SECTOR - CAPITAL GOODS & MANUFACTURING · Ramesh Babu N, Professor IIT Madras, Chennai Member 11. Bharat Heavy Electricals Ltd, R.K. Sridharan, Manager/HRDC Ranipet, Tamil Nadu Member

Machinist & Operator Advance Machine Tool (CITS)

GOVERNMENT OF INDIA

Ministry of Skill Development & Entrepreneurship Directorate General of Training

CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE EN-81, Sector-V, Salt Lake City, Kolkata – 700091

NSQF LEVEL - 6

SECTOR - CAPITAL GOODS & MANUFACTURING


Machinist & Operator Advance Machine Tool

(Engineering Trade)

SECTOR - CAPITAL GOODS & MANUFACTURING

(Revised in 2019)

CRAFT INSTRUCTOR TRAINING SCHEME (CITS)

NSQF LEVEL - 6

Developed By

Ministry of Skill Development and Entrepreneurship

Directorate General of Training

CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE EN-81, Sector-V, Salt Lake City, Kolkata – 700 091


The DGT sincerely acknowledges contributions of the Industries, State Directorates, Trade

Experts, Domain Experts and all others who contributed in revising the curriculum. Special

acknowledgement is extended by DGT to the expert members who had contributed

immensely in this curriculum.

List of Expert members participated for finalizing the course curricula of Machinist & Operator Advance Machine Tool - CITS

S No.

Name & Designation Sh/Mr/Ms

Organization Remarks

Members of Sector Mentor council

1. A. D. Shahane, Vice-President,

(Corporate Trg.)

Larsen & Tourbo Ltd.,

Mumbai:400001

Chairman

2. Dr. P.K.Jain, Professor IIT, Roorkee, Roorkee-247667,

Uttarakhand

Member

3. N. Ramakrishnan, Professor IIT Gandhinagar, Gujarat-382424 Member

4. Dr. P.V. Rao, Professor IIT Delhi, New Delhi-110016 Member

5. Dr. Debdas Roy, Asstt. Professor NIFFT, Hatia, Ranchi-834003,

Jharkhand

Member

6. Dr. Anil Kumar Singh, Professor NIFFT, Hatia, Ranchi-834003,

Jharkhand

Member

7. Dr. P.P. Bandyopadhyay Professor IIT Kharagpur, Kharagpur-

721302, West Bengal

Member

8. Dr. P.K. Ray, Professor IIT Kharagpur, Kharagpur-

721302, West Bengal

Member

9. S. S. Maity, MD Central Tool Room & Training

Centre (CTTC), Bhubaneswar

Member

10. Dr. Ramesh Babu N, Professor IIT Madras, Chennai Member

11. R.K. Sridharan,

Manager/HRDC

Bharat Heavy Electricals Ltd,

Ranipet, Tamil Nadu

Member

12. N. Krishna Murthy Principal

Scientific Officer

CQA(Heavy Vehicles), DGQA,

Chennai, Tamil Nadu

Member

13. Sunil Khodke Training

Manager

Bobst India Pvt. Ltd., Pune Member

14. Ajay Dhuri TATA Motors, Pune Member

15. Uday Apte TATA Motors, Pune Member

16. H B Jagadeesh, Sr. Manager HMT, Bengaluru Member

17. K Venugopal

Director & COO

NTTF, Peenya, Bengaluru Member

18. B.A. Damahe, Principal L&T

Institute of Technology

L&T Institute of Technology,

Mumbai

Member

19. Lakshmanan. R

Senior Manager

BOSCH Ltd., Bengaluru Member

ACKNOWLEDGEMENT


20. R C Agnihotri

Principal

Indo- Swiss Training Centre

Chandigarh, 160030

Member

Mentor

21. Sunil Kumar Gupta (Director) DGET HQ, New Delhi. Mentor

Members of Core Group

22. N. Nath. (ADT) CSTARI, Kolkata Co-ordinator

23. H. Charles (TO) NIMI, Chennai. Member

24. Sukhdev Singh (JDT) ATI Kanpur Team Leader

25. Ravi Pandey (V.I) ATI Kanpur Member

26. A.K. Nasakar (T.O) ATI Kolkata Member

27. Samir Sarkar (T.O) ATI Kolkata Member

28. J. Ram Eswara Rao (T.O) RDAT Hyderabad Member

29. T.G. Kadam (T.O) ATI Mumbai Member

30. K. Mahendar (DDT) ATI Chennai Member

31. Shrikant S Sonnavane (T.O) ATI Mumbai Member

32. K. Nagasrinivas

(DDT)

ATI Hyderabad Member

33. G.N. Eswarappa (DDT) FTI Bangalore Member

34. G. Govindan, Sr.

Draughtsman

ATI Chennai Member

35. M.N. Renukaradhya, Dy.

Director/Principal Grade I.,

Govt. ITI, Tumkur Road,

Banglore, Karnataka

Member

36. B.V. Venkatesh Reddy. JTO Govt. ITI, Tumkur Road,

Banglore, Karnataka

Member

37. N.M. Kajale, Principal, Govt. ITI Velhe, Distt: Pune,

Maharashtra

Member

38. Subrata Polley, Instructor ITI Howrah Homes, West Bengal Member

39. VINOD KUMAR.R Sr.

Instructor

Govt.ITI Dhanuvachapuram

Trivendrum, Dist., Kerala

Member

40. M. Anbalagan, B.E., Assistant

Training Officer

Govt. ITI Coimbatore, Tamil

Nadu

Member

41. K. Lakshmi Narayanan, T.O. DET, Tamil Nadu Member

Other industry representatives

42. Venugopal Parvatikar Skill Sonics, Bangalore Member

43. Venkata Dasari Skill Sonics, Bangalore Member

44. Srihari, D CADEM Tech. Pvt. Ltd.,

Bengaluru

Member

45. Dasarathi. G.V. CADEM Tech. Pvt. Ltd.,

Bengaluru

Member

46. L.R.S. Mani Ohm Shakti Industries, Bengaluru Member


S No. Topics Page No.

1. Course Overview 1

2. Training System 2-5

3. General Information 6-7

4. Job Role 8

5. Learning Outcome 9-11

6. Course Content

Trade Technology 12-21

Engineering Technology 22-26

Training Methodology 27-34

7. Assessment Criteria 35-43

8. Infrastructure 44-50

9. Annexure I - Format for Internal Assessment 51

CONTENTS

1


The Craft Instructor Training Scheme is operational since inception of the Craftsmen

Training Scheme. The first Craft Instructor Training Institute was established in 1948.

Subsequently, 6 more institutes namely, Central Training Institute for Instructors (now

called as National Skill Training Institute (NSTI)), NSTI at Ludhiana, Kanpur, Howrah,

Mumbai, Chennai and Hyderabad were established in 1960 by DGT. Since then the CITS

course is successfully running in all the NSTIs across India as well as in NCVT affiliated

institutes viz. Institutes for Training of Trainers (IToT). This is a competency based course for

instructors of one year duration. “Machinist & Operator Advance Machine Tool” CITS trade

is applicable for Instructors of “Machinist” & “Operator Advanced Machine Tool

Maintenance” CTS Trades.

The main objective of Crafts Instructor training programme is to enable Instructors

explore different aspects of the techniques in pedagogy and transferring of hands-on skills

so as to develop a pool of skilled manpower for industries, also leading to their career

growth & benefiting society at large. Thus promoting a holistic learning experience where

trainee acquires specialized knowledge, skills & develops attitude towards learning &

contributing in vocational training ecosystem.

This course also enables the instructors to develop instructional skills for mentoring

the trainees, engaging all trainees in learning process and managing effective utilization of

resources. It emphasizes on the importance of collaborative learning & innovative ways of

doing things. All trainees will be able to understand and interpret the course content in right

perspective, so that they are engaged in & empowered by their learning experiences and

above all, ensure quality delivery.

1. COURSE OVERVIEW

https://www.teamlease.com/operator-advanced-machine-tool-maintenance-jobs



2


2.1 GENERAL

CITS courses are delivered in National Skill Training Institutes (NSTIs) &NCVT

affiliated institutes viz., Institutes for Training of Trainers (IToT). For detailed guidelines

regarding admission on CITS, instructions issued by DGT from time to time are to be

observed. The course is of one-year duration. It consists of Trade Technology (Trade skills

and Trade knowledge), Training Methodology and Engineering Technology/ Vocational

science/ Soft skills. After successful completion of the training program, the trainees appear

in All India Trade Test for Craft Instructor. The successful trainee is awarded CITS certificate

by NCVT.

2.2 COURSE STRUCTURE

Table below depicts the distribution of training hours across various course elements during a period of one year:

S No. Course Element Notional Training Hours

1. Trade Technology

Professional Skill (Trade Practical) 704

Professional Knowledge (Trade Theory) 220

2. Engineering Technology

Workshop Calculation & Science 88

Engineering Drawing 132

3. Training Methodology

TM Practical 352

TM Theory 220

4. Library 44

5. Project Work/ Industrial visit 160

6. Revision & Examination 160

Total 2080

2.3 CAREER PROGRESSION PATHWAYS

Can join as an Instructor in a vocational training Institute/ technical Institute.

Can join as a supervisor in Industries.

2.4 ASSESSMENT & CERTIFICATION

The CITS trainee will be assessed for his/her Instructional skills, knowledge and attitude towards learning throughout the course span and also at the end of the training program.

2. TRAINING SYSTEM

3


a) The Internal Assessment during the period of training will be done by Formative Assessment Method to test competency of instructor with respect to assessment criteria set against each learning outcomes. The training institute has to maintain an individual trainee portfolio in line with assessment guidelines. The marks of internal assessment will be as per the template provided in Annexure – I. b) The Final Assessment will be in the form of Summative Assessment Method. The All India Trade Test for awarding National Craft Instructor Certificate will be conducted by NCVT at the end of the year as per the guidelines of DGT. The learning outcome and assessment criteria will be the basis for setting question papers for final assessment. The external examiner during final examination will also check the individual trainee’s profile as detailed in assessment guideline before giving marks for practical examination.

2.4.1 PASS CRITERIA

S No.

Subject Marks Internal

assessment Full

Marks

Pass Marks

Exam Internal

assessment

1. Trade Technology

Trade Theory

100 40 140 60 24

2. Trade Practical

200 60 260 120 36

3. Engineering Technology

Workshop Cal. & Sc.

50 25 75 30 15

4. Engineering Drawing

50 25 75 30 15

5. Training Methodology

TM Practical

200 30 230 120 18

6. TM Theory 100 20 120 60 12

Total Marks 700 200 900 420 120

The minimum pass percentage for practical exam is 60% & minimum pass

percentage of theory subjects is 60%.

2.4.2 ASSESSMENT GUIDELINE

Appropriate arrangements should be made to ensure that there will be no artificial barriers to assessment. The nature of special needs should be taken into account while undertaking the assessment. While assessing the major factors to be considered are approaches to generate solutions to specific problems by involving standard/non-standard practices.

Due consideration should also be given while assessing for teamwork,

avoidance/reduction of scrap/wastage and disposal of scrap/waste as per procedure, behavioral attitude, sensitivity to the environment and regularity in training. The sensitivity towards OSHE and self-learning attitude are to be considered while assessing competency. Assessment will be evidence based comprising of the following:

4


Demonstration of Instructional Skills (Lesson Plan, Demonstration Plan)

Record book/daily diary

Assessment Sheet

Progress chart

Video Recording

Attendance and punctuality

Viva-voce

Practical work done/Models

Assignments

Project work

Evidences of internal assessments are to be preserved until forthcoming yearly examination for audit and verification by examining body. The following marking pattern to be adopted while assessing:

Performance Level Evidence

(a) Weightage in the range of 60%-75% to be allotted during assessment

For performance in this grade, the candidate should be well versed with instructional design, implement learning programme and assess learners which demonstrates attainment of an acceptable standard of crafts instructorship with occasional guidance and engage students by demonstrating good attributes of a trainer.

Demonstration of fairly good skill to establish a rapport with audience, presentation in orderly manner and establish as an expert in the field.

Average engagement of students for learning and achievement of goals while undertaking the training on specific topic.

A fairly good level of competency in expressing each concept in terms the student can relate, draw analogy and summarize the entire lesson.

Occasional support in imparting effective training.

