine 15 hours 10 hours 60 hours 60 hours 75 hours 70 hours Module 8: Perform Grinding Machine LU-1: Perform Off-hand Grinding 06 hours 20 hours 26 hours Operations LU-2: Perform Surface Grinding 09 hours 20 hours 29 hours Aim: Be able to perform on grinding machines (Off-hand, surface, LU-3: Perform Universal Cylindrical Grinding 10 hours 40 hours 50 hours cylindrical and tool & cutter grinding Machines). LU-4: Perform Tool and Cutter Grinding 10 hours 40 hours 50 hours Page 12

17 Module 9: Perform Shaper Machine operations Aim: Be able to perform on shaper Machines (Square & V shaping). LU-1: Perform Squared Shape Work Piece LU-2: Perform V shape work piece 08 hours 07 hours 20 hours 30 hours 28 hours 37 hours Module-10: Implement Energy Management Measures Aim: Be able to measure energy use and consumption, energy cost calculation, inspection of machine LU-1: Measure energy use and consumption of machine LU-2: Perform electrical energy cost calculation of machine LU-3: Select tools and machining parameters as per job 12 hours 8 hours 5 hours 24 hours 16 hours 20 hours 36 hours 24 hours 25 hours 22 hours LU-4: Perform inspection of machine 6 hours 16 hours Module-11 Apply Noise Prevention Measures Aim: Be able to conduct Noise survey and suggest measures to control and prevent noise pollution. Module-12: Implement Waste Management Measures Aim: Be able to identify wastages and take appropriate measures to control and prevent the wastages LU-1: Carry out noise survey of workplace LU-2: Rank areas for noise according to NEQS LU-3: Report assessed noise control measures LU-1: Identify process and system wastages LU-2: Take measures to control wastage 2 hours 2 hours 3 hours 9 hours 12 hours 6 hours 4 hours 6 hours 24 hours 9 hours 8 hours 6 hours 9 hours 33 hours 21 hours Module 13: Develop Professionalism Aim: Be able to Communicate with other And Upgrade professional skills adopt team work LU-1: Perform Communication with others LU-2: Upgrade professional skills LU-3: Work in a team 08 hours 15 hours 20 hours 00 hours 00 hours 00 hours 08 hours 15 hours 20 hours Page 13

18 Module 14: Computer Skills I Aim :Learn to use Computer Effectively Module 15: Computer Skills II Aim: Get awareness of latest drawing and designing tools through computer applications used in the industry Module 16: English Skills I Aim: To enhance students understanding about English language for reading, listening and speaking LU-1 Introduction to Computer LU-2 MS-Word (Basic to intermediate) LU-3 MS-Excel (Basic to intermediate) LU-1 Introduction to CAD 0 hours 40 hours 40 hours LU-2 AutoCAD (Basic to intermediate). 0 hours 40 hours 40 hours LU-1. Introduction to Listening Part I - Listening to match Information LU-2. Introduction to Listening Part II - Listening to Respond LU-3. Introduction to Listening Part III - Following Conversations LU-4. Introduction to Listening Part IV- Listening for Key Information LU-5.Introduction to Reading Part I- Reading to Understand the Sequence of a Text LU-6. Introduction to Reading Part II - Understanding the Text Structures LU-7. Introduction to Reading Part III - Understanding the Purpose of Text LU-8. Introduction to Reading Part IV - Reading for Key Information 40 hours 0 hours 40 hours Page 14

19 Module 17: English- II Aim: To improve their writing Capacity and enable them to speak English language fluently LU-1. Introduction to Writing Part I Completing a form LU-2. Introduction to Writing Part II Connecting errors LU-3. Introduction to Writing Part III Communicating Ideas and Information LU-4. Introduction to Writing Part IV Writing a text LU-5. Introduction to Speaking Part I Introduction to Language LU-6. Introduction to Speaking Part II Social Situations LU-7. Introduction to Speaking Part III 40 hours 0 hours 40 hours Exchanging information and opinions LU-8. Introduction to Speaking Part IV Presenting a Module 18: Secondary skills and activities Aim: To add value in monthly assessment and extra curriculum activities Topic LU-1. Monthly test LU-2. Sports LU-3. Events 0 hours 40 hours 40 hours Module 19:Secondary skills and activities II other essential life skills Aim: To add value in monthly assessment and extra curriculum activities LU-1. Monthly test LU-2. Students projects LU-3. Industrial visit 0 hours 80 hours 80 hours Page 15

