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SYLLABUS OF SEMESTER SYSTEM
FOR THE ROLE OF
Press Operator
(CAPITAL GOODS)
Under
High Employment Potential
Courses through Flexi MOUs
(One Year/Two Semesters)
Designed in
2014
By
Government of India
Ministry of Labour & Employment (DGE&T)
FORMAT
1. Cover Page
2. Title
3. General Information
4. Week wise contents of TT and TP (In tabular form)
5. Tools and Equipment List- Broad Specification
6. List of Consumables
7. Trade Testing and Certification
8. Further Learning Options
9. List of Trade Committee Members
GENERAL INFORMATION
1.Name of the Course Certificate Course in Press Operations 2. N.C.O Code No. 3.Qualification Pack Code No. 4.Duration of Training One Year (Two semesters)
5.Entry Qualification 10th Pass
6.Unit Strength 20 Trainees (Two Batches of 10 Trainees each)
7.Space Norms a) Class room: 30sqm. b) Workshop: 80sqm.
8.Power Norms a) Class room: 1kw (6000lumen) b) Workshop: 2kw (30,000lumen)
9.Job Role: By the end of course the trainee will be able to:-
Study the drawings of incoming components and finished parts and carry out visual inspection
Carry out press set up
Identify press tools corresponding to the part
Perform press operations
Identify proper tool, tool handling and maintenance
Unload the components and carry out inspection/visual using measuring instruments and gauges
Identify problems and escalate as per the defined procedure
Conduct himself as per the guidelines related to behaviour and attitude for the industrial environment
Communicate effectively as per organisational hierarchy
Follow safety regulations without any deviation
Apply the principles of 5S in the work area
Perform quality checks
Carry out reporting and documentation
10. Instructor’s Qualification Graduate Degree holders in Mechanical Engineering at least2years post qualification experience in Manufacturing (Press Operation).
11.Trainer Qualifications (a) Academic Qualification: (i) Graduate Degree in Mechanical Engineering Or (ii) Diploma in Mechanical Engineering (b) Technical Qualification: (i) Graduate Degree holders in Mechanical Engineering with at least 2years post qualification experience in Manufacturing (Press Operation). Or (ii) Diploma holders in Mechanical Engineering with at least 4years post qualification experience n Manufacturing (Press Operation). (c) Desirable Qualification: N/A
Syllabus for the role of Press Operator (Capital Goods)
First Semester (Semester Code No – PRO: SEM-I)
Duration: Six Months
Syllabus for TP01 and TT01
Week wise content Index of First Semester
Sl. No.
Week No.
Contents Heading Duration
Practical Theory
1. 1,2 Introduction to Manufacturing Industry, Overview of the job role of Press Operator, Engineering work place skills
PRO-100 Introduction
2 Week
2. 3 Safety, health and environment PRO-200 SHE
1 Week
3. 4 Engineering materials PRO-300 ENG MAT
1 Week
4. 5 Reading of drawings PRO-400 REA DRA
1 Week
5. 6 Material handling PRO-500 MAT HAN
1 Week
6. 7 Press working terminology PRO-600 PRS TER
1 Week
7. 8, 9 Machines used in press shop PRO-700 MAC PRS
2 Weeks
8. 10, 11, 12 Press operation PRO-800 PRS OPR
3 Weeks
9. 13 Press tools PRO-900 PRS TLS
1 Week
10. 14 Tool and die sets PRO-1000 TLS DIE
1 Week
14. 15 to 23 OJT / Project work/ Site Visit 20+4 Weeks
15. 24 Revision 1 Week
16. 25,26 Examination 2 Weeks
Syllabus for the role of Press Operator (Capital Goods) First Semester (Semester Code No – PRO: SEM-I)
Duration: Six Months
Syllabus for TP01 and TT01
Week No.
Trade Practical
Trade Theory
1,2 Activities pertaining to the following: communication, writing skill, listening skills, presentation skills, time management, grooming, team work, work ethics, identification of safe areas with respect to floor marking, emergency response procedures
Introduction to Manufacturing Industry, Overview of the job role of Press Operator, Engineering work place skills
3 Study of work place to identify the hazards
and suggest mitigation, application of first
aid,
Activities pertaining to health awareness,
identification of hazardous wastes and
disposal as per the norms, activities
pertaining to electrical safety, lock out and
tag out procedures
Safety, health and environment Hazard identification and avoidance of accident,
Electrical safety ,
Preventive measures for electrical accidents,
Disposal procedure of waste materials,
4 Identification and selection of engineering
materials, visual inspection of materials,
measuring and sizing the raw materials,
material testing
Engineering materials, commonly used materials, metallurgy, physical and mechanical properties of materials, selection of materials for components and press tools, material testing,
5 Study and interpretation of engineering
drawings, preparation of engineering
drawings
Reading of drawings, types and formats of engineering drawings, graphic language and symbols of engineering drawing, dimensioning, isometric and orthographic projections, sectional views and shop floor drawings
6 Activities pertaining to manual handling
and material handling equipment viz
hydraulic trolley, forklift etc,.
