REDESIGNED MODULES FOR THE SECTOR OF AUTOMOBILE UNDER MODULAR EMPLOYABLE SKILLS (MES) Redesigned in - 2015 By Government of India Directorate General of Employment & Training Ministry of Labour & Employment (DGE&T)
GENERAL INFORMATION FOR AUTOMOTIVE PAINT REPAIR Name of Sector AUTOMOBILE Name of Module MES Code Competency as per N C O Code Duration of Course Entry Qualification of Trainee Automotive Paint repair AUR 1. Follow safe practice on Work 2. Able to do First Aid 3.Handling of General Tools, Special tools, equipments and Machineries available in the Painting shop 4.Able to do painting and paint repair in 4 wheelers 2000 Hrs ( One Year) Minimum 10th Std Pass., 18 years of Age Unit size (No. of Trainees) 20 Power Norms Space Norms(Workshop and Class Room) Job Profile Objective Terminal competency Instructor Qualification Desirable Qualification 6 KW - (a) Class Room: 1 KW (b) Workshop: 5 KW 210 sq. m - (a) Class Room: 30 Sq. meter @ 1.5 sq. meter per trainee (b) Workshop: OEM authorized service Workshop Auto body Painter 1. Producing Automotive Body Painter for automotive workshop by pinning with following Employability skills (i) Safety awareness about work safety, tools, Equipment & Machine safety, Personal safety, Fire safety and Environmental safety. ii)skills to do Auto Body Painting work of four wheeler 2. Self-employment in the area of Auto body Painting and Paint Repair 1. Follow safe practice on Work 2. Able to do First Aid 3.Handling of General Tools, Special tools, equipments and Machineries available in the Automobile paint shop &Paint Repair 4. Able to carry out painting and paint repair in 4 wheeler vehicles Degree in Chemical /Mechanical /Automobile Engg. With one year relevant experience OR Diploma in Chemical/Mechanical/ Automobile Engg. With two year relevant experience OR NTC/NAC in Automobile/ Painting trade group with three years of relevant experience Craft Instructor Certificate(CIC)
Course Contents for Automotive Paint Repair (AUR ) Practical Competencies Workshop Safety Underpinning Knowledge(Theory) Workshop Safety Develop Safety attitude by using of Personal Protective Equipments (PPE). First-Aid methods Use of fire extinguishers. Practice health & safetyfamiliarize, select, proper use, maintain and store tools, equipments, Consumables clothing safety Familiarization with the institute, importance of the course. Familiarization with automotive sector. Occupational health and safety. Accidents- Definition types and causes. First-Aid, nature and causes of injury and utilization of first-aid. Safety: - its importance, classification, personal, general, workshop and Vehicle safety. General safety precaution observed in the institute and section, safety rules for bench work. Safety signs and norms. Fires: - types, causes, use of fire extinguisher, how to use. Use of personal protective Equipments (PPE), standardization.
Behavioral Training: Behavioral Training: Aptitude developing exercises Communication skill developing exercises Psychology: definition of psychology, definition of education, training, knowledge, skill, attitude, aptitude, teaching and learning. Personal hygiene: definition, methods of maintaining cleanliness, conditions of maintaining disinfected/germ free health Motivation:- definition, kinds of motivation, elements of motivation, use of motivation, techniques, sources of motivation, methods of motivation, maintaining learners interest, causes of loss of interest. Communication:- Elements of communication, procedure step in communication, media, classification, 5W s and 1H in communication7c s in communication, credibility gap, listening, tips for improving communication skills, barriers in communication. Workshop discipline and culture: - Rules to be followed in the workshop. Organization Structure. Nature of work is to be done. Role and duties in the workshop
Technical English Read a technical text Writing a letter Read and write Service Job card, Service and owner s manual, Service bulletins, Circulars and notices Technical English Group: A (Glossary) Introduction: Difference between general English and technical English Application of technical English at work Glossary of technical terms used in the industry. Group: B (Basic grammar) Articles (a, an, the) Editing (Correcting of passages with changing of words like articles, preposition, verbs, tenses etc.) Omission (Correcting of passages with putting new and right words) Syntax (Agreement between subject and verb) Use of preposition (fill in the blanks) Tense (knowledge of all kind of tenses-present past future) Group: C (writing skill) Report writing(making a report of a topic) Letter writing(writing official and formal letters) Group: D (Reading section) Read technical texts and give answers.