(b) Weightage in the range of 75%-90% to be allotted during assessment

For performance in this grade, the candidate should be well versed with instructional design, implement learning programme and assess learners which demonstrates attainment of a reasonable standard of crafts instructorship with little guidance and engage students by demonstrating good attributes of a trainer.

Demonstration of good skill to establish a rapport with audience, presentation in orderly manner and establish as an expert in the field.

Above average in engagement of students for learning and achievement of goals while undertaking the training on specific topic.

A good level of competency in expressing each concept in terms the student can relate, draw analogy and summarize the entire lesson.

Little support in imparting effective training.

(c) Weightage in the range of more than 90% to be allotted during assessment

For performance in this grade, the candidate should be well versed with

Demonstration of high skill level to establish a rapport with audience, presentation in

5


instructional design, implement learning programme and assess learners which demonstrates attainment of a high standard of crafts instructorship with minimal or no support and engage students by demonstrating good attributes of a trainer.

orderly manner and establish as an expert in the field.

Good engagement of students for learning and achievement of goals while undertaking the training on specific topic.

A high level of competency in expressing each concept in terms the student can relate, draw analogy and summarize the entire lesson.

Minimal or no support in imparting effective training.

6


Name of the Trade Machinist & Operator Advance Machine Tool - CITS

Reference NCO 2015 2356.0100, 7223.0500

NSQF Level Level-6

Duration of Craft Instructor Training

One Year

Unit Strength (No. Of

Student) 20

Entry Qualification

Diploma/Degree in Mechanical/ Production/ Metallurgy / Mechatronics Engineering from AICTE recognized Board / University.

OR

National Trade Certificate in the relevant trade

OR

National Apprenticeship Certificate in the relevant trade

Space Norms 120 Sq. m

Power Norms 21 KW

Instructors Qualification for

1. Machinist &

Operator Advance

Machine Tool - CITS

Trade

Degree / Diploma in Mechanical / Production Engineering from AICTE recognized Board / University with two / five year experience respectively.

OR NTC/ NAC passed in the relevant trade with seven years experience in relevant field. Essential: Craft Instructor Certificate in relevant Trade under NCVT.

2. Workshop

Calculation & Science

Degree in any Engineering discipline with two years experience in relevant field.

OR Diploma in any Engineering discipline with five years experience in relevant field.

OR NTC/ NAC in the related trade with seven years experience in relevant field. Essential: Craft Instructor Certificate in RoDA Trade.

3. Engineering

Drawing

Degree in any branch of Mechanical Engineering with two years experience in relevant field.

OR

3. GENERAL INFORMATION

7


Diploma in any branch of Mechanical Engineering with five years experience in relevant field.

OR NTC/ NAC in the Draughtsman Mechanical/ Relevant trade with seven years experience in relevant field. Essential: Craft Instructor Certificate in RoDA Trade.

4. Training

Methodology

Degree in any engineering discipline with two years experience in relevant field.

OR Diploma in any engineering discipline with five years experience in relevant field.

Essential: Craft Instructor Certificate in the relevant Trade under NCVT.

Distribution of training on Hourly basis: (Indicative only)

Total Hrs /week

Trade Practical

Trade Theory

Workshop Cal. & Sc.

Engg. Drawing

TM Practical

TM Theory

Library

40 Hours 16 Hours 5 Hours 2 Hours 3 Hours 8 Hours 5Hours 1 Hour

8


Brief description of job roles: Manual Training Teacher/Craft Instructor; instructs students in ITIs/Vocational Training Institutes in respective trades as per defined job role. Imparts theoretical instructions for the use of tools & equipment of related trades and related subjects. Demonstrate process and operations related to the trade in the workshop; supervises, assesses and evaluates students in their practical work. Ensures availability & proper functioning of equipment and tools in stores.

The advanced machine operator performs various types of power driven metal

cutting or grinding machines for cutting and grinding metal. Studies drawings or measures

out sample with appropriate measuring instruments to note different dimensions and

sequence of operations required. Selects metal piece and marks it or gets it marked for

machining operations required. Fastens metal in chuck, jig or other fixture and respective

tool or cutter, according to sequence of operation, on appropriate machine (lathe, shaper,

milling, slotting, drilling, grinding).Checks machine setting or sets it for stipulated machine

operations. Selects machine feed and speed and starts machine. Controls flow of coolant

(cutting lubricant) and manipulates hand wheels or applies automatic controls to feed tool

to metal or metal to tool. Observes cutting or grinding both from marking and machine

readings, checks for dimensions as necessary and removes parts when machining is

completed, checks completed part with measuring instruments and gauges to ensure

prescribed accuracy. Makes adjustments if necessary and repeats operations, as required,

on same or other machines. May assist in setting up machine for repetitive work, change

tools, make simple adjustments, clean and oil machine. Does process planning, tool and

cutting parameters selection, programming, setup and operation for cutting parts on CNC

vertical machining center and CNC lathe.

Reference NCO:

a) 2356.0100 - Manual Training Teacher/Craft Instructor / NA b) 7223.0500 - Mechanist, General/Machinist / NA

4. JOB ROLE

9


Learning outcomes are a reflection of total competencies of a trainee and assessment

will be carried out as per the assessment criteria.

5.1 TRADE TECHNOLOGY

1. Demonstrate workshop safety measures and monitor job as per specification

perform different types of filing jobs, pedestal grinder operations and check for

dimensional accuracy by using appropriate measuring and checking instruments.

2. Plan and manage the work to make jobs as per requirement selecting different

operations ensuring accuracy by using appropriate measuring instruments [power

saw machine operation, external and internal thread cutting (using tap and die),

demonstrate reaming (manual/ on machine), counter-boring, counter-sinking].

3. Plan, organize and perform various jobs by selection of appropriate operation, tools,

accessories, attachments and processes like making flat surface, angular surface,

slot, formed surfaces, dovetail and T-slots etc. on shaping machine. Assess accuracy

using appropriate measuring instruments.

4. Monitor & supervise work to ensure correct functional operation, selection of

appropriate tools, accessories, attachments and processes like making of flat surface,

angular surface, slot, formed surfaces, dovetail and T-slots etc. on Planer machine.

Check accuracy using appropriate measuring instruments.

5. Identify slotting machine parts, mechanisms & their functions. Conduct & review

various jobs on slotting machine. Evaluate accuracy with appropriate instruments.

[Key-way cutting, regular and irregular polygon, spline cutting etc.].

6. Identify lathe machine parts, mechanisms & their functions. Perform & review

various jobs on lathe machine. Assess accuracy with appropriate instruments. [Plain

turning, facing, taper turning, step turning, drilling & boring, knurling, thread cutting

external and internal etc.].

7. Identify milling machine parts, mechanisms & their functions. Plan, organize and

make various jobs by selection of appropriate operation, tools, accessories,

attachments and processes on milling machine. Check accuracy with appropriate

instruments. [Face milling, slot milling, gang milling, angular milling, end milling and

process of up & down milling etc.].

8. Demonstrate parts of vertical milling machine, mechanisms & their functions.

Monitor selection of appropriate operation, tools, accessories, attachments and

processes on vertical milling machine. Check accuracy with appropriate instruments.

[Operation: -slot milling, end milling, pocket milling, dovetail, T-slot milling and cam

profile milling etc.]

9. Plan and perform simple repair, overhauling of different machines used in machinist

section and Check for functionality. [Cleaning, oiling, greasing, belt replacement and

setting etc.].

5. LEARNING OUTCOME

10


10. Demonstrate various types of grinding on jobs using different types of grinding

machines (surface and cylindrical grinder etc.). Explain wheel Mounting, balancing,

dressing & truing and other setting for surface / cylindrical grinder. Explain Honing

and lapping and its practice. Check accuracy with appropriate instruments. [Surface

grinding, angular grinding, cylindrical grinding, step and camshaft grinding etc.].

11. Execute and monitor operations of sharpening/ re-sharpening different cutting tools

and cutters using tool and cutter grinder. Check accuracy with appropriate

instruments. [Plain milling cutter, side & face milling cutter, angular cutter, end mill

etc.].

12. Analyze & set different machining parameters and cutters to prepare components by

performing different milling operation with indexing. [Different machining

parameters – feed, speed and depth of cut. Different components – Rack, Spur Gear,

External Spline, Clutch, Helical Gear, bevel gear, cam profile, worm & worm wheel].

13. Demonstrate operations on machines and check components and its functioning.

[Machines: - EDM, Gear Shaper, Gear Hobber, Jig Boring, Broaching and CMM].

14. Plan, and perform setting of job and tool in CNC turning centre/ CNC machining

centre. Produce components through various modes of operations, prepare/ edit

part program, simulation and execution as per drawing/ requirement. [face milling

and drilling application, tool selection and setting on machine, tool offset].

5.2 ENGINEERING TECHNOLOGY

15. Demonstrate basic mathematical concept and principles to perform practical

operations.

16. Explain basic science in the field of study including simple machines.

17. Apply engineering drawing for different application in the field of work.

5.3 TRAINING METHODOLOGY 18. Plan & prepare the learners for the class using basics of educational psychology &

motivational techniques. 19. Analyze the syllabus of the Course.

20. Plan & prepare the training session using various methods viz. 4 step method,

question & questioning technique etc.

21. Communicate effectively with the trainees both verbally and non-verbally.

22. Use Instructional Technology & facilitate the training program.

23. Design written instructional materials and implement for imparting training.

24. Assess, evaluate and certify the tests.

25. Organize workshop and classroom learning observing instructional methods.

26. Counsel & mentor the trainees by identifying their Strength & Weaknesses.

27. Develop Entrepreneurship skills.

28. Apply ICT & Internet in training (computer based training) and various types of

Distance learning programmes.

29. Plan and conduct sessions to impart competency based skills and knowledge.

11


30. Apply Adult Learning Principles.

31. Develop and implement continuous professional development plan.

12


SYLLABUS - MACHINIST & OPERATOR ADVANCE MACHINE TOOL (CITS)

TRADE TECHNOLOGY

Week No.

Reference Learning Outcome

Professional Skills (Trade Practical)

Professional Knowledge (Trade Theory)

1-2 Demonstrate workshop

safety measures and

monitor job as per

specification perform

different types of filing

jobs, pedestal grinder

operations and check

for dimensional

accuracy by using

appropriate measuring

and checking

instruments.

Occupational Safety & Health Importance of housekeeping & good shop floor practices. 1. Follow Health, Safety and

Environment guidelines, legislations & regulations as applicable.

2. Dispose as per procedure of waste materials like cotton waste, metal chips/burrs etc. Basic safety introduction, Personal protective Equipments (PPE):-

3. Ensure Basic injury prevention, Basic first aid, Hazard identification and avoidance, safety signs for Danger, Warning, caution & personal safety message.

4. Use Preventive measures for electrical accidents & steps to be taken in such accidents.

5. Use Fire extinguishers. Technical English: 6. Prepare different types of

documentation as per industrial need by different methods of recording information.

Basic Life support training: 7. Be able to perform DRSABCD:

D: Check for Danger R: Check for a Response S: Send for help A: Open the Airway B: Check for normal

Breathing C: Perform CPR (Cardio

Pulmonary Resuscitation) D: Attach Defibrillator /

Monitor as soon as available.

Introduction of First aid. Operation of electrical mains. Introduction of PPEs. Response to emergencies e.g.; power failure, fire, and system failure Soft Skills: its importance and Job area after completion of training. Introduction to 5S concept & its application. Importance of 5S implementation throughout CITS course-workplace cleaning, machine cleaning, signage, proper storage of equipment etc. Importance of Technical English terms used in industry -(in simple definition only)Technical forms, process charts, activity logs, in required formats of industry, estimation, cycle time, productivity reports, job cards. Basic Life support (BLS):- Basic Life Support (BLS) techniques for drowning, choking, electrocution, neck and spinal injury, including CPR (cardiopulmonary resuscitation). Introduction of Basic Hand Tools and Cutting Tools. Linear measurement: - a) Line standard b) End standard. Precision Measuring Instruments like Vernier Calliper,

Micrometers height Gauge

etc with their parts, principle,

reading, application, least

count, application of Dial Test

Indicator, care and maintenance

6. COURSE CONTENT

13


8. Illustrate different types of

machines and safety related to each machines.

9. Perform Filing job including flatness, Squareness and parallelness. Material identification.

10. Review care and maintenance of measuring tools like Vernier calipers, steel rule, try square, vernier micrometer, height gauge, combination set etc.