20 Module 20: On-the-Job Training Aim: Gain real workplace understanding, skills and experience Orientation of real workplace environment, skills and experience Module 21: On the Job Training Aim: Deepen the understanding and skills for the concepts taught in the modules and building skills for Self - learning. Review and Preparation Aim: To review the content and assess through examination for output and quality of the trained person LU-1 Company orientation LU-2 Health, Safety & Environment overview LU-3 Personal protective equipment (PPE) LU-4 Central Documentation Department LU-5 Maintenance / operations LU-6 Production & process control (PPC) LU-1 Review of OJT of phase I LU-2 Quality Assurance / Quality Control LU-3 Inventory Management LU-4 Maintenance / operation /Documentation LU-5 Commissioning and operation of Mechatronics system LU-6 Trouble shooting and problem solution LU-1. Review, recap and reflection LU-2. Final examination preparation 0 hours 800 hours 800 hours 0 hours 800 hours 800 hours 0 hours 40 hours 40 hours Page 16

21 2 TEACHING AND LEARNING GUIDE FOR MACHINIST 2.1 MODULE-1: BASIC BENCH WORK Duration Theory Practical 80 hours 20 hours 60 hours Learning Unit Learning Outcomes Learning Elements Duration Materials LU-1: Carry out Sawing Trainee should be able to: Selection of blade according to martial of workpiece. Ensure the blade is set in the frame of hacksaw as per procedure. Perform marking as per drawing. Demonstrate procedure of setting blade in hacksaw. Perform sawing according to marked line ensure accuracy. Perform measuring Observe personal and workplace safety at all times. Explain properties of workpiece metals. Describe types of Hacksaw blades. Describe the importance of safety precaution. Explain interpretation of drawings & surface symbols. Describe the use of measuring and marking tools. Explain the important of clamping of work piece. Describe the marking as per given drawing. Explain t he procedure of s a w i n g with hand hacksaw. Practical Exercise Sawing Total: 11hrs. Theory: 03hrs. Practical: 08 hrs. Required Work bench vice Tri square Scriber Hand hack saw with blade Steel Rule Personal Protective Equipment Punching / marking Tools MS Flat Learning Place Theory: Class room Practical: Lab /workshop Page 17

22 Learning Unit Learning Outcomes Learning Elements Duration Materials LU-2: File the Work Piece to Produce required Smoothness Trainee must be able to: Identified the bench workshop tools. Identified the kind of file and their uses. Identified the clamping workpiece properly. Perform and select files according to dimension and finishing. Perform the clamping of work- piece firmly and properly. Demonstrate procedure of filing Perform measuring Observe personal and tool safety. Marking for Sawing Exercise Sawing Exercise Understand The Bench work shop tools and their application Knowledge of different files and their uses. Explain the different filling operation, parallel filling, curved edge, even surface and square filling. Profile filling with key file needle file set Describe the clamping of workpiece as required. Understand and use of marking tools. Understand and use of measuring tools Knowledge of filling procedure. Emphasize the importance of safety precaution. Total: 38 hrs. Theory: 10 hrs. Practical: 28 hrs. Required 100x62x15mm Work bench with vice Files Scriber Steel rule Vernier Caliper Try square Personal Protective Equipment Learning Place Theory: Class room Practical: Lab/ Workshop Page 18