Basic Computer Awareness Basic Computer Awareness Booting The Computer, Opening Windows Menus, using the mouse, refresh computer desktop using right click of the mouse, copy the file into hard disk, create a directory in hard disk, use my documents, use start menu for opening an application, to open a document recently written, change control panel settings for display, change the volume, Familiarize with Keyboard and Keys. Techniques of changing Desktop Screen properties, Control Panel User Accounts, customizing icons, writing a sample text using Notepad, Using Paint for drawing figures to get accustomed with mouse, saving a file. Using Windows Explorer, Install a software, Remove a Software, Add new hardware to the system (like a Printer, Change the system date and Time, changing the Regional Settings of the system like country, Currency, Date Format, Using Start Menu, Creating Desktop Short Cuts Open internet explorer, receive and send emails from the account. Search using Yahoo and Google for certain topics, download a file from the internet, and save it. Familiarizing With Disk Drives, Booting Of a Computer System, Left Click And Use Of Operating Systems Like Windows XP,, Windows 7, Menu System, Tool Bars, File Structures, Directories, Use of desktop, control panel settings, Explorer, regional settings, creating shortcuts, Creating sample documents using MS WORD. Text wrapping, Text Formatting, Changing Letters to different case, drawing table, Page formatting, using different Font Types, Printing a document Using Excel as spread Sheet, Familiarizing with Cells, Formulae, Text, Numbers, and date,, Copying Formulae, Text and Numbers, Using borders, Merging Cells, Unmerging, Changing Cell width, Row height, Printing an area of the sheet, Options of Printing like fit to paper, shrinking, etc., Using different Sheets in a work book, changing Colour of cells, fonts, text. Study of Internet Explorer, Modem, Settings in the IE and Modem, Dial Up and Broadband connections, Outlook Express, Viewing Email from the web site and Outlook Express, Creating email Accounts, using search engines
Workshop Calculation & Science Units & Measurements Systems of units, Fundamentals and derived units Conversion of units and applied problems. FPS, CGS, MKS and SI units Plotting and reading of simple graph. Ratio and Percentage Direct Indirect Calculate the Percentage of Metal removal by machining and metal added by welding Trigonometry: trigonometrically ratios and simple formulae, calculate the area of triangle by using trigonometry and application of Pythagoras theorem, calculate height and distance by using trigonometry. Definition Force, Pressure, and their units, problems simple machines Classification of ferrous and nonferrous metal and alloys. Physical and mechanical properties of metal Meaning of H.P., I.H.P., B.H.P., and F.H.P. and CC and Torque. Engineering Drawing Introduction to Engineering Drawing and its importance. Different types of standards used in engineering drawing.