11. Demonstrate handling of measuring instruments, checking of zero error, finding of least count.

3

-do-

12. Demonstrate and practice on Pedestal grinders. Safety, selection, use of grinding wheels.

13. Assess & monitor precision job for fitting machining, grinding.

14. Demonstrate and practice on twist drill bit grinding.

Concept of interchange ability, Elements of interchangeable System Types of fit - clearance, transition, interference, selective assembly- definition & function, Hole basis system, shaft basis system.

4 Plan and manage the work to make jobs as per requirement selecting different operations ensuring accuracy by using appropriate measuring instruments [power saw machine operation, external and internal thread cutting (using tap and die), demonstrate reaming (manual/ on machine), counter-boring, counter-sinking].

15. Perform & evaluate raw material cutting as per size in Power Hacksaw machine.

16. Plan & perform internal and external thread making with the use of Tap and Die.

17. Use Hand Reamer and machine reamer.

Surface Finish and Symbols. Power Transmission - Classification, types, elements, individual vs. group drive. Related to various machine tools.

5

-Do-

18. Practice on Drilling, Counter sinking, counter boring, use of hand reamer and machine reamer.

Drilling Machine- Specifications and types Constructions - pillar drill and radial drill. Different operation in drilling machine Drill - nomenclature, types Reamers - types, nomenclature Tap drill size, calculation

14


Cutting speed, feed, depth of cut, drilling time, calculations.

6

-Do-

19. Demonstrate Work holding devices - drill jig, vice, V-block, direct clamping on table.

20. Check accuracy of different types of tool holding devices.

Practice on Drilling, Counter sinking, Counter boring

7 Plan, organize and perform various jobs by selection of appropriate operation, tools, accessories, attachments and processes like making flat surface, angular surface, slot, formed surfaces, dovetail and T-slots etc. on shaping machine. Assess accuracy using appropriate measuring instruments.

21. Demonstrate and practice on various chip formation process on shaper operations like - Flat surface, Angular surface, Slot, Formed surface etc.

Cutting tools materials-HCS,HSS, Tungsten carbide, coated carbide, ceramics - Properties and uses - Cutting tool life -Equation for cutting tool life - Factors affecting on cutting tool life. Tool failure reasons, Cutting tool classifications, nomenclature of a single point cutting tool, tool angles and its influence. Machinability, classification in Cutting tool.

8

-Do-

22. Demonstrate and practice on shaping machine.

Introduction to Hydraulic drives, need and applications. Hydraulic shaper -Working principle, construction & quick return mechanism.

9

-Do-

23. Plan & organize shaping Contours with form Tools Shaping a 'V' Block.

24. Demonstrate cutting Keyways in a bush (internal) T-slots etc.

Shaper Machine: Construction, types and parts. Specification of Shaper and applications. Crank slotted link mechanism (adjustment of length of stroke &position of stroke). Quick Return Mechanism.

10 Monitor & supervise work to ensure correct functional operation, selection of appropriate tools, accessories, attachments and processes like making of flat surface, angular surface, slot, formed surfaces, dovetail and T-slots etc. on Planer machine. Check accuracy using appropriate measuring

25. Demonstrate and practice on planning machine.

Planning m/c- Specifications, construction & types. Quick return mechanism a) Open & Cross belt b) Variable speed.

15


instruments.

11

-Do-

26. Plan a flat Surface, slot cutting, angle cutting on Planner Machine.

Cutting speed, feed, depth of cut & machining time calculation in Shaper & Planer Types of Cutting tool. Job holdings devices - Fixture, Vice, Directly over table. Difference between Planner & Shaper.

12 Identify slotting machine

parts, mechanisms &

their functions. Conduct

& review various jobs on

slotting machine.

Evaluate accuracy with

appropriate

instruments. [Key-way

cutting, regular and

irregular polygon, spline

cutting etc.].

27. Plan & arrange exercises of cutting Key ways.

28. Check machining of Regular Polygon.

29. Check spline fitting on slotting.

Slotting Machine: Specifications, types. Construction & applications. Different types of Tools used

Work and Tool Holding

devices.

13 Identify lathe machine parts, mechanisms & their functions. Perform & review various jobs on lathe machine. Assess accuracy with appropriate instruments. [Plain turning, facing, taper turning, step turning, drilling & boring, knurling, thread cutting external and internal etc.].

30. Plan, perform & assess different operations on lathe.

Lathe Machine: Working principle, types & construction Different parts and their functions Drives - cone pulley, back gear, all geared drive Attachment and accessories Different mechanisms - apron mechanism, feed mechanism

14

-Do-

31. Demonstrate Taper turning by different methods to an accuracy of 0.04 mm

Tool setting in correct center height - effects of rake & clearance angle Different operation on lathe Taper turning methods, working principle and calculations. Thread cutting - Different types, Gear Calculation, Tool Setting, Checking the thread,

16


15

-Do-

32. Review Tool angle measurement, regrinding of cutting tool for orthogonal and oblique cutting.

33. Use the above tool for practical.

Orthogonal and oblique cutting, cutting force, cutting power, Concept of chip formation, types of chips. Built-up edge formation. Coolant used in metal cutting and its applications

16

-Do-

34. Analyze & assess eccentric turning to an accuracy of 0.04 mm.

Definition and calculation of Cutting speed, feed, depth of cut & machining time of lathe.

17

-Do -

35. Plan & organize thread cutting in Lathe Machine - gear calculation, tool setting, measurement of thread sections, arrangement in cutting.

Capstan and turret lathe Need and application of capstan &turret lathe. Comparison between capstan and turret lathe.

18

-Do -

36. Industrial Visit Job holding devices - chucks,

collets, bar feeding

mechanism. Tool holding

devices - roller steady box,

knee tool holder & self-

opening die. 19 Identify milling machine

parts, mechanisms & their functions. Plan, organize and make various jobs by selection of appropriate operation, tools, accessories, attachments and processes on milling machine. Check accuracy with appropriate instruments. [Face milling, slot milling, gang milling, angular milling, end milling and process of up & down milling etc.].

37. Demonstrate and practice on Milling Operations.

38. Monitor & ensure plain milling, step milling to an accuracy of 0.04 mm.

Milling Machine Milling Machine construction, different types, parts and specification. Different accessories and attachments for Milling Machine. Difference between plain milling & universal milling. Cutter holding device, Work holding Devices.

20

-Do-

39. Perform & monitor slot milling, angular milling

Milling processes- Peripheral milling, Up & Down milling, Different type of Milling operations - Face milling, End milling, Straddle milling, Plain milling, Side milling, Angular milling, Gang milling, End milling etc.

17


21 Demonstrate parts of

vertical milling machine,

mechanisms & their

functions. Monitor

selection of appropriate

operation, tools,

accessories,

attachments and

processes on vertical

milling machine. Check

accuracy with

appropriate

instruments.

[Operation: -slot milling,

end milling, pocket

milling, dovetail, T-slot

milling and cam profile

milling etc.]

40. Demonstrate and practice on Vertical Milling Machine.

JIGS & FIXTURE Definition, Purpose, Difference between Jigs & Fixture Locating principle, locating elements, Clamping elements, types of clamp Different types of Jigs and Fixture.

22

-Do -

41. Demonstrate and practice on Milling Operations. T - slot and Dovetail milling

Milling cutters- Types, elements, negative rake cutter (purpose). Cutting speed, feed, depth of cut & machining time calculations.

23-26 Revision

27 Plan and perform simple repair, overhauling of different machines used in machinist section and Check for functionality. [Cleaning, oiling, greasing, belt replacement and setting etc.].

42. Plan & arrange simple Maintenance jobs on the machines used in Machinist Section.

Introduction to General Maintenance, objective, classification (Routine, Breakdown, preventive, emergency etc.) Maintenance planning , planning activities, routine card, critical path scheduling , planned maintenance cycle, spare part planning, standard time for maintenance work.

18


28

-Do-

43. Perform Simple Maintenance jobs on the machines used in Machinist Section.

44. Demonstrate and practice, fitting of different types of milling cutters on different arbores, tool holders and fitting of inserts on cutter/tool holders.

ISO tool nomenclature, tool holders, inserts for tool holders for different operation like plain turning, threading, grooving, and parting-off. Use of collets, adopters, boring bars & precision boring bars. Different types of milling cutters such as face cutter, side & face cutter, angular milling cutter form cutters & insert used on it. Concept of wiper insert in face cutters.

29 Demonstrate various

types of grinding on jobs

using different types of

grinding machines

(surface and cylindrical

grinder etc.). Explain

wheel Mounting,

balancing, dressing &

truing and other setting

for surface / cylindrical

grinder. Explain Honing

and lapping and its

practice. Check accuracy

with appropriate

instruments. [Surface

grinding, angular

grinding, cylindrical

grinding, step and

camshaft grinding etc.].

45. Demonstrate surface grinding.

46. Assess balancing & mounting a grinding wheel, Dressing & Truing.

47. Perform dry run and its importance. Practice on Surface Grinding.

Grinding Machine - Types, Construction, Operations and parts. Specification of a grinding wheel.

30

-Do-

48. Perform & practice cylindrical Grinding

Factors selecting a grinding wheel, inspection of grinding wheel, Balancing & Mounting a grinding wheel Glazing & Loading of wheels. Care & Maintenance of grinding wheel. Dressing & Truing

31

-Do-

49. Execute Honing & Lapping practice.

Honing & Lapping - Principle & Use. Concept of heat treatment of steel & purpose of heat treatment. Iron -carbon diagram

32 -Do- 50. Evaluate Countershaft Introduction to conventional

19


Turning Precision Cylindrical Grinding practice.

and non-conventional Sources of energy. Differentiates between conventional energy and Non-conventional energy. Advantages and disadvantages of non- Conventional energy. Solar energy.

33 Execute and monitor operations of sharpening/ re-sharpening different cutting tools and cutters using tool and cutter grinder. Check accuracy with appropriate instruments. [Plain milling cutter, side & face milling cutter, angular cutter, end mill etc.].

51. Demonstrate Tool and Cutter grinding practice - Plain milling cutter, Side & Face milling cutter, Angular cutter.

52. Visit to heat treatment Industry.

Heat treatment, its objective. Different types of heat treatment process like Annealing, normalizing, hardening, tempering of steel. Purpose & uses of each process. Study of Surface hardening – Carburizing, Nitriding, cyaniding, Flame hardening, Induction hardening principle, purpose & uses.

34 Analyze & set different machining parameters and cutters to prepare components by performing different milling operation with indexing. [Different machining parameters – feed, speed and depth of cut. Different components – Rack, Spur Gear, External Spline, Clutch, Helical Gear, bevel gear, cam profile, worm & worm wheel].

53. Demonstrate and practice on indexing head.

54. Monitor clutch milling operation.

Indexing- Purpose, types, description & working principle, gear cutting with indexing head and calculation.

35

-Do-

55. Perform & assess spur gear milling and rack cutting with simple dividing head and milling machine.

Different methods of Gear Manufacturing process, study and application of dividing head for gear cutting using milling machine.

36

-Do-

56. Plan & perform helical gear cutting, bevel gear cutting.

Types of gear- important terms and definition related to spur gear (pitch, pitch circle, addendum, dedendum, module etc.), velocity ratio, simple gear train, compound gear train, power transmitted

20


by gears, Calculation on spur gear train. Mass production of gear - Gear shaper, Gear Hobber.

37

-Do-

57. Check machining of different types of cams.

Cam - types, application in modern machines, its special advantages, manufacturing processes, calculation for milling different cams.

38 -Do-

58. Practice on machining worm and worm wheel.

Bearing, Comparator gauge- Introduction, construction, types & uses.

39 Demonstrate operations

on machines and check

components and its

functioning. [Machines:

- EDM, Gear Shaper,

Gear Hobber, Jig Boring,

Broaching and CMM]

59. Demonstrate jig boring Machine using audio visual aids.

Jig boring - concept, application and its operation. Development in cutting tool material and effects of alloying elements in cutting tools. Introduction to powder metallurgy & its application and uses.

40 -Do-

60. Practice demonstrations on Gear Shaper and Gear Hobber.

Limit gauge, Sine bar, slip gauge-Introduction, construction, types & uses.

41

-Do-

61. Practice demonstrations on broaching machine

Broaching Machine:

Construction, types, parts,

operation and specifications. Advantage & disadvantage of using a Broaching machine. Broaching tool - Elements, free hand sketch of a Broach tool.