23 Learning Unit Learning Outcomes Learning Elements Duration Materials Practical Exercise Filing Exercise (channel) Required MS Channel 100x75x38x6 Learning Place Squaring Exercise MS Flat 100x62.5x15 LU-3: Produce Threads on Work Piece Trainee should be able to: Identify different kind of taps & die according to requirement Perform clamping of workpiece as required. Perform tap and die alignment. Demonstrate procedure of Knowledge of different kind of taps & die according to requirement Knowledge of calculation for drill size for internal threading. Describe the clamping of workpiece as required. Describe the threading by hand. Describe the threading by die and taps. Total: 20 hrs. Theory: 04hrs. Practical: 16 hrs. Bench and bench vice Tap set Tap handle Oil/Lubricant Tri square Thread gauges Theory: Class room Practical: Lab/work shop threading with die and tap. Ensure tap and die alignment. Perform oil and lubricants Ensure use of oil and lubricants while threading. during threading. Avoid unwanted engraving Knowledge of threading procedure and slips. for accurate and dimensionally Demonstrate proper threading correct. Page 19

24 Learning Unit Learning Outcomes Learning Elements Duration Materials LU-4: Perform Hand Reaming procedure. Observe personal and workplace safety at all times. Trainee should be able to: Identify different kind of reamer standard according to requirement Perform clamping of workpiece as required. Perform reaming by hand. Demonstrate proper reaming procedure. Apply oil and lubricants while reaming. Observe personal and workplace safety at all times. Adopt safety during threading. Practical Exercise Marking for Threading Exercise Knowledge of different kind of reamer standard according to requirement Knowledge of calculation for reamer drill size Describe the clamping of workpiece as required. Describe the reaming by hand reamer. Ensure reamer alignment. Ensure use of oil and lubricants during reaming. Knowledge of reaming procedure for accurate and dimensionally correct. Adopt personal and tool safety during reaming. Total: 11 hrs. Theory: 03 hrs. Practical: 08 hrs. Required MS Flat 100x62.5x15 MS Flat 100x62.5x15 Bench vice Hand reamer Handle of reamer Oil/Lubricant Try square Learning Place Theory: Class room Practical: Lab/ Work shop Page 20

25 Learning Unit Learning Outcomes Learning Elements Duration Materials Required. Practical Exercise Marking for Reaming MS Flat 100x62.5x15 Learning Place Reaming Exercise MS Flat 100x62.5x15 Page 21

26 2.2 MODULE-2: PERFORM DRILLING MACHINE OPERATIONS Objective of the Module: Be able to prepare drilling, Counter Boring and Counter Sinking on machine reaming. Duration Theory Practical 40 hours 10 hours 30 hours Learning Unit Learning Outcomes Learning Elements Duration Materials LU-1: Produce Holes using Drilling Machine Trainee should be able to: Perform basic mathematical calculation for drilling operations. Identify machine controls. Perform proper clamping the workpiece. Select and set feed and RPM Identify the produce to required quality and within the specified dimensional accuracy. Perform marking as per drawing. Perform drilling on drilling Understand of construction of different type of drills machine. Knowledge of different type of drills machine and their functions. Calculate cutting speed, feed and RPM on drilling machine the drill size for reaming Describe the drilling on marked point. Describe the drilling procedure Understand the use of oil and coolant. Apply tool and machine safety on drill machine Understand and use of measuring tools Total: 14hrs. Theory: 04hrs. Practical: 10hrs Required Drilling Machines Drill chuck with Key Drill bits Machine Vice Marking Tools Measuring Tools Drill Sleeve and Socket Personal Protective Equipment Learning Place Theory: Class room/ Salon Practical: Lab/ work shop Page 22

27 Learning Unit Learning Outcomes Learning Elements Duration Materials machine Perform measuring Shut down the equipment to a safe condition on conclusion of the machining activities Practical Exercise; Marking for Drilling Exercise; Required MS Flat 100x62.5x15 Learning Place LU-2: Perform Counter Boring and Counter Sinking Trainee should be able to: Perform basic mathematical calculation for Counter Boring and Counter Sinking Explain types of counter sinking and counter boring tools and their implications. Knowledge of Calculation cutting Total: 12 hrs. Theory: 02hrs. Counter boring tools Counter sinking tools Theory: Class room operations. speed, feed and R.P.M for Counter Practical: Cutting oil Practical: Perform proper clamping the workpiece. Select correct Counter Boring and Counter Sinking tool in terms of size, shape, type, and grade for the work. Identify the produce to required quality and within the specified dimensional accuracy. Perform marking as per Boring and Counter Sinking on drilling machine. Identify the marking as per drawing. Describe the Counter Boring and Counter Sinking on marked point. Understand the use of coolant. Understand and use of measuring tools Explain safety precautions during counter boring and counter sinking operations. 10hrs Vernier caliper Lab Work shop Page 23

