automotive clutch operator (multiskilled) -...
TRANSCRIPT
SYLLABUS OF SEMESTERSYSTEM
FORTHE ROLE OF
Automotive Clutch Operator (Multiskilled)
Under
High Employment Potential
Courses through Flexi MOUs
(One Year/TwoSemesters)
Designed in
2015
By
Government of India
Ministry of Labour & Employment (DGE&T)
FORMAT
1. Cover Page
2. Title
3. General Information
4. Week wise contents ofTT and TP(Intabular form)
5. Tools and Equipment list- broadspecification
6. List ofthe consumable
7. Trade testingand certification
8. Further learningoptions
9. List ofTrade Committee Members
GENERAL INFORMATION
1.Name of theCourse Certificate Course inAutomobile Clutch Manufacturing - Multiskilled
2.N.C.O.CodeNo. - 3.Qualification PackCode No. - 4.DurationofTraining One Year (Two semesters)
5.EntryQualification 10thstd Age –Above 18 Yrs
6.UnitStrength 20 Trainees (TwoBatches-eachbatchof 10Trainees)
7.Space Norms a) Class room:30sqm. b) Workshop:80 sqm.
8.PowerNorms a) Class room: 1kw (6000lumen) b) Workshop:2kw (30,000lumen)
9.Job Role:
Atthe endof course thetrainee willbe able to:- Describe Automobile Clutches Perform press operations Carry out Blanking ,piercing ,Drawing and Coining Perform die-casting Perform machining operations Load the component Unload the components and carry out inspection/visual using measuring instruments
and gauges Interpret Engineering drawings. Carry out Shot blasting ,Trimming and Deburring Perform Preventive Maintenance. Carryout Plasma ,Progressive and TIG welding Carryout Heat treatment and Glueing Carryout Assembly Operation for Dry and Wet clutch. Follow best practices pertaining to Quality Inspection. Communicate effectively Maintain health and safety at workplace
Handle different types of fire extinguisher
Follow proper housekeeping practices . Adhere to companys Policies and Procedures. Apply the principles of 5S ,5T in the work area
10.Instructor’sQualification Graduate in Mechanical Engineering at least2years post qualification
11.Instructor’s/Trainer’s Qualification (a) AcademicQualification: (i) Graduate in Mechanical Engineering Or (ii) Diploma in Mechanical Engineering (b) TechnicalQualification: (i) For Graduate Degree holders in Mechanical Engineering, at least 2 years post qualification experience in Automobile industries (Clutch Manufacturing preferred) OR (ii) For Diploma holders in Mechanical Engineering at least 4years post qualification experiencein Automobile industries (Clutch Manufacturing preferred) (c)DesirableQualification: N/A
Syllabus for the role of Automobile Clutch Manufacturing - Multiskilled First Semester (Semester Code No – ACM:SEM-I)
Duration: Six Months
Syllabus for TP01and TT01 Week wise contentIndex ofFirst Semester
Sl. No.
Week No.
Contents Heading Duration
Practical Theory
1. 1 & 2 Communication Skills, Time Management,Policies and Procedures, Team work,Computing skills.
ACM-100 Workplace skills
2 Week
2. 3 & 4
Health & Safety-identify the hazards, application of first aid
ACM-200 Health & Safety
2 Week
3. 5 & 6 Types of clutches
ACM-300 CLUTCHES
2 Week
4. 7, 8 & 9 Blanking, Drawing, Piercing, Deburring/restrike, coining.
ACM-400 Press shop
3 Week
5. 10 & 11 Melting of raw materials, casting, Trimming, Deburring, Shot blast
ACM-500 Die casting
2 Week
6. 12, 13, 14 & 15 Study and interpretation of engineering drawing
ACM-600
Engineering drawing 4 Weeks
7. 16, 17, 18 & 19 Turning, Drilling, Broaching, Facing, Chamfering, Grooving, Threading, Grinding
ACM-700 Machining
4 Weeks
8. 1 to 19 OJT /Projectwork/Site Visit 19
Weeks
9. 20, 21, 22 & 23 Revision 4 Weeks
10. 24 & 25 Examination 2 Weeks
Syllabus for the role of Automobile Clutch Manufacturing - Multiskilled First Semester (SemesterCode No – ACM:SEM-I) Duration:Six Months
Syllabus for TP01and TT01
Week No.