42-43

-Do-

62. Perform demo on EDM using audio visual aids.

Non-Conventional Machining Difference between conventional & non-conventional machining. Different types like - a)EDM b) USM c) ECM d) LBM, and their Application

44

-Do-

63. Plan & arrange an assembly job preparation combining different machining operations.

64. Practice on demonstrations of CMM operation using audio visual aids.

Inspection and Quality Control Inspection, Need and types of inspection. Quality control and quality assurance Meaning and need for quality control Statistical quality control Q.C. curves. Concept of TQM Machine capability studies Surface protection method. Co-ordinate Measuring Machine (CMM) and its function.

21


45 Plan, and perform setting of job and tool in CNC turning centre/ CNC machining centre. Produce components through various modes of operations, prepare/ edit part program, simulation and execution as per drawing/ requirement. [face milling and drilling application, tool selection and setting on machine, tool offset].

65. Identify & select different parts & different drives, accessories, tools of CNC machine.

NUMERICAL CONTROL MACHINE TOOL Introduction, N.C. & C.N.C. M/c Comparison between N.C. & C.N.C. M/c Advantages of C.N.C. M/c Construction and different parts & CNC machine.

46

-Do-

66. Make part-programming and practice on simulation software.

Different types of control system used in CNC Machines Flow Chart for manufacturing Components in CNC Machine

47-48

-Do-

67. Plan & program for face milling and drilling application and setting of job on CNC machine, check tool selection and setting. Edit the program on the machine and manufacturing of components.

Fundamental of manual part programming : Axis identification , Coordinate system, M/c zero, job zero, Reference Zero, G-Codes & M-Codes, Work Offset, Tool Offset. Feed function, Spindle Speed Function, Simple part program.

49-50 INDUSTRIAL VISIT AND RELATED PROJECT WORK

51-52 Revision & Examination

Note: More emphasis to be given on video/real-life pictures during theoretical classes. Some real-life pictures/videos on the skills/ topics taught may be shown to the trainees to give a feel of Industry and their future assignment.

22


CORE SKILLS - ENGINEERING TECHNOLOGY

S No. Workshop Calculation and Science Engineering Drawing

1. Unit: Systems of unit- FPS, CGS, MKS/SI unit, unit of length, Mass and time, Conversion of units. Material Science: properties -Physical & Mechanical, Types -Ferrous & Non-Ferrous, difference between Ferrous and Non-Ferrous metals, introduction of Iron, Cast Iron, Wrought Iron, Steel, difference between Iron and Steel, Alloy steel, carbon steel, stainless steel, Non-Ferrous metals, Non-Ferrous Alloys.

Engineering Drawing: Introduction and its importance. Relationship to other technical drawing types Conventions. Viewing of engineering drawing sheets. Method of Folding of printed Drawing Sheet as per BIS SP:46-2003

2 Fractions: Fractions, Decimal fraction, L.C.M., H.C.F., Multiplication and Division of Fractions and Decimals, conversion of Fraction to Decimal and vice versa. Simple problems using Scientific Calculator. Mass .Weight and Density : Mass, Unit of Mass, Weight, difference between mass and weight, Density, unit of density, specific gravity of metals.

Drawing Instruments : their Standard and uses Drawing board, T-Square, Drafter (Drafting M/c), Set Squares, Protractor. Drawing Instrument Box (Compass, Dividers, Scale, Diagonal Scales etc). Pencils of different Grades, Drawing pins / Clips.

3 Square Root: Square and Square Root, method of finding out square roots, Simple problem using calculator. Ratio & Proportion :

Simple calculation on related problems. Speed and Velocity: Rest and motion, speed, velocity, difference between speed and velocity, acceleration, retardation, equations of motions, simple related problems.

Lines : Definition, types and applications in Drawing as per BIS SP:46-2003. Classification of lines (Hidden, centre, construction, Extension, Dimension, Section). Drawing lines of given length (Straight, curved). Drawing of parallel lines, perpendicular line. Methods of Division of line segment.

4. Percentage: Introduction, Simple calculation. Changing percentage to decimal and fraction and vice-versa. Work, Power and Energy: work, unit of work, power, unit of power, Horse power of engines, mechanical efficiency, energy, use of energy, potential and kinetic energy, examples of potential energy and kinetic energy.

Drawing of Geometrical Figures: Definition, nomenclature and practice of angle measurement and its types, method of bisecting. Triangle - different types - Rectangle, Square, Rhombus, Parallelogram.Circle and its elements.

5. Algebra: Addition, Subtraction, Multiplication, Division, Algebraic formula, Linear equations (with two variables). Heat & Temperature: Heat and temperature, their units, difference between heat and temperature, boiling point, melting point, scale of temperature, relation between different scale of temperature, Thermometer,

Lettering and Numbering as per BIS SP46-2003: - Single Stroke, Double Stroke, inclined, Upper case and Lower case.

23


pyrometer, transmission of heat, conduction, convection, radiation.

6. Mensuration: Area and perimeter of square, rectangle, parallelogram, triangle, circle, semi circle, Volume of solids - cube, cuboid, cylinder and Sphere. Surface area of solids -cube, cuboid, cylinder and Sphere. Basic Electricity: Introduction, use of electricity, how electricity is produced, Types of current_ AC, DC, their comparison, voltage, resistance, their units. Conductor, insulator, Types of connections - series, parallel, electric power, Horse power, energy, unit of electrical energy.

Dimensioning: Definition, types and methods of dimensioning (functional, non-functional and auxiliary). Types of arrowhead. Leader Line with text

7. Trigonometry: Trigonometrical ratios, measurement of angles. Trigonometric tables. Levers and Simple Machines: levers and its types. Simple Machines, Effort and Load, Mechanical Advantage, Velocity Ratio, Efficiency of machine, Relationship between Efficiency, velocity ratio and Mechanical Advantage.

Free hand drawing of: Lines, polygons, ellipse, etc. Geometrical figures and blocks with dimension. Transferring measurement from the given object to the free hand sketches.

8. Number system: decimal and binary, Octal Hexa decimal. BCD code, conversion from decimal to binary and vice-versa, all other conversions. Practice on conversions. Friction: Laws of friction, co- efficient of friction, angle of friction, simple problems related to friction. Lubrication Rectifier: RMS. Maximum, Average values of voltage and current in rectifiers form factor, ripple factor.

Sizes and Layout of Drawing Sheets: Basic principle of Sheet Size. Designation of sizes. Selection of sizes. Title Block, its position and content. Borders and Frames (Orientation marks and graduations). Grid Reference. Item Reference on Drawing Sheet (Item List)

9. Estimation & costing: Simple estimation of the requirement of materials etc. as applicable to the trade. Problems on estimation and costing. Further Mensuration: Volumes of frustums including conical frustums. Graph- Basics, abscissa, co-ordinate etc. Y = mz and Y= mx + c graph

Forces: Resolution and composition of forces. Representation of force by vectors, simple problems on lifting tackles like jib wall,

Method of presentation of Engineering Drawing Pictorial View Orthogonal View Isometric view

24


crane-Solution of problems with the aid of vectors. General condition of equilibriums for series of forces on a body. Law of parallelogram, Triangle Law, Lami’s Law theorem.

10. Simple Problems on Profit & Loss. Simple and compound interest. Centre of gravity: Centre of gravity concept and C.G. of different lamina. Equilibrium different kinds stable, unstable and neutral. Law of parallelogram force. Triangle law, Lami’s theorem stable, unstable and neutral equilibrium.

Symbolic Representation (as per BIS SP:46-2003) of: Fastener (Rivets, Bolts and Nuts) - Bars and profile sections. Weld, brazed and soldered joints. Electrical and electronics element. Piping joints and fittings.

11. FLUID MECHANICS Properties of fluid (density, viscosity, specific weight, specific volume, specific gravity) with their units. Concept of static pressure, intensity of pressure and pressure head, Pascal’s law. Concept of atmospheric pressure, gauge pressure, absolute pressure, vacuum and differential pressure. Types of flow (laminar and turbulent). Rate of discharge. Reynolds No. Equation of continuity; Bernoulli’s theorem (without proof) and its applications. Losses in flows. Fluid moving machineries (construction and operation only). Pumps – positive displacement; centrifugal Fans, blowers and compressors – single stage multi-stage Specifications & ratings of Fluid Mechanics Machineries.

Construction of Scales and diagonal scale Practice of Lettering and Title Block Dimensioning practice: Position of dimensioning (unidirectional, aligned, oblique as per BIS SP:46-2003). Symbols preceding the value of dimension and dimensional tolerance. Text of dimension of repeated features, equidistance elements, circumferential objects. Construction of Geometrical Drawing Figures: Different Polygons and their values of included angles. Inscribed and Circumscribed polygons. Conic Sections (Ellipse & Parabola).

12. Electricity Ohm’s law, Kirchhoff’s law Simple Problems on series and parallel circuits. Concept of AC/DC. AC Induction Motors (Squirrel cage and slip ring) – uses, constructions and connections Starters – DOL, Star-delta, soft & VFD General safety measures while handling electrical machines.

Drawing of Solid figures (Cube, Cuboids, Cone, Prism, Pyramid, Frustum of Cone and Pyramid.) with dimensions. Free Hand sketch of hand tools and measuring tools used in respective trades. Projections: Concept of axes plane and quadrant. Orthographic projections. Method of first angle and third angle projections (definition and difference). Symbol of 1st angle and 3rd angle projection as per IS specification. Drawing of Orthographic projection from isometric/3D view of blocks Orthographic Drawing of simple fastener (Rivet, Bolts, Nuts&

25


Screw). Drawing details of two simple mating blocks and assembled view.

13. ALGEBRA Indices, Concept and rules, Examples on indices. Application of Quadratic equations. Arithmetic Progression, its nth term and sum of n terms with their applications to engineering problems. Geometrical Progression, its nth term and sum of n terms and to infinity with application to engineering problems. Meaning of the terms n! (Factorial n), nCr. Examples. Binomial theorem (expansion without proof) for positive integral index (expansion and general term).

Sign & Symbol Trade related Alternating Current Drawing of simple electrical circuit using electrical symbols. Drawing of sine square & triangular waves. Diagram of battery charging circuit. Practice in reading typical example of circuit containing R, L & C. Reading of electrical drawing. Electronic components Symbols for electronic components. Diode, Transistor, Zener diode, SCR, UJT, FET, IC, Diac, Triac, Mosfet, IGBT etc. Drawing of half wave, Full wave and Bridge rectifier circuit. Drawing circuit for a single stage Amplifiers and Multi stage Amplifies and types of signals. Drawing of circuit containing UJT, FET & Simple power control circuits. Free hand drawing of Logic gates and circuits.

14 MENSURATION: Area & Volume of different geometrical shapes (2D &3D). TRIGNOMETRY Concept of angles, measurement of angles in degrees, grades and radians and their conversions. Trignometrical ratios and their relations. Review of ratios of some standard angles (0, 30,45,60,90 degrees), Compound angles, multiple angles, and sub-multiple angles (2A, 3A, A/2) inverse circular functions. Height & Distances, Simple problems.

Electric wirings & Earthing Detailed diagram of calling bell, & Buzzers etc Free hand sketching of Staircase wiring. Drawing the schematic diagram of plate and pipe earthing. Diagram for electroplating from A.C / D.C source. DC machines Graphic symbols for Rotating machines. Sketching of brush and brush gear of D.C. machines. Sketching of D.C. 3-point and 4-point starter. Layout arrangement of D.C. Generators & motors, control panel. Exercises on connection to motors through Ammeter, voltmeter & K.W. meters of electrical wiring diagram. Drawing the schematic diagram of D.C. motor speed control by Thyristor / DC Drive.

15. MENSURATION: Area & Volume of different geometrical shapes (2D &3D). TRIGNOMETRY Concept of angles, measurement of angles in degrees, grades and radians and their conversions. Trignometrical ratios and their relations.

Transformer Graphic symbols for Transformers. Free hand sketching of transformer and auxiliary parts and sectional views. Sketching a breather. Drawing the diagram of typical marking plate of a distribution transformer. Illumination

26


Review of ratios of some standard angles (0, 30,45,60,90 degrees), Compound angles, multiple angles, and sub-multiple angles (2A, 3A, A/2) inverse circular functions. Height & Distances, Simple problems.

Free hand sketching of Mercury vapour lamp, sodium vapour lamp, fluorescent tube (Single & Twine), MHL lamp and their connection.