28 Learning Unit Learning Outcomes Learning Elements Duration Materials LU-3: Perform Machine Reaming drawing. Perform Counter Boring and Counter Sinking on drilling machine. Perform measuring Trainee should be able to: Identify machine controls. Selection of reamer as drawing requirement Perform proper clamping the workpiece. Perform marking as per drawing. Perform the produce to required quality and within the specified dimensional accuracy. Perform reaming on drilling machine Perform measuring With plug gauge Practical Exercise; Marking for Countersinking Counter boring Countersinking &Counter boring Exercise; Calculate cutting speed, feed and RPM on drilling machine for reaming. Calculate drill size for reaming. Identify the marking as per drawing. Understand the type and use of coolant. Understand and use of measuring tools (Plug gauge, inside micrometer) Explain safety precautions during reaming operations. Practical Exercise Marking for Reaming Exercise Total: 14hrs. Theory: 04hrs. Practical: 10hrs Required MS Flat 100x62.5x15 Drilling Machines Drill chuck with Key Machine Vice Measuring Tools (Plug gauge, inside micrometer) Personal Protective Equipment Reamers Plug gauge Oil/Lubricants MS Flat 100x62.5x15 From drilling Exercise Learning Place Theory: Class room Practical: Lab/ Work shop Page 24

29 2.3 MODULE-3: APPLY OCCUPATIONAL HEALTH & SAFETY PROCEDURES AT WORKPLACE Objective of the Module: Be able to prepare Occupational Health & Safety Procedures at Workplace Duration Theory Practical 30 hours 15 hours 15 hours Learning Unit LU-1 Identify hazards in workplace environment Learning Outcomes Learning Elements Duration Materials Trainee should be able to: Identify drawing and interpret work processes and procedures correctly. Identify risk of hazards at workplace. Recognize engineering processes, tools, equipment and consumable materials that have the potential to cause harm. Identify any potential hazards and take appropriate action to minimize the risk. Understand drawing and engineering processes and procedures correctly Knowledge of techniques and methods to identify the risks of hazards at workplace. Knowledge of any potential hazards and takes appropriate action to minimize the risk. Adopt health and safety precautions of work shop.( Worksite Hazardous Materials Information Systems (WHMIS), fire regulations, Total: 08 hrs. Theory: 04 hrs. Practical: 04 hrs. Required Health and safety manual. Learning Place Theory: Class room Practical: Lab/ Work shop Page 25

30 Learning Unit LU-2: Comply with Occupationa l l Health and Safety Precautions Learning Outcomes Learning Elements Duration Materials Health and safety precautions of the company. Techniques and methods to identify the risks of hazards at workplace. Dealing with hazards to avoid any accident or injury. Safety reporting procedures and documentation. Trainee should be able to: Create safe environment Apply Occupational Health and Safety Act, Regulation and Code. Safe own self and other. Aware worksite hazard accident and emergency Situations Identify chemical e.g. skin, use, storage, disposal, procedures, consequences of not following Knowledge and understanding of hazards to avoid any accident or injury on workplace. Prepare check list for safety hazardous. Knowledge of reporting procedures and documentation. Explain the role of the employer and employee in regard to Occupational Health and Safety (OH&S) regulations Worksite Hazardous Materials Information Systems (WHMIS), fire regulations, Explain industry practices for hazard assessment and control procedures. Describe the responsibilities of workers and employers to apply emergency Total: 08 hrs. Theory: 04 hrs. Practical: 04 hrs. Required Overall combination Safety shoes Safety gloves Safety goggles Safety helmet Ear plugs Fire extinguisher Learning Place Theory: Class room Practical: Lab/ Work shop Page 26