Practice : Layout of drawing sheet Types of lines Thickness, shade of lines and its General applications. Draw figures involving horizontal, vertical and inclined lines Type of Angle, Triangles and their types. Lettering styles- Single stroke letters, Gothic letters as per IS standard. Lettering practice Dimensioning- Types of dimension, elements of dimensions, Methods of indicating Values, Arrangement and indication of dimensions. Free hand sketching of straight lines, rectangular, circles, squares, Polygons, ellipse. Prepare proportionate free hand sketches of plane figures. Sketch horizontal, vertical and inclined line by free hand, Draw circles by free hand using square and radial line method, Draw arcs and ellipse by free hand Auto Paint repair Auto Paint repair Practice health & safetyfamiliarize and practice Proper use, maintain and store tools, equipments, Consumables clothing safety Safety precautions and first aid. Proper use, care and maintenance of tools and equipments. Basic of Automobiles, Introduction to Automotive Terms Practice on removing paint from the damaged area Practice on mixing and applying Familiarization with various components of car & their functions - Battery, Tire, Spark plug, Injector, Oil filter, fuel filter, Air
body filler filter, Engine oil, coolant etc. Practice on sanding(block) Practice on mixing and applying putty Practice on applying primer Basics of Electricity - Electricity principals, Ground connections, Ohms law, Voltage current & Resistance measurement using Multimeter Practice on feather edge sanding and masking Base coat application Surface cleaning and degreasing Practice on spray gun adjustments - testing spray pattern, gun direction, spray overlap, spray gun handling, gun speed, gun triggering etc. Second and third coat application Personal Protective Equipments used in Painting Process: Importance of PPE's, General Protection - Usage of Painting clothes (lint free), Eye Protection - Safety glasses, Foot Protection - Safety shoes, Hearing Protection - Ear Plugs, Respirator Masks - coding system, Respirators fitting and maintenance, Respirators Inspection, Hand Protection - Nitrile & Cotton gloves, Storage of PPE's Preheating the vehicle and cooling Cutting, scuffing, rubbing and polishing Inspecting the painted area Paint Basics: Components of Paint - Binder/Resin, Pigments, Additives, Hardener & Solvents, Paint drying mechanisms, Paint drying process, function of paint, Anti-chip coatings, identifying paint film thickness using Elcometer, Paint shop repair process, Storage of Paint products, Waste Management guidelines, Fire risks & prevention, Fire extinguisher classification. Refinishing Materials: Familiarization with refinishing materials like Paints, Primer, top coats, Sealant. Composition of Paint - Paint Pigments, Binders, Solvents & Paint Additives, Different type of body fillers, putty - Usage & Application procedure, Familiarization with abrasive material, grit, grit ratings, open and
closed grit coat, grinding discs, sanding paper - hand sanding, masking tapes, masking paper etc. Tools & Equipments used in Paint Repair: Spray Gun: Spray gun and its parts, basic stages of atomization, high volume low pressure spray gun (HVLP), types of spray gun gravity feed, siphon feed, pressure feed. Usage and maintenance. Gun Maintenance: Spray gun cleaning tank, manual spray gun cleaning, spray gun lubrication Paint Booth: Basic components of spray booth - Cabin, Doors, Lightening, and Air handling Unit, Controls, Filtration system, heating system. Air exchange direction - Cross draft or Down draft, Separate spraying & Drying booths, Application booth, Drying booth, Operation, Maintenance, Filters replacement, Alternate Paint drying technology, Fuel & Electricity consumption in Paint booth and how to save them. Air-supplied respirators: - Type of respirators- hood type and the face shield type Other Equipments like - Tack cloth, Painting stands, Paint mixing steel container & scale, Paint strainer, masking tape Surface Preparation: Reason of surface preparation, Abrasives & Sanding - Removal of unwanted material from the surface, Restoring form and shape, gaining a finish, "P" number of abrasive
grits, Progressive sanding, Abrasive papers and discs, Sanding tools - Sanders, Dust extraction unit - orbital sanders, Random orbital sanders, Hand sanding blocks, single action sanders, Dry sanding process using sanders, comparison between wet & dry sanding, surface scuffing & surface cleaning Putty Application: Definition of Polyester putty, Difference between polyester putty & Body Filler, Tools required to mix & apply polyester putty, hardener mixing ratio in polyester putty, application of putty, Defects in polyester putty application Corrosion Elimination & Prevention: Corrosion identification, Corrosion removal & elimination, Tools & equipments required, Work techniques, Metal priming / protection, Anti-corrosion primer/filler/surfacer, drying techniques, sanding & joint sealing, Primer application, sanding, seam sealer application Masking Techniques: Basic ways to mask the parts of a vehicle, need of masking, Masking technique - Masking tape, Masking paper, Masking film (plastic), soft foam masking, wheel masking, masking panel gaps, masking openings, reverse masking, liquid masking Paint Application: Solvent & Water Borne : Paint refinish procedures, Difference between OEM paint & Refinish Paint, Blend repair, top coat, Base coat, clear coat, prime
coat, Preparing refinish materials, Different colour effects, Hardeners or Activators, Application of coats, removal of masking materials