16. MATRICES A brief idea of determinant of order three. Definition. Examples of expansion. Matrix of order m x n, Addition, subtraction & multiplication of matrix. VECTOR ALGEBRA Addition, subtraction & multiplications of vectors with applications. (5 hrs.)

Three phase Induction motor Free hand sketching of Slip-ring and Squirrel cage Induction motor. Typical wiring diagram for drum controller operation of A.C. wound rotor motor. Drawing the schematic diagram of Autotransformer starter, DOL starter and Star Delta Starter. Drawing the schematic diagram of A.C. motor speed control by SCR /AC Drive. Alternator Tracing of panel wiring diagram of an alternator. Drawing the schematic diagram of automatic voltage regulators of A.C. generators.

17. FUNCTIONS Concept of limit, continuity, derivatives (1st Order) interpretation as rate, tangent, etc. Maxima, minima STATISTICS Frequency tables, normal distribution; central tendencies – mean, median, mode Dispersion – range, Standard deviation, simple idea of probability.

Winding Drawing the development diagram for D.C. Simplex Lap & Wave windingwith brush position. Drawing the development diagram of A.C 3 – Phase, 4 Pole 24 slots single layer winding. Control Panel Practice in reading panel diagram. Local & Remote control of Induction motor with inching. Forward & Reverse operation of Induction motor Automatic Star Delta Starter Automatic star delta starter with change of direction of rotation Sequential control of three motors. Domestic Appliances Fire, Alarms, Electric Iron, Heater, Electric Kettle, Heater / Immersion Heater, Hot Plate, etc. Distribution of Power Types of insulator used in over head line. (Half sectional views)

Revision

27


TRAINING METHODOLOGY

(Common for all CITS Trades)

Unit No.

Reference Learning Outcome

Professional Skills of TM (TM Practical)

Professional Knowledge of TM (TM Theory)

1. Plan & prepare the learners for the class using basics of educational psychology & motivational techniques.

Roles and Responsibilities of an Instructor 1.1 Case study on

Instructors and trainees relationship.

1.2 Practice Questionnaire on types of learners.

1.3 Practice Questionnaire on the knowledge of trainees with reference to training procedures.

1.4 Conduct Mock sessions and demos on lecture practices.

1.5 Practice principles of Vocational Training.

1.6 Conduct Feedback session by trade Instructors about nature of instructions.

1.7 Practice Markle’s and Ausubel’s instructional model.

1.8 Practice to highlight specific traits and skills for relevant trade(s).

Roles and Responsibilities of an Instructor

Introduction.

Orientation.

Skill Development programmes of DGT – Current Status.

Teaching Vs Trainer/Teacher.

Difference between Vocational Education and Vocational Training.

Principles of Vocational Training.

Instruction vs. Teaching – (i) Principles of Instruction. (ii) Principles of Instruction. (iii)Difference between Instruction and Teaching. (iv) Common defects in Instruction.

Characteristics of good Instruction.

Qualities, Personality Traits and Responsibilities of good Instructor – (I) Qualities (Requisites) of Good Instructor (II) Personality Traits of good Instructor. (III) Responsibilities of good Instructor.

2. -do- Psychology of Learning 2.1 Demonstrate

psychological parameters like Personality, Aptitude, Skills, values and Potentials through PPT, Video Show or Educational Film.

2.2 Show the effects of psychology of learning in Education & Training

Psychology of Learning

Developmental psychology - Developmental tasks based on stages of development (Age 14 yrs. onward.)

Psychology of learning (i) Nature and Principles of Learning (ii)Factors (Motivation, Interest and Attitude) affecting Learning.

Theories of learning – Pavlov, Throndike,

28


by various exercises.

2.3 Interpret various experiments on theories of learning by the different psychologists, their effects in learning situation and relation with Laws of learning.

2.4 Identify various learning styles. (Auditory, Visual and Kinesthetic modality).

2.5 Conduct a session to motivate trainees.

2.6 Conduct Transaction analysis in a workshop.

2.7 Practice Questionnaire on personality development for assessing the psychological attributes.

Koheler/Gestatt and Skinner.

Individual differences of learners.

Motivation – (i) Concept of Motivation (ii) Determinants of Motivation (Anxiety, Need & Difficulty of tasks) (iii) Theories of Motivation –

Maslow McClelland and

Atkinson theory.

Transaction analysis in a Class room.

Assessment of Prior Learning to identify the strength & Weakness of Trainees and Planning the Strategies of Delivery.

3. Analyze the syllabus of the Course.

Analysis of Syllabus and Course Construction 3.1 Conduct group

discussion on designing a training curriculum

3.2 Conduct Group task for analyzing syllabus.

3.3 Discuss about Job / Task and Elements of skills.

3.4 Draft the Outlines of a syllabus highlighting- must know, should know & could know.

3.5 Prepare project work on “listing of topics and break up of syllabus” using ADDIE Model.

3.6 Conduct a group exercise to prepare schedule of instructions.

3.7 Plan & design a sample course reflecting principles like- simple to complex and concrete to abstract.

Analysis of Syllabus and Course Construction

Syllabus and its formation - Factors for formulation of syllabus Aims and Writing Learning objectives.

Analysis of a Syllabus - Methods of analysis, time and syllabus.

Methods of Analyzing the Syllabus - Breakup of syllabus and schedule of instruction with time duration.

Identification of skills and Knowledge ADDIE Model Instructional Designing Process.

Construction of course outline - Course construction (Arrangement related classes etc.,)

Time management and its concept in formulation of a trade syllabus and instruction with time duration.

29


4. Plan & prepare the

training session using various methods viz. 4 step method, question & questioning technique etc.

Planning for Instruction 4.1 Conduct individual

tasks to prepare & set questions on different levels of learning in psychomotor domain according to Bloom’s Taxonomy.

4.2 Conduct group discussion to highlight different phases of skill learning.

4.3 Role play on steps of imparting skills.

4.4 Conduct a practicing session on use of question and questioning techniques.

4.5 Conduct a buddy activity to make objectives/learning outcomes and prepare a lesson plan.

4.6 Prepare demonstration plan and define its objective.

4.7 Plan & prepare different written instructional materials.

4.8 Use teaching practices and assess body language.

Planning for Instruction and skills practice

Skill and its basic elements (Behavioral objects of Bloom Taxonomy).

Phases of acquiring skills.

Steps in imparting Skills.

Question & questioning techniques.

Lesson plan.

Demonstration plan.

Different methods of imparting skills.

Delivery techniques of different methods (4 Step method).

5. Communicate effectively with the trainees both verbally and nonverbally. Use Instructional Technology & facilitate the training program.

5.1 Group discussion of 4 step method and analyze the same.

5.2 Follow the process of communication and practice use of non-verbal communication to convey messages.

5.3 Practice on pre-listening activity and respond them.

5.4 Conduct an activity showing the effects of Dale cone learning experience.

5.5 Prepare charts, transparencies, slides,

Instructional Technology and facilitate learning

Teaching practice through moderation 2. A comparison with conventional method with modern Training – By Trainer 3. Group discussion of 4 step method – Test method – By Trainer 4. Project work & display on making working model – mockups Project Work By Trainer & Trainees.

Communication: (Class Room) 1. Communication process & elements of communication – By Trainer.

30


posters, mock-ups.

5.6 Train on different types of board (Black board, white board, flannel board, magnetic board etc.) in a classroom session.

5.7 Use and maintain OHP. 5.8 Use and maintain

Digital Camera. 5.9 Use and maintain LCD

projector and smart board.

5.10 Conduct micro teaching practices.

2. How good listener and what type of communicator you are - By Trainer 3. Discussion with trainer on improving individual talents in public speaking - By Trainees.

Dale cone of experience Different Types of Teaching Learning Aids: Projected/ Non Projected Using different types of board in a class room session. Black board, White board, Flannel board, Magnetic board etc.

Chalk Board/ White Board practice How to use it.

Application, use & maintenance of OHP.

Application, use & maintenance of Digital Camera.

Application, use & maintenance of LCD projector and Smart board.

Micro – Teaching concept.

6. Design written instructional materials and implement for imparting training.

Written Instructional Materials 6.1 Plan & prepare the

different WIM. 6.2 Activity on making job

sheets, Information Sheet, Assignment Sheet, Experiment Sheet, Pre-job Check Sheet and Final Job Check Sheet.

6.3 Guide the trainees how to maintain the records properly.

Written Instructional Materials

Written Instructional Materials.

Operation sheet.

Job sheet.

Information Sheet.

Assignment Sheet.

Experiment Sheet.

Pre-job Check Sheet.

Final Job Check Sheet.

Daily Dairy, Progress Chart, Maintaining Theory & Practical records.

7. Assess, evaluate and certify the tests.

Assessment and Certification Test & Evaluation – its importance 7.1 Case study on different

types of tests & its necessity.

7.2 Conduct group discussion on various tests under aegis of

Assessment and Certification Test & Evaluation – its importance

Current methods applied in DGT Schemes.

Characteristic of a good Test.

Rule for preparation of Objectives types test Items.

31


NCVT.

7.3 Conduct group assignment on setting different types of question on various levels of learning in cognitive domain according to Bloom’s Taxonomy.

7.4 Prepare an ideal question paper & evaluate it.

7.5 Apply evaluation techniques & marking schemes for assessing Theory & Practical content of a sample syllabus.

7.6 Use Formative Assessment techniques for awarding sessional marks.

7.7 Use Summative Assessment techniques.

7.8 Undertake competence based assessment as per standards.

Preparing Student Multiple Choice Types Matching Types Short Answer Types.

Preparation of Questions Paper.

Evaluation of Theory & Practical Test (Kirkpatrick evaluation model).

NCVT as a certifying agency – certificates issue under aegis of NCVT.

Concept of formative assessment and summative assessment.

Prepare for undertaking assessment of competence as per standards.

Conduct assessment of competence.

8. Organize workshop and classroom learning observing instructional methods.

Organization and Management of Instructional Functions 8.1 Organize Group

discussion among the trainees on management of Instructional functions.

8.2 Illustrate Instructional areas layout, its utility & space.

8.3 Conduct group activities for completion of given job.

8.4 Conduct group activity reflecting proper housekeeping and analyze the same.

8.5 Conduct Debate on conventional

Organization and Management of Instructional Functions

Training & Managerial responsibilities Introduction & discussion on managerial responsibilities.

Management of Workshop & Class room.

Group teaching and learning.

Instructional area – house keeping Need for proper housekeeping & safety rules and overview – By Trainer.

Basic quality Concept & 5’S.

Colour Dynamics.

Safety in Instructional Area.

32


housekeeping vs. 5’s concept.

8.6 Conduct activity on Colour Dynamics.

8.7 Activity on various safety measures, slogans, precaution etc.

9. Counsel & mentor the trainees by identifying their Strength & Weaknesses

Counseling & Mentoring 9.1 Activity on handling

trainee’s grievances. 9.2 Activity on rating of

characteristic according to graph printing.

9.3 Analyze the different characteristics that forms the base of ethics. React to real life ethical situation.

9.4 Prepare parameters for assessing skills of a good trainer and list out in the chart format.

9.5 Activity on self rating skills in each area by circling the appropriate number.

9.6 Activity on - tips to crack interview, Introduce yourself, your skills with confidence.

9.7 Practice tricky questions meant to test thinking skills using lateral thinking.

Counseling & Mentoring

Handling trainee’s grievances - Define Grievances, Types of Grievances, Cooperate Grievances, Do’s & Don’ts in Grievances.

Boosting Morale - Boosting ethics & Development work environment, ethics theory, Development of work environment & training process, knowledge of presentation & self motivation.

Identifying the strengths - SWOT Analysis. Define SWOT analysis, Important of SWOT analysis, characteristics of SWOT analysis, Example of SWOT analysis related with Trade development in detail.

Seeking/ Retrieving Labour Market Information - Labour Market Strategy/ Potential. Define marketing, Tools of marketing, 7 Ps define market strategy, important of market strategy, use of strategy in trade theory (Labour Market Information).

Techniques of writing good CV.

Further Learning pathways.

10. Develop Entrepreneurship skills.

Entrepreneurship Development 10.1 Conduct case study

on Entrepreneurship skills.

10.2 Activity on leadership

Entrepreneurship Development

Leadership - Define leadership, types of leadership, leadership Traits, Functions of leadership,

33


skills.