31 Learning Unit LU-3: Apply Personal Protective and Safety Equipment Learning Outcomes Learning Elements Duration Materials manufacturers' instructions Use Electrical equipment their storage, maintenance and repair Identify workshop regulations, and hygiene practices Select, use and maintain appropriate Personal protective equipment(ppe) for workshop applications Trainee should be able to: Select personal protective equipment in terms of type and quantity according to work orders. Understand wear, adjust, and maintain personal protective equipment to ensure correct fit procedures. Describe positive tradesperson attitudes with respect to housekeeping, personal protective equipment and emergency procedures. Describe the health and safety risks that can arise as a result of accidents. Describe the roles and responsibilities of employers and employees with respect to the selection and use of personal protective equipment (PPE). Describe fire hazards, classes, procedures and equipment related to fire protection Knowledge of personal protective equipment. Ensure the use wear, adjust, and maintain personal protective equipment correct fit and optimum protection in compliance with company Store the PPEs at neat and clean place Total: 08 hrs. Theory: 04 hrs. Practical: 04 hrs. Required Smoke alarm First aid box Overall combination Safety shoes Safety gloves Safety goggles Learning Place Theory: Class room Practical: Lab/ Work shop Page 27

32 Learning Unit LU-4: Practice safe work habits to ensure safety at workplace. Learning Outcomes Learning Elements Duration Materials and optimum protection in compliance with company procedures. Ensure personal protective equipment is cleaned and stored in proper place. Explain the use Personal Protective Equipment. Identify the types of PPE. Protective clothing and equipment (PPE) to be worn and where it can be obtained. Safely maintaining the PPEs. Trainee should be able to: Knowledge of wear required clothing (not lose or torn), confine long hair, and remove watch or ring in accordance with company procedures. Apply work procedures and approaches that ensure and clean after each use. Knowledge of personal protective equipment Type and size (fit size for person). Ensure the wear (PPE) clothing and equipment. Knowledge of Importance of safety at work and its implications. Ensure wear clothing recommended by (PPEs) confine long hair, and remove watch or ring. Ensure personal safety as well as tools and work safety. Total: 08 hrs. Theory: 04 hrs. Practical: 04 hrs. Required Safety helmet Ear plugs First aid box Earth wire Fire extinguisher Tool box/bins Safety covers First aid Learning Place Theory: Class room Practical: Lab/ Work shop Page 28

33 Learning Unit Learning Outcomes Learning Elements Duration Materials personal safety as well as others safety. Demonstrate good housekeeping in the workplace by cleaning up spills or leaks. Keep work area clean and clear from oil and chips, and storing tools or equipment, so that the potential for accident or injury is prevented. Ensure tools or equipment are in place and available in proper place. Importance of safety at work and its implications. Work safety procedures and guidelines. Demonstrate good housekeeping in the workplace. Demonstrate work area clean and clear from oil and chips, and storing tools or equipment, so that the potential for accident or injury is prevented. Required box Safety equipment Learning Place Page 29

34 2.4 MODULE-4: CARRY OUT MAINTENANCE OF TOOLS AND MACHINES Objective of the Module: Be able to prepare Maintenance of Tools and Machines housekeeping. Duration Theory Practical 30 hours 15 hours 15 hours Learning Unit LU1: Perform Preventive Maintenance of Machines and Tools Learning Outcomes Learning Elements Duration Materials Required Trainee should be able to: Prepare oiling and greasing chart (daily, weekly as machine requirement). Prepare machine history record date of installation condition, oiling and maintenance has to done. Inspect and assess the general condition of an assigned machine on regular basis. Observe problems and carry out routine maintenance as per given instructions and Understand machine operations Understand oiling greasing rotation machine Identify faulty/damaged/ worn out parts and can remove small fault. Maintain history record of assign machine. Observe routine maintenance problems and can solve them. Demonstrate daily check of assigned machine on regular basis. Write report to authority those problems which are beyond the scope him. Total: 15 hrs. Theory: 08 hrs. Practical: 08 hrs. Wrench set L-Key set Spanner set Hammer Chisel Bearing puller Safety equipment Machinist toolkit Learning Place Theory: Class room Practical: Lab/ Work shop Page 30