Material handling, manual handling, material handling equipment, loading and unloading practices, safe operations in shop environment
7 Preparation of machinery sketches
identifying the parts, explaining the parts
and functions of presses, activities
pertaining to safe operations
Press working terminology, blanking, drawing etc; parts of press, functional description, working principle, definition of stroke, shut height and die space, safety features
8, 9 Operations of machines in press shop,
operation of tool sharpening machinery Machines used in press shop, ,mechanical and hydraulic presses, tool sharpening machinery, accessories for press working machinery
10, 11, 12
Operation of various types of presses to
manufacture various components meeting
the quality and productivity norms, Press operation, operation of manual, NC, and CNC presses, safe operations, study of SOP
13 Selection of proper press tools, tool fitting,
activities pertaining to proper tool storage,
report on tool manufacturing and heat
treatment
Press tools, types of press tools, application of press tools, manufacturing and heat treatment of press tools, tool storage
14 Selection of proper tool and die sets, tool
fitting, activities pertaining to proper tool
and die sets storage, report on tool and
die sets manufacturing and heat treatment
Tool and die sets, types of tool and die sets, application of tool and die sets, manufacturing and heat treatment of tool and die sets, tool and die sets storage
15 to 23
Site visit/OJT /Practical’s
24
Revision
25, 26
Examination
Syllabus for the role of Press Operator (Capital Goods)
Second Semester (Semester Code No – PRO: SEM-II)
Duration: Six Months
Syllabus for TP02 and TT02
Week wise content Index of Second Semester
Sl. No.
Week No.
Contents Heading Duration
Practical Theory
1. 1
Cutting forces during press work
PRO-1100 CUT PRS
1 Week
2. 2 Handling and maintenance of press tools PRO-1200 CRE MNT
1 Week
3. 3
Introduction to press tool design PRO-1300 PRS TLD
1Week
4. 4, 5,
Introduction to tool and die making PRO-1400 INT TDM
2 Weeks
5. 6 Quality inspection PRO-1500 PRS QUT
1 Week
6. 7 Productivity PRO-1600 PRS PRO
1 Week
7. 8 Reporting and documentation PRO-1700 PRS DOC
1 Week
8. 9 to 23 OJT /Project work/Site Visit 9+16Weeks
9. 24 Revision 1 Week
10. 25,26 Examination 2 Weeks
Syllabus for the role of Press Operator (Capital Goods)
Second Semester (Semester Code No – PRO: SEM-II)
Duration: Six Months
Syllabus for TP02 and TT02
Week No.
Trade Practical
Trade Theory
1 Exercises in estimation of cutting forces,
study of factors affecting cutting forces,
preparation of chart relating tool
geometry and cutting process
Cutting forces during press work, estimation of
cutting forces, factors affecting cutting forces,
influence of tool geometry on cutting forces
2 Identification of defects in tools, practice
proper storage of tools on rack Handling and maintenance of press tools
3 Preparation of tool sketches, write-up on
press tool design, preparation of tool
drawings
Introduction to press tool design
4, 5 Report on tool and die making process,
practice tool and die making
Introduction to tool and die making
6 Use of measuring instruments,
equipment and gauges, practice visual
inspection, follow the quality working
instruction manuals,
Quality, importance of quality, defects in components, root cause analysis, quality management system, quality working instructions, quality circles, measuring instruments ,equipment and gauges, calibration of instruments
7 List hourly production rate of presses in
the shop, list factors affecting
productivity along with suggestions to
improve productivity, follow the SOP to
ensure productivity, calculation of scrap
wastage
Productivity, factors effecting productivity, production norms, components of cycle time, machine utilization, standard operating procedures
8 Study of all the reports pertaining to
production and quality, practice filling up
the documents related to shop floor
operations, maintain the documents, as
per the industry norms
Reporting and documentation ,reporting on production status, quality of inputs, error messages during the operation of the machines, conditions of machine and accessories ,defects in finished parts etc; and documentation as per the company norms
9 to 23
Working in press shop manufacturing
components meeting the quality and
productivity norms, OJT/Project work/Site Visit
24
Revision
25, 26
Examination
LIST OF TOOLS & EQUIPMENT
SL.
No.
Name of items Quantity
1. PPE 5 Sets
2. Basic tool kit 5 Sets
3. Fire extinguisher 1
4. First aid kit 1
5. Measuring tool set 5
6. Material Testing equipment
7. Desktop with Auto CAD software 2
8. Bending press* 1
9. Punching press* 1
10.
Tool and cutter grinder* 1
11 Machines used for tool and die making* (Drilling, milling, shaping, turning and grinding)
1
12 Hydraulic trolley, forklift 1 each
* Will be provided as part of OJT along with materials and consumables
Trade Testing and Certification
As per the NCVT norms
Further Learning Options Upon successful completion of this Course the candidate will be eligible for attending the advanced Courses in Press Operation.
List of Trade Committee Members Sl.No NAME&DESIGNATIONS
/SHRI REPRESENTING ORGANIZATION
REMARKS
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