10.3 Activity on reducing stress at workplace.

10.4 Trace and interpret the sequence of operation for setting up a small business from the flow sequence diagram.

10.5 Draw a diagram for the product chosen by trainee.

10.6 Activity to prepare the impact of quality and list the importance of quality.

styles of leadership.

Stress management - Define Management, Type of stress Management, How to improve stress in workplace, Team leader in workplace.

Time management - Workplace time Management, maintain Time management, Benefits of Time Management in workplace, Time management schedule.

Self Employment as a Career path - Define Entrepreneurship, Strategy of entrepreneurship, Market Research.

Implementation of self Employment in workplace Ps, Mange self employment in workplace.

Quality consciousness – its relevance.

Interaction with Industries current example of different ITI.

Conducting Seminars / Case studies.

11.

Apply ICT & Internet in training (computer based training) and various types of Distance learning programmes.

ICT and Internet 11.1 Browse internet, Use

Email applications, Fax etc.

11.2 Prepare transparency with the help of computer.

11.3 Prepare PPTs using Power Point.

Distance Learning Programme 11.4 Interactive Class on

Video Conference / Practice.

11.5 Practice on installation and commissioning of equipments at Spokes.

ICT and Internet

Use of Internet in teaching, Training and learning - How to use internet, Email application, Fax.

Computer aided learning, training and teaching.

Use, application and maintenance of computer.

Distance Learning Programme

Why Distance Learning - Define Distance Learning, Types of Distance Learning Advantages & Disadvantages of Distance Learning, Importance of distance Learning.

Distance Pathways - Define Distance Pathways, Types of Pathways, Handling of

34


Pathways.

Organisations adopting Distance Learning.

Initiative of DGET – current detail/ History of DGET &Further scope.

Success stories / Best Practices – Inspection, insp ect, Demo displacement.

Future Trends – Smart Learning, eLearning, Virtual Classroom.

Limitations of Distance Learning.

12. Plan and conduct sessions to impart competency based skills and knowledge.

Interpret NSQF and QP 12.1 Browse National

Frameworks of different countries.

12.2 Browse the components of National Framework (NSQF).

12.3 Interpret NSQF Gazette Notification.

12.4 Study of related QP/NOS from the NQR.

12.5 Explore the related STT module of the trade.

12.6 Interpret given QP. 12.7 Interpret given NOS. 12.8 Interpret different

learning outcomes of various levels.

12.9 Make learning outcomes for a sample syllabus.

Interpret NSQF and QP

Overview of NSQF, QP, NOS, Learning outcomes, Performance criteria.

Role of NSDA, NSDC and SSC.

13. Apply Adult Learning Principles.

Principles of Adult Learning 13.1 Apply adult learning

in simulated environment.

13.2 Conduct Role plays applying the principles of adult learning.

Principles of Adult Learning

Assumptions of Adult learning.

Principles of adult learning and how to apply them in training delivery.

Factors affecting adult learning.

Techniques to create and maintain a positive learning environment.

35


14. Develop and

implement continuous professional development plan.

Prepare for Continuing Professional Development 14.1 Develop a

professional development plan to enhance professional capabilities.

14.2 Conduct Group discussion on CPD and its importance.

Prepare for Continuing Professional Development

Importance of continuous learning and professional development.

Personal development and professional goals & objectives.

Professional Development plan.

36


LEARNING OUTCOME ASSESSMENT CRITERIA

TRADE TECHNOLOGY (TT)

1 Demonstrate workshop safety measures and monitor job as per specification perform different types of filing jobs, pedestal grinder operations and check for dimensional accuracy by using appropriate measuring and checking instruments.

1.1 Demonstrate pedestal grinding machine operation with its components.

1.2 Demonstrate appropriate work supporting devices.

1.3 Assess the setting of job as per shape.

1.4 Demonstrate the appropriate wheel type.

1.5 Check and demonstrate operation of the Grinding machine observing standard operating practice correct position of standing for operator.

1.6 Perform and monitor pedestal grinder operation viz., make components such as cutting tools like single point cutting tools, threading tools, parting tool, drill bits as per specification.

1.7 Check accuracy/ correctness of job using appropriate gauge and measuring instruments for their functional requirement.

1.8 Ensure safety procedure during above operation as per standard norms and company guidelines.

2 Plan and manage the work to make jobs as per requirement selecting different operations ensuring accuracy by using appropriate measuring instruments [power saw machine operation, external and internal thread cutting (using tap and die), demonstrate reaming (manual/ on machine), counter-boring, counter-sinking].

2. 1 Demonstrate power-saw machine operation with its components.

2. 2 Demonstrate appropriate work holding devices and acquaint 2. 3 with functional application of each device.

2. 4 Assess setting the job on table as per shape.

2. 5 Demonstrate setting of the power saw machine on appropriate speed & feed.

2. 6 Check operation of the power saw machine and demonstrate standard operating practice.

2. 7 Perform threading - external and internal using tap and die, counter-boring, counter-sinking and reaming operation using appropriate tools.

2. 8 Check accuracy/ correctness of job using appropriate gauge and measuring instruments for their functional requirement.

2. 9 Ensure safety procedure during above operation as per standard norms and company guidelines.

3 Plan, organize and perform various jobs by selection of appropriate operation, tools, accessories, attachments and processes like making flat surface, angular surface, slot, formed surfaces, dovetail and T-slots etc. on shaping machine. Assess accuracy

3.1 Demonstrate working principles, mechanisms, parts with their functions and safety aspect of shaping machine.

3.2 Explain functional application of different levers, stoppers, adjustment etc. for shaping machine.

3.3 Demonstrate different lubrication points of shaping machine.

3.4 Monitor lubricants and their usage for application in shaper machine as per machine manual.

3.5 Illustrate different job holding devices and acquaint with functional application of each device.

7. ASSESSMENT CRITERIA

37


using appropriate measuring instruments.

3.6 Evaluate shaping machine with required alignment and check for its functional usage to perform shaping machine operations.

3.7 Assess problem solving by applying basic methods and information during setting.

3.8 Demonstrate safety procedure during operation as per standard norms.

4 Monitor & supervise work to ensure correct functional operation, selection of appropriate tools, accessories, attachments and processes like making of flat surface, angular surface, slot, formed surfaces, dovetail and T-slots etc. on Planer machine. Check accuracy using appropriate measuring instruments.

4.1 Demonstrate working principles, mechanisms, parts with their functions and safety aspect of planer.

4.2 Describe functional application of different levers, stoppers, adjustment etc. for planer.

4.3 Demonstrate different lubrication points of shaping machine.

4.4 Monitor lubricants and their usage for application in planer as per machine manual.

4.5 Explain different job holding devices and acquaint with functional application of each device.

4.6 Evaluate planer with required alignment and check for its functional usage to perform planer operations.

4.7 Analyze & assess problem solving by applying basic methods and information during setting.

4.8 Demonstrate safety procedure during operation as per standard norms.

5 Identify slotting machine parts, mechanisms & their functions. Conduct & review various jobs on slotting machine. Evaluate accuracy with appropriate instruments. [Key-way cutting, regular and irregular polygon, spline cutting etc.].

5.1 Demonstrate working principles, types of slotter, mechanisms, specification, parts with their functions, different operations, processes and safety precautions.

5.2 Ascertain cutting tool, holding devices, coolants required, raw

material etc. as per drawing/requirement of job.

5.3 Determine machine parameters feed, speed & depth of cut through calculations.

5.4 Collect and organize information to determine use of specific machine, operation, processes.

5.5 Make automatic movements setting for various cutting operations as and when required.

5.6 Select and justify use of various accessories, attachments, cutter holding and work holding devices.

5.7 Check and evaluate skill of operating with consideration for dimensional accuracy of job and method of performing slotting operations and processes.

5.8 Measure / check the dimensions or geometry with instruments / gauges as per drawing within the prescribed accuracy.

5.9 Evaluate consciousness about safety procedures as per

standard norms and specific on the machine.

5.10 Conclude possible solutions the problem arising in execution

using desired mathematical skills, knowledge of facts, principles,

processes and general concept in the field of work.

38


6 Identify lathe machine parts,

mechanisms & their functions. Perform & review various jobs on lathe machine. Assess accuracy with appropriate instruments. [Plain turning, facing, taper turning, step turning, drilling & boring, knurling, thread cutting external and internal etc.].

6.1 Demonstrate working principles, types of lathe, mechanisms, specification, parts with their functions, different operations, processes and safety precautions.

6.2 Ascertain & use cutting tool/holding devices/

coolants/required raw material etc. as per

drawing/requirement of job.




6.6 Select and justify use of various accessories, attachments, cutter holding and work holding devices.

6.7 Check and evaluate skill of operating with consideration for dimensional accuracy of job and method of performing lathe operations and processes.

6.8 Measure / check the dimensions or geometry with instruments / gauges as per drawing within the prescribed accuracy.



6.10 Conclude possible solutions the problem arising in execution using desired mathematical skills, knowledge of facts, principles, processes and general concept in the field of work.

7 Identify milling machine parts, mechanisms & their functions. Plan, organize and make various jobs by selection of appropriate operation, tools, accessories, attachments and processes on milling machine. Check accuracy with appropriate instruments. [Face milling, slot milling, gang milling, angular milling, end milling and process of up & down milling etc.].

7. 1 Demonstrate working principles, types, mechanisms, specification, parts with their functions, different operations, processes and safety precautions.

7. 2 Ascertain & select cutting tool/ holding devices/ coolants required/ raw material etc. as per drawing/requirement of job.

7. 3 Collect and organize information to determine use of specific machine, operation, processes.

7. 4 Determine machine parameters feed, speed & depth of cut through calculations.

7. 5 Make automatic movements setting for various cutting operations as and when required.

7. 6 Select and justify use of various accessories, attachments, cutter holding and work holding devices.

7. 7 Check and evaluate skill of operating with consideration for dimensional accuracy of job and method of performing milling operations and processes.

7. 8 Measure / check the dimensions or geometry with instruments / gauges as per drawing within the prescribed accuracy.

7. 9 Evaluate consciousness about safety procedures as per


39


7. 10 Conclude possible solutions the problem arising in

execution using desired mathematical skills, knowledge of facts, principles, processes and general concept in the field of work.

8 Demonstrate parts of vertical milling machine, mechanisms & their functions. Monitor selection of appropriate operation, tools, accessories, attachments and processes on vertical milling machine. Check accuracy with appropriate instruments. [Operation: -slot milling, end milling, pocket milling, dovetail, T-slot milling and cam profile milling etc.]

8. 1 Demonstrate working principles, types, mechanisms, specification, parts with their functions, different operations, processes and safety precautions.

8. 2 Ascertain, select & use cutting tool/ holding devices/ coolants/ required raw material etc. as per drawing/requirement of job.

8. 3 Collect and organize information to determine use of specific machine, operation, processes.

8. 4 Determine machine parameters feed, speed & depth of cut through calculations.

8. 5 Make automatic movements setting for various cutting operations as and when required.

8. 6 Select and justify use of various accessories, attachments, cutter holding and work holding devices.

8. 7 Check and evaluate skill of operating with consideration for dimensional accuracy of job and method of performing vertical milling operations and processes.

8. 8 Measure / check the dimensions or geometry with instruments / gauges as per drawing within the prescribed accuracy.

8. 9 Evaluate consciousness about safety procedures as per


8. 10 Conclude possible solutions the problem arising in execution using desired mathematical skills, knowledge of facts, principles, processes and general concept in the field of work.

9 Plan and perform simple repair, overhauling of different machines used in machinist section and Check for functionality. [Cleaning, oiling, greasing, belt replacement and setting etc.].

9.1 Ascertain and select tools and materials for the repair, overhauling and make this available for use in a timely manner.

9.2 Plan & organize work in compliance with standard safety norms.

9.3 Demonstrate possible solutions and agree tasks within the team.

9.4 Select specific parts to be repaired and ascertain for appropriate material and estimated time.

9.5 Repair, overhaul and assemble the parts in the machine with the help of blue print.

9.6 Check for functionality of part and ascertain faults of the part/ machine in case of improper function.

9.7 Rectify faults of assembly.

10 Demonstrate various types of 10.1 Demonstrate grinding machine working principles, types,

40


grinding on jobs using different types of grinding machines (surface and cylindrical grinder etc.). Explain wheel Mounting, balancing, dressing & truing and other setting for surface / cylindrical grinder. Explain Honing and lapping and its practice. Check accuracy with appropriate instruments. [Surface grinding, angular grinding, cylindrical grinding, step and camshaft grinding etc.].

mechanisms and parts with their functions.