35 Learning Unit Learning Outcomes Learning Elements Duration Materials Required schedules. Report to authority that problems which are beyond the scope him. Read maintenance schedule Identify faulty/damaged/ worn out parts Troubleshooting of minor faults Learning Place LU-2: Perform Trainee should be able to: General Clean and maintain all bench- Knowledge of material, tools and Total: Tool racks Theory: Housekeeping work tools and machines as equipment for Straightening the hair 15 hrs. Grease gun Class and Maintenance of Machines and Tools. per housekeeping checklists or instructions given. Prepare check list for daily cleanliness of the workplace. Respond appropriately to safety hazards on all bench- Knowledge of guidelines and checklists to conduct maintenance and housekeeping of machines and tools Adopt habit daily cleanliness of the machine and workplace. Adopt habit daily and as per given check Theory: 07 hrs. Practical: 07 hrs. Oil gun Cotton rags Tool grinders Machinist toolkit room Practical: Lab/ Work shop work tools and machines. list of oiling and lubrication. Identify all the tools and Knowledge of storing all tools and material in proper place to material in specify place. ensure safe work. Page 31

36 Learning Unit Learning Outcomes Learning Elements Duration Materials Required Knowledge of methods and techniques for cleanliness and maintenance of machines and tools. Prepare Specific guidelines and checklists to conduct maintenance and housekeeping of machines and tools. Learning Place Page 32

37 2.5 MODULE-5: PERFORM LATHE MACHINE OPERATIONS Objective of the Module: Be able to perform all common +complex.lathe operations by using conventional lathe machine. Duration Theory Practical 220 hours 40 hours 180 hours Learning Unit LU-1: Perform Facing Operations Learning Outcomes Learning Elements Duration Materials Required Learning Place Trainee should be able to: Understand the construction of lathe machine and their uses. Understand the attachment of lathe machine. Identified the lathe tools and their settings. Prepare tools for required operation etc. (facing). Mount the clamping device and clamping job property Clamp the tool and set center position. Perform facing and Centre drilling as prescribe procedure. Explain the construction of Lathe machine and their type. Enlist the main part of lathe machine and their uses. Describe the Lathe machine attachment and their uses. Deduct the small fault and repair them. Knowledge of Calculation cutting speed, RPM and feed on Lathe. Enlist the required tools for job and clamping device. During use measuring tool store Total: 23 hrs. Theory: 04 hrs. Practical: 15 hrs. Lathe Machine Cutting Tools Venire Caliper Personal Protective Equipment Theory: Class room Practical: Lab/ work shop Page 33

38 Learning Unit Learning Outcomes Learning Elements Duration Materials Required Learning Place De-burr the job and check size with Vernier caliper on all steps. Shut down the machine while checking of size. Adopt personal safety, Tool and work safety on Lathe machine. separately. Tools equipment used cleaned and stored as specified. Wear specified cloths for in the work shop handle the heavy part carefully. Keep working space clean from oil and chips. Practical Exercise; Round bar M.S. Round Ø 25 X115mm LU-2: Perform Turning Trainee should be able to: Identified the lathe turning tools and its angles. Selection of cutting tool for turning Total: 35 hrs. Lathe Machine Cutting Tools Theory: Class room Operations Clamp the lathe turning tools and their settings (Centre position of machine spindle). Mount the work holding device and clamp the workpiece firmly. Calculation of cutting speed, RPM and feed for turning. Enlist the required tools for job and clamping device. Describe the clamping device Theory: 05 hrs. Practical: 30 hrs. Vernier Caliper Personal Protective Equipment Files Practical: Lab/ work shop Calculate and set cutting and clamping of job. speed, RPM and feed for Describe the Clamping of tool Page 34

39 Learning Unit LU-3: Perform Drilling / Boring Operations Learning Outcomes Learning Elements Duration Materials Required Learning Place turning. and set center position. Perform turning as prescribe procedure have the required quality Shut down the machine while checking of size. Personal safety, Tool and work safety Trainee should be able to: Identified the difference between drilling and boring. Identified the drill and boring tools and their settings. Select and set the drilling holding device, mount the drill. Handle sharp tools with care. Explain the use of measuring and cutting tools and it cares. Tools equipment used cleaned and stored as specified place. Wear specified cloths for in the work shop handle the heavy part carefully Practical Exercise; Blade Holder I Blade Holder II Measuring Exercise Knowledge of drilling and boring difference and it purpose. Describe selection of drills and boring tool as per drawing. Calculate cutting speed, RPM and feed for drilling and boring. Total: 35 hrs. Theory: 05 hrs. Practical: 30 hrs. M.S. Round Ø 25 X100mm M.S. Round Ø 25 X90mm M.S. Round Ø 44X155mm Drill Drill chuck Boring Tool Vernier caliper Depth gauge Personal Protective Theory: Class room Practical: Lab/ work shop Page 35