10.2 Relate the selection of grinding wheel/holding devices/ coolants/ required raw material etc. as per drawing/requirement of job.

10.3 Collect and organize information to determine use of specific

machine, operation, processes, grinding wheels etc..

10.4 Trace and correct defects such as loading, glazing, manufacturing defects etc. of grinding wheel wherever possible.

10.5 Calculate feed, speed & depth of cut for a particular operation and job.

10.6 Set machine for automatic/manual operation.

10.7 Assess setting of the job on machine table as per operation

using holding devices.

10.8 Select and justify appropriate method to perform surface and cylindrical grinding operations on jobs.

10.9 Measure / checking the dimensions with instruments / gauges as per drawing for achieving required accuracy.

10.10 Demonstrate dressing, truing, balancing and mounting of grinding wheel using various tools and maintain the grinding wheel.

10.11 Demonstrate possible solutions to problems using desired mathematical skills, knowledge of facts, principles, processes and general concept in the field of work.

10.12 Evaluate consciousness about safety procedures as per standard norms and specific on the machine.

11 Execute and monitor operations of sharpening/ re-sharpening different cutting tools and cutters using tool and cutter grinder. Check accuracy with appropriate instruments. [Plain milling cutter, side & face milling cutter, angular cutter, end mill etc.].

11. 1 Demonstrate the tools & cutter grinder machine working principles, mechanisms and parts with their functions, accessories & attachments.

11. 2 Evaluate re-sharpening of radial clearance angle on various cutting tools considering different cutting angles of the tool.

11. 3 Check operation of the grinder to observe standard operating practice.

11. 4 Identify and correct defects such as loading, glazing,

manufacturing defects etc. of grinding wheel wherever

possible.

11. 5 Demonstrate dressing, truing, balancing and mounting of

grinding wheel using various tools and maintain the

grinding wheel.

11. 6 Check accuracy/ correctness of job using appropriate gauges and measuring instruments for their functional requirement.

11. 7 Ensure safety rules when performing the above operations.

12 Analyze & set different machining parameters and

12.1 Select cutter as per specification of gear/ cam/ clutch/ rack/ worm & worm wheel and plan to make the same as per

41


cutters to prepare components by performing different milling operation with indexing. [Different machining parameters – feed, speed and depth of cut. Different components – Rack, Spur Gear, External Spline, Clutch, Helical Gear, bevel gear, cam profile, worm & worm wheel].

drawing.

12.2 Work out and apply indexing parameters as per different components to be produced to determine gear setting and set indexing head, milling machine.

12.3 Demonstrate possible solutions within the team using desired mathematical skills, knowledge of facts, principles, processes and general concept in the field of work to set the indexing head.

12.4 Solve problems during operation by selecting and applying basic methods, tools, materials and collect and organize information for quality output.

12.5 Set the job and produce component following the standard operating procedure with compliance to safety rules when performing the above operations.

12.6 Make components observing standard operating procedure.

12.7 Measure with instruments/gauges as per drawing and check functionality of gear.

12.8 Avoid waste, ascertain unused materials and components for disposal, store these in an environmentally appropriate manner and prepare for disposal.

13 Demonstrate operations on machines and check components and its functioning. [Machines: - EDM, Gear Shaper, Gear Hobber, Jig Boring, Broaching and CMM].

13.1 Demonstrate working principles, mechanisms, parts with their functions and safety aspect of machine.

13.2 Demonstrate appropriate machine parameters to set automatic movements for various cutting operations and compliance with safety rules.

13.3 Demonstrate appropriate method to perform respective operation on the machine and make required mathematical calculations for the same.

13.4 Identify appropriate raw material, cutting tool, holding devices and coolants accordingly calculate the cutting speed, feed and depth of cut.

13.5 Demonstrate possible solutions using desired mathematical skills, knowledge of facts, principles, processes and general concept in the field of work and collect and organize information to determine use of specific machine.

13.6 Demonstrate method of measuring and checking of the dimensions/ geometry of job using CMM machine/ instruments/ gauges as per drawing.

14 Plan and perform setting of job and tool in CNC turning centre/ CNC machining centre. Produce components through various modes of operations, prepare/ edit part program, simulation and execution as per drawing/ requirement.

14.1 Demonstrate working principles, types, mechanisms, specification, parts with their functions, different operations, processes, identify axis, drives, coordinate system and safety precautions.

14.2 Select cutting tool/ holding devices/ accessories/ attachments/ coolants required/ raw material as per drawing/ job requirement.

14.3 Demonstrate the setting of job, machine and the

42


ENGINEERING TECHNOLOGY

15 Demonstrate basic mathematical concept and principles to perform practical operations.

15.1 Test basic skills on arithmetic, algebra, trigonometry and statistics.

15.2 Applications will be assessed during execution of assessable outcome and will also be tested during theory and practical examination.

16 Explain basic science in the field of study including simple machines.

16.1 Test skills on science in the field of study including electronic components, electric wiring & earthing, DC machines, transformer, Control Panel, Domestic Appliances etc.


17 Apply engineering drawing for different application in the field of work.

17.1 Test basic skills on engineering drawing.


TRAINING METHODOLOGY

18 Plan & prepare the learners for the class using basics of educational psychology & motivating techniques.

18.1 Implement techniques based on psychological parameters like Personality, Aptitude, Skills, values and Potentials.

18.2 Use different experiments on theories of learning by the different psychologists and their effect in learning situation and relation with Laws of learning.

[face milling and drilling application, tool selection and setting on machine, tool offset].

component as per standard operating procedure involving different operations.




14.7 Plan and prepare/ edit part program as per drawing, simulate for its correctness with appropriate software/ simulator.

14.8 Test/Dry run the part program on the machine.

14.9 Evaluate skill of operating with consideration for accuracy of job and method of performing various operations and processes.

14.10 Evaluate accuracy/ correctness of job using appropriate gauge and measuring instruments.



14.12 Conclude possible solutions the problem arising in execution using desired mathematical skills, knowledge of facts, principles, processes and general concept in the field of work.

43


18.3 Demonstrate on Modality Learning (Auditory, Visual and

Kinesthetic modality).

18.4 Set Questionnaire on personality development for assessing the psychological attributes.

18.5 Motivate trainees for the training session.

19 Analyse the syllabus of the Course.

19.1 Select salient points on designing a training curriculum.

19.2 Analyse a sample syllabus.

19.3 Discuss Elements of skills, Outlines of a syllabus.

19.4 Make project work on making break up of syllabus and list of topics - Video show/PPT of ADDIE Model.

19.5 Design schedule of instructions.

19.6 Construct a sample course using principles of teaching.

20 Plan & prepare the training

session using various methods viz. 4 step method, question & questioning technique etc.

20.1 Set questions on different levels of learning in psychomotor domain according to Bloom Taxonomy.

20.2 Demonstrate the steps of imparting skills.

20.3 Prepare lesson plan and demonstration plan using 4 Step methods.

20.4 Use questioning techniques.

21 Communicate effectively with the trainees both verbally and non-verbally.

21.1 Identify the process of communication.

21.2 Use verbal & non-verbal communication to convey messages, pre-listening activity and respond to them.

21.3 Communicate effectively with the trainees in training session.

22 Use Instructional Technology & facilitate the training program.

22.1 Use various instructional Technologies viz. OHP, Digital Camera, LCD projector, smart board etc.

22.2 Plan and design charts, transparencies, slides, posters, mock-ups etc.

22.3 Conduct micro teaching sessions.

23 Design written instructional materials and implement for imparting training.

23.1 Plan & prepare different WIM viz. Operation sheet, Job sheet, Information Sheet, Assignment Sheet, Experiment Sheet, Experiment Sheet, Final Job Check Sheet etc.

23.2 Maintain various records viz. Daily Dairy, Progress Chart, Theory & Practical records etc.

24 Assess, evaluate and certify the tests.

24.1 Identify different types of test & its necessity.

24.2 Set different types of question on different levels of learning in cognitive domain according to Bloom Taxonomy.

24.3 Set an ideal question paper & evaluate.

24.4 Apply various evaluation techniques & marking schemes.

24.5 Undertake competence based assessment as per standards.

24.6 Conduct formative assessment and summative assessment.

25 Organize workshop and classroom learning observing instructional methods.

25.1 Carry out management of Workshop & Class room.

25.2 Demonstrate group teaching and learning.

25.3 Explain housekeeping & safety rules in Instructional area.

44


25.4 Conduct debate on quality Concept & 5’S.

26 Counsel & mentor the trainees by identifying their Strength & Weaknesses.

26.1 Handle trainee’s grievances.

26.2 Boost Morale of trainees.

26.3 Conduct SWOT analysis for identifying their Strength & Weaknesses.

26.4 Plan and Prepare the parameters for skills required to become a good trainer.

26.5 Write a good CV.

27 Develop Entrepreneurship skills.

27.1 Use effective leadership Traits.

27.2 Apply Stress management techniques.

27.3 Plan & Use Time management techniques.

27.4 Interpret the sequence of operation for setting up a small business from the flow sequence diagram

27.5 Analyze the impact of quality and list the importance of quality.

28 Apply ICT & Internet in training (computer based training) and various types of Distance learning programmes.

28.1 Use internet, Email application, Fax etc.

28.2 Prepare transparency sheet with the help of computer.

28.3 Prepare Slides by Power Point.

28.4 Conduct Interactive Class on Video Conference.

28.5 Install and commission equipments at Spokes level.

29 Plan and conduct sessions to impart competency based skills and knowledge.

29.1 Interpret one NSQF, QP, NOS etc.

29.2 Explain learning outcomes.

29.3 Identify different roles of NSDA, NSDC and SSC.

30 Apply Adult Learning Principles.

30.1 Apply adult learning in simulated environment.

30.2 Identify various factors affecting adult learning

30.3 Use role plays using the principles of adult learning.

30.4 Apply techniques to create and maintain a positive learning environment.

31 Develop and implement continuous professional development plan.

31.1 Develop a professional development plan to enhance professional capabilities.

31.2 Implement CPD in instructor career.

45


LIST OF TOOLS AND EQUIPMENT FOR MACHINIST & OPERATOR ADVANCE MACHINE TOOL (CITS)

S No. Name of the Tool & Equipment Specification Quantity

A. Hand Tools

1. Steel Rule 30 cm. graduated both in Metric

units. 4 nos.

2. Divider 150 mm 4 nos.

3. Centre Punch 4 nos.

4. Hammer Ball Pane 0.8 Kg approx. with handle 10 nos.

5. Combination Plier 150mm 05 nos.

6. Safety goggles 10 nos.

7. File flat Bastard 300mm 10 nos.

8. File flat 2nd Cut 250mm 10 nos.

9. Engineers Screw Driver 200 mm 10 nos.

10. File flat smooth 200mm 10 nos.

11. Cold chisel flat 25x200mm 10 nos.

12. Surface Plate 600x600X80mm grade 1 1 no.

13. Marking Table 1200X1200x900mm high 1 no.

14. Scribing Block Universal 300mm 04 nos.

15. V-Block 100/7-80-A 2 nos.

16. Try Square 300mm/ 150 mm 10 nos.

17. Straight Edge Steel 500mm 1 no.

18. Steel Tape 2 meter in Case 1 no.

19. Soft Hammer 250 gm with Handle 04 nos.

20. Sprit level 25 cm 1 no.

21. Hammer B.P 450 gm 8 nos.

22. Screw Driver, heavy duty 300 mm 4 nos.

23. Hammer lead 1 kg 2 nos.

24. Combination Set 300mm 1 Set

25. Screw driver 100mm 4 nos.

26. Allen hexagonal Keys 2.5 to 12mm 4 Sets

27. Spanner Double Ended metric 6 sets

28. Adjustable Spanner 300mm 2 nos.

29. Reduction Sleeve Morse taper 1-1,3-1,4-1,4-2,5- 1,5-2,6-1. 2 sets

30. Angle Plate Size 200x100x200mm 2 nos.

31. Angle Plate Adjustable 250x150x175mm 2 nos.

32. Solid parallels in pair (different size) in metric

20 nos.

33. Oil cane pressure feed 500mg. 6 nos.

34. Oil stone 150x50x25mm 2 nos.

35. Number drill H.S.S (Parallels shank) 1-80Nos 1 set

36. Drill (Parallel Shank) 1.00mm to 10.00mm with 0.1mm difference

2 sets

8. INFRASTRUCTURE

46


37. Twist Drills 10.00mm to 12.5mm.with 0.5mm

difference 2 sets

38. Drill Chuck 0 to20 with taper shank 4 nos.

39. Centre Drill Al to 5 2 sets

40. Grinding wheel dresser (diamond) 6 nos.

41. Grinding wheel dresser Hunting Type 2 nos.

42. Clamp "C"100mm 2 nos.

43. Clamp "C"200mm 2 nos.

44. Tap & Die set in box metric pitch 1 Set

45. File Flat 2Nd cut 250mm 6 nos.

46. File Flat smooth 200mm 6 nos.

47. File H/R 2Nd cut 250mm 6 nos.

48. File Triangular smooth 200mm 6 nos.

49. Needle File set 6 nos.

50. File Square 2ND cut 250mm. 6 nos.

51. Reamer 6mm to 25 mm by 1 mm step 1 sets

52. Reamer Adjustable 10mm to 15mm by 0.75mm step 1 sets

53. Hacksaw frame Adjustable with blades.

250-300mm 10 nos.

54. Machine Vice 100mm jaw swivel base. 4 nos.

55. Machine Vice 200mm swivel base. 4 nos.

56. Machine Vice 160mm swivel base. 4 nos.

57. Hand Vice 50mm jaw. 2 nos.

58. Universal machine vice 160mm 4 nos.

59. Universal table angle plate 1 no.

60. Taper shank twist drill set 13mm to30mm, to suit radial drilling machine

1 sets

61. Shaper tool holder turret type 10 nos.

62. Knurling tools (set of 3) straight and diamond

4 Set

63. Plier cutting 200mm 4 nos.

64. Magnifying- Glass 75mm 2 nos.

65. Carbide Tipped Tools of different sizes and shapes (through away tips)

10 Sets

66. Hand hammer 1 kg with handle 2 nos.

67. Equipment for conducting BLS (Basic Life Support) training.

1 set

B. Measuring Tools

68. Micrometer outside 0-25mm 2 nos.



71. Digital Micrometer outside 0-25mm 1 nos.



74. Digital Vernier Caliper 200mm 3 nos.

75. Micrometer depth gauge 0-200mm 2 nos.

76. Dial Vernier caliper 300mm 2 nos.

77. Vernier height gauge 250mm 2 nos.

78. Vernier bevel protractor with blade 150mm 2 Sets

47


79. Bevel gauge 200mm 2 nos.

80. Telescopic gauge 13mm to 300rnm 1 set

81. Sine Bar 200mm 2 nos.

82. Inside Micrometer 25-50mm 2 nos.

83. Inside Micrometer 50-150mm 2 nos.

84. Dial Test Indicator with magnetic base.

2 nos.

85. Centre gauge 60 3 no.

86. Slip gauge set (normal set) metric Set of 116pcs. 2 Sets

87. Screw pitch gauge for metric pitches (25-6)

2 Sets

88. Radius gauge metric set (1-6) 2 Sets

89. Plug gauges 5mm to 25mm by 2.5mm step 2 Sets

90. Ring gauges 5mm to 25mm by 2.5mm

step(GO & NO GO) 2 Sets

91. Feeler Gauge 2 nos.

92. Snap Gauge 5mm to 25mm by 2.5mm step 1 no.

93. Vernier Caliper 200mm 02 nos.

C. Milling Cutters

94. Cylindrical cutter 63x100x27mm 04 nos.

95. Cylindrical cutter 75x80x27mm 04 nos.

96. Side and face cutter 100x8x27mm 04 nos.




100. Equal angle cutter 45/100x28x27mm 02 nos.



103. "T" Slot Cutter Dia-18,Width-8,shank-

12mm 04 nos.

104. "T" Slot Cutter Dia-21,Width-9,shank-12mm 04 nos.

105. "T" Slot Cutter Dia-25,Width-11,shank-16mm 04 nos.

106. "T" Slot Cutter Dia.-32,Width.-14,shank-16mm 04 nos.

107. Single angle cutter 63x18x27x45 R.H 02 nos.

108. Single angle cutter 63x18x45 L.Hx27mm 02 nos.

109. Single angle cutter 63x18x60 R.Hx27mm 02 nos.

110. Single angle cutter 63x18x60 L.Hx27mm 02 nos.

111. Double Unequal Angular cutter 40x16x27mmx48x12 L.H 02 nos.

112. Double Unequal Angular cutter 40x16x27mmx53x12 R.H 02 nos.

113. End Mill Cutter H.S.S,(6mm to 18mm) 12 nos. in

a set 02 sets

114. Concave cutter H.S.S 75X18X27mm 02 nos.

115. Convex cutter H. S. S 75X18X27mm 02 nos.

116. Corner Rounding Cutter 12x10x27mm 02 nos.

117. Corner Rounding Cutter 36x15x27mm 02 nos.

118. Slotting Cutter 100x30x27mm 02 nos.

119. Slotting Cutter 100x12x27mm 02 nos.

120. Slitting Saw cutter 150x2.5x27mm 02 nos.

48


121. Slitting Saw cutter 150x3x27mm 03 nos.

122. Slitting Saw cutter 100x4x27mm 03 nos.

123. Dovetail milling cutter parallel shank 6x22mmx45 05 nos.




127. Shell & End mill cutter 40x32x27mm 02 nos.

128. Shell & End mill cutter 50x36x27mm 02nos.

129. Face mill cutter with inserted tip 6x80x27mm 3 nos.



132. Involutes gear module 2 module PA 20 %° 1 Set

133. Involutes gear module 2.5 module PA 20 %° 1Set

C. List of Machines &Equipment for the trade machinist

134. Shaping machine 450mm stroke (motorized) with

all attachments. 2 nos.

135. Shaping machine 315mm stroke (hydraulic) with all

attachments 2 nos.

136. Double column planer 1500x1000x1000(motorized)

with all attachments. 1 no.

137. Slotter 180mm (motorized) with all

attachments. 2 nos.

138.

SS and SC centre lathe (all geared) with having minimum specification as: centre height 150 mm and centre distance 1000 mm along with 4 jaw and 3 jaw chucks, auto feed system, safety guard, motorized coolant system and lighting arrangement.

3 nos.

139. Drilling Machine pillar type 0- 20mm capacity with drill chuck & key.

1 no.

140. Radial Drill 1200mm area motorized with tapping attachment

1 no.

141. Pedestal Grinder Double End type. 2 nos.

142. Power Saw Machine 1 no.

143.

Universal Milling machine with minimum specification as: Table Length x width 1200 x 300 mm having motorized up & down movement along with auto feed arrangement and with following attachments such as: a. Vertical head b. Slotting attachment c. Rack cutting attachment d. Rotary table e. Dividing head f. Adaptors, arbors and collects etc. for holding straight shank

2 nos.

49


drills and cutters from 3 mm to 25 mm.

144.

Horizontal Milling Machine with minimum specification as: Table Length x width 1200 x 300 mm having motorized up & down movement along with auto feed arrangement and 150mm Universal vice.

3 nos.

145.

Vertical Milling Machine with minimum specification as: Table Length x width 1200 x 300 mm having motorized up & down movement along with auto feed arrangement in X-Y direction along with 150mm universal vice.

3 nos.

146.

Surface Grinding Machine

with minimum specification as: Grinding machine plain surface, wheel dia. 175 mm (or near) with reciprocating table having longitudinal table traverse 200 mm (or near) fully automatic and fitted with adjustable traverse stops, machine to be fully motorized and fitted with ace guards and pumps, tank and pump fittings and also to be supplied with magnetic chuck 250 x 112 mm. Diamond tool holder, set of spanners, grease gun, oil-can and spare grinding wheel for general purpose grinding.

2 nos.

147.

Cylindrical Grinder with minimum specification as: Grinding machine external cylindrical fully motorized and supplied with face plates and driving dogs, 3-jaw self centering chuck 4- jaw independent chuck tail stock assorted centers, stud pumps tank all guards and pipe fittings spanners and grease gun (each machine to be supplied with assorted grinding wheels and tool grinding machine for general purpose work with internal grinding attachment) to accommodate 750mm job with centre height 150mm and wheel diameter x width = 300 x 25mm.

1 no.

148.

CNC Machining Centre

with minimum specification as: Table size:500x250mm Travel X-axis x Y-axis x Z-axis: 300 x 250 x 250mm Auto Tool Changer: 8 nos.

1 no.

50


Spindle power: 3.7kW (continuous rating) preferably with popular control system like Fanuc/Sinumeric along with motorized coolant system.

149.

CNC milling tools to suit above machine: to accommodate face cutter, shell end mill cutter, taper shank and parallel shank drills/cutters, Reamers. taps with suitable tool holders.

2 sets each along with cutters &inserts.

150.

CNC turn Centre

with minimum specification as: Chuck size: 1 35mm Between centre distance: 250mm Travel in X: 1 00mm Travel in Z: 200mm No. of tool stations: 8 station turret Spindle power: 3.7kW (continuous rating) preferably with popular control system like Fanuc/Sinumeric along with motorized coolant system.

1 no.

151.

Tool holders to suit the CNC machine for Turning, Threading (external & internal), Grooving(external & internal), Parting off operations, Drilling, Boring, Under cutting (with 20 inserts for each operation)

2 each

152. Power Saw Machine - hydraulic feet system

- 400 mm blade size 1 no.

153. Co-ordinate Measuring Machine (Optional)

1 no

154. EDM (Optional) 1 no

155. Gear Shaper 1 no.

156. Gear Hobber 1 no.

157. Jig Boring (Optional) 1 no.

158.

Multimedia teach ware/ courseware for CNC technology and interactive CNC part programming software for turning & milling with virtual machine operation and simulation using popular operation control system such as Fanuc, Siemens, etc. (Web-based or licensed based) (10 trainess + 1 faculty)

11 users

159. PCs with MS-Windows-7 or latest to run above simulation software, networked on LAN.

11 nos.

D. List of Furniture, Accessories and Audio Visual Aids

51


160. Class Room Chairs (armless) / Dual desk may also be allowed

20 /10 nos.

161. Class Room Tables (3ft X 2ft) / Dual desk may also be allowed

20 /10 nos.

162. Chair for Trainer (armed) movable 01 no.

163. Table for Trainer with Drawer and cupboard

4 % ft X 2 % ft 01 no.

164. LCD / LED Projector 01 no.

165. Multimedia Computer System with all accessories

with UPS (0.5 KVA) 01 set

166. Computer Table 01 no.

167. White Board (6ft X 4 ft.) 01 no.

168. LCD Projector Screen 01 no.

169. Air Conditioner 1.5Ton (OPTIONAL) 02 nos.

170. Wall Clock 01 no.

171. Wall charts, Transparencies and DVDs related to the trade

As required

172. Laser Printer with scanner 01 no.

173. Steel Cupboard with 8 pigeon lockers 3 nos.

174. Work bench for fitters with two vices of 100mm 2 nos.

175. Steel cupboard 180x90x45cm 2 nos.

176. Steel cupboard 120x60x45cm 2 nos.

177. Multi drawer tool rack trolley with minimum 4 drawers and 20

tool capacity 04 nos.

178. First aid box. 1 no.

51


ANNEXURE – I

Name & Address of the Assessor: Year of Enrollment:

Name & Address of NSTI/ IToT: Date of Assessment:

Name & Address of the Industry: Assessment location: Industry/NSTI/IToT

Trade Name: Examination: Duration of the Trade/course:

Learning Outcome:

S N

o.

Maximum Marks (Total 100 Marks) 15 5 20 25 20 15

Tota

l In

tern

al

Ass

ess

men

t M

arks

Res

ult

(Y

/N)

Candidate Name Father's/Mother’s

Name

Safe

ty C

on

scio

usn

ess

& W

ork

pla

ce

Hyg

ien

e

Att

end

ance

/

Pu

nct

ual

ity

Pla

nn

ing

of

assi

gned

ta

sk

Exe

cuti

on

of

pla

nn

ed

wo

rk

Qu

alit

y o

f P

erfo

rman

ce

VIV

A

1

2

FORMAT FOR INTERNAL ASSESSMENT

Documents

SECTOR - CAPITAL GOODS & MANUFACTURING · Ramesh Babu N, Professor IIT Madras, Chennai Member 11. Bharat Heavy Electricals Ltd, R.K. Sridharan, Manager/HRDC Ranipet, Tamil Nadu Member