40 Learning Unit Learning Outcomes Learning Elements Duration Materials Required Learning Place Drill the hole as prescribe procedure up to require size Clamp the boring tools and their settings (Centre position of machine spindle). Perform boring as prescribe procedure have the required quality De-burr the workpiece and checking the size (Shut down the machine). Check quality of the component produced at different intervals. Observe Personal safety, Tool and work safety Explain the drilling clamping device and clamp the drill Describe the clamping device and clamping job firmly properly Describe the Clamp of boring tool and set center position. Explain boring as per drawing. Check size of drilled and bored workpiece. Wear specified cloths for in the work shop handle the heavy part carefully. Describe Safety precautions and procedures. Practical Exercise; Equipment Lathe Machine Bush Gear Wheel (Three pieces) Paper Weight M.S. Round Ø 28 X45mm M.S. Round Ø68X22mm M.S. Square 44X44mm Page 36

41 Learning Unit LU-4: Perform Taper Turning Operations Learning Outcomes Learning Elements Duration Materials Required Learning Place Trainee should be able to: Knowledge of the different kind Adopted taper turning method of taper turning method. Total: Lathe Machine Theory: as per workpiece required. Selection of taper turning tools for internal & external taper turning. Clamp the tool and set Centre position. Perform internal & external taper turning. Calculate and set setting angle for taper turning. Perform taper turning as prescribe procedures have the required quality. Perform resetting if required. Perform check taper with Vernier caliper then with taper gauge. Shut down the machine while checking of taper. Personal safety, Tool and Knowledge of internal & external taper turning setting angle. Knowledge of machine calculation for taper turning. Knowledge of procedures of taper turning operation Knowledge of checking with Vernier caliper then with the taper gauge. Tools equipment used cleaned and stored as specified. Wear specified cloths for in the work shop handle the heavy part carefully. Keep working space clean from oil and Chips. Practical Exercise; Drill body 33 hrs. Theory: 03 hrs. Practical: 30 hrs. Cutting Tools Vernier Caliper Personal Protective Equipment Files Checking gauges Bevel protector M.S. Round Ø 22X 220mm Class room Practical: Lab/ workshop Page 37

42 Learning Unit Learning Outcomes Learning Elements Duration Materials Required Learning Place work safety Plummet M.S. Round Ø 22X 30mm, & Ø 22X 50mm LU-5: Perform Trainee should be able to: Identified the knurling purpose Select type of knurling tool as Total: Lathe Machine Theory: Knurling and kind. per workpiece required. 23 hrs. Knurling Tools Class room Operations Selection of Knurling tools as drawing requirement and clamp and set prescribe of procedures. Knowledge of the different Knurling and knurling tools. Knowledge of knurling purpose. Knowledge of machine Theory: 03 hrs. Practical: 20 hrs. Personal Protective Equipment Files Practical: Lab/ work shop Select and set machine for calculation for Knurling. Knurling. Calculate cutting speed, RPM Perform Knurling as prescribe and feed for Knurling. procedures have the required quality. Clamp and set Knurling tool straight and Centre position. Checking knurled workpiece. Adopted Knurling procedures Shut down the machine while Perform Knurling. checking of size. Check impression if ok complete Personal safety, Tool and work in one cut. safety. Apply coolant during Knurling Check Knurling size as per drawing with Vernier caliper. Page 38

43 Learning Unit LU-6: Perform Threading Operations Learning Outcomes Learning Elements Duration Materials Required Learning Place Personal safety, Tool and work Trainee should be able to: Describe the kind of threads as per standard. Describe the thread as per shape. Describe the thread characteristics.(shape And standard) Describe the kind of thread cutting tools metric, metric fine, pipe, acme, square buttress threads ( internal/external) Calculate thread formulas, bore size for internal thread safety. Practical Exercise; Centre Punch Shank Screw with Taper Knowledge of thread kind as per standard. o o o o Matric thread (American National Standard Thread) Matric fine thread Unified Thread - UNC Unified Course Thread Series - UNF Unified Fine Thread Series - UNEF extra fine thread series Knowledge of thread as per shape. o V thread Total: 71 hrs. Theory: 16 hrs. Practical: 55 hrs. M.S. Round Ø 12X105mm M.S. Round Ø 38X 84mm, Ø 38X 53mm, Ø 31X 32mm Lathe Machine Threading Tools Personal Protective Equipment Files Thread Pitch Gauge Tool Centre Gauge Vernier Caliper Thread ring and plug gauge Revolving Centre Theory: Class room Practical: Lab/ work shop Page 39

44 Learning Unit Learning Outcomes Learning Elements Duration Materials Required Learning Place Describe the thread cutting o Acme thread. tools angles. o Square thread Perform grinding the threading o Buttress thread tools Internal/ External according to thread angle. and setting of thread cutting tools. Calculate and set lead for thread cutting. Perform thread cutting as prescribe procedures have the required quality. Perform checking of thread with thread gauge (Thread ring or plug gauge) Observe personal and workplace safety. Knowledge of thread characteristics.(shape And standard) Knowledge of thread calculation formulas. Knowledge of thread cutting procedures. Knowledge of threads and cutting tools angle. Knowledge of calculation for bore size for internal thread. Ensure all the required threading cutting Procedure and completed. Knowledge of with thread checking gauges (Thread ring or plug gauge) Mind the safety precautions Page 40

45 Learning Unit Learning Outcomes Learning Elements Duration Materials Required Learning Place involved in threading operations. Practical Exercise; Spindle & thread Bush M.S. Round Ø 24X 260mm, Ø 18X 20mm, Brass 33X28mm Pipe Long Thread M.S. Round Ø 25X 64mm, Ø 22X 12mm Page 41

46 2.6 MODULE-6: PERFORM MILLING MACHINE OPERATIONS Objective of the Module: Be able to perform common milling operation and produce commonly used square, slotting, drilling, boring and gears. Duration Theory Practical 240 hours 60 hours 180 hours Learning Unit LU-1: Produce a Squared Shape Work Piece Learning Outcomes Learning Elements Duration Materials Required Trainee should be able to: Explain the construction of milling Total: Milling machine Select the milling cutters and machine and their uses 35 hrs. Machine Vice their settings. Enlist the main part of milling Theory: Tri square Selection clamping device for machine and their uses 15 hrs. Vernier Caliper different milling operations. Deduct the small fault and repair Practical Dial indicator with Mount and dial the machine vice them. 20 hrs. magnet stand according to job requirement. Enlist the main attachment of Personal Protective Mount arbor and cutter for milling machine. Equipment squaring. Calculate and set cutting speed, Mount cutters and work piece in RPM and feed. the machine. Interpreting information given in Perform clamping for squaring the engineering drawings and job as proper procedure. specifications Learning Place Theory: Class room Practical: Lab/ work shop Page 42

47 Learning Unit Learning Outcomes Learning Elements Duration Materials Required Ensure all the required squaring Explain square milling procedure. prescribe procedures have been Perform checking size and right completed to the given angle with the tri square. specification. Safety guidelines and procedures Perform De-burring. for milling machine. Check size and angle after each Safety checks for operating on step. milling machine. Identify safety hazards related Handle and sharp cutter with care. with milling operations and take Tools equipment used cleaned appropriate steps to avoid any and stored as specified. injury or accident. Keep working space clean from oil and chips. Practical Exercise; Base Nut M.S. Flat 50x31x90 Learning Place Tool Holder Side Turning Tool Circular Cutter Straight Edge M.S. Flat 38x25x155 M.S. Flat 31x22x150 M.S. Flat 40x40x25 M.S. Flat 37x10x100 Page 43