TradePractical
TradeTheory
1 & 2 ACM-100
Workplace skills:
Activities pertaining to:
Communication skills
Time Management
Teambuilding skills
Team work
Computing skills
Basic communication skills (Importance
of communication, verbal
communication and non verbal
communication)
Policies and procedures
Managing time effectively through
planning
Behaviour skills (attitude problem
solving thinking skills confident building)
Workplace Ethics.
Computing skills
(Introduction,Computer and its
applications, Basics of Opertaing
system, Basic operations of word
processing Basics of excel work sheet
Basics of computer network, meaning of
world wide web).
3 & 4 ACM-200 Health & Safety Activities pertaining to: Study of work place to identify the hazards and suggest mitigation application of first aid, Identification of Hazardous waste and disposal as per the norms , Activities pertaining to electrical safety block out tag out procedures
Introduction to Occupational safety and
health and its importances at workplace
Hazards Identification and avoidance of
accidence
Introduction of personal protective
equipment
Do’s and don’ts during the process
Fire extinguisher
safety guidelines
Housekeeping activities
MSDS
Disposal procedure of waste material
Response to emergencies examples
Power failure, fire and system failure
5 & 6 ACM-300 Clutches Identification of parts of clutches of dry and wet clutches for both 2 and 4 wheeler Identification of various types of clutches
Introduction to clutches
Principles of Clutch
Single Plate Clutch
Multiplate Clutch
Types of clutch
o Centrifugal clutch.
o Semi-centrifugal clutch.
o Hydraulic clutch
o Positive clutch.
o Vacuum clutch.
o Electromagnetic clutch
7, 8 & 9 ACM-400
Press shop:
OJT- Automobile industry Practice operation of various types of press to produce various components of clutch meeting the quality and productivity norms Practice Blanking, Drawing ,Piercing Deburring/restrike ,Coining
Introduction to press tools
Application of press tools
Press working Terminology
Theory of shearing
Operations of CNC Machines
Blanking Process and its tools and dies
DrawingProcess and its tools and dies
PiercingProcess and its tools and dies
Deburring/restrike
Coining Process
10 & 11 ACM-500
Die casting:
OJT- Automobile industry
Practice Weighing of raw
materials, Melting, casting,
Trimming,Deburring,Shot blasting.
Introduction to Die casting Machine
Property of material such as AL and Zn
Die casting defects such as part unfilled,
blow holes, air bubbles, Part dent, Heat
mark and scratches
Melting
Casting
After Mould operations
o Trimming
o Deburring
o Shot blasting
12, 13, 14 & 15
ACM-600
Engineering drawing:
Study and interpretation of
engineering drawing, Prepartion
of engineering drawing.
Reading of drawing
Types and formats of engineering
drawing
Graphic language and machinist
engineering drawing
Dimensioning
Isometric and orthographic projections
sectional views and shop floor drawing
16, 17, 18 & 19
ACM-700 Machining Operation: OJT- Automobile industry Practice Turning , Drilling,
Broaching, Facing, Chamfering,
Grooving, Threading, Grinding
Introduction to cnc machines • Cutting tools& Equipments.
Turning Operation
DrillingOperation
BroachingOperation
FacingOperation
ChamferingOperation
GroovingOperation
ThreadingOperation
Grinding Operation
All weeks – 1 to 19 Site visit/OJT /Practical’s
Week 20, 21, 22 & 23
Revision
Week 24 & 25 Examination
Syllabus for the role of Automobile Clutch Manufacturing - Multiskilled Second Semester (Semester Code No – ACM: SEM-II) Duration: Six Months
Syllabus for TP02and TT02
Week wise content Index of Second Semester
Sl. No.
Week No Contents Heading
Duration Practical Theory
1. 1 & 2
Preventive Maintenance ,Machine Breakdown.
ACM-800 Basic machine maintenance
2 Weeks
2. 3 & 4 EWPS ACM-900
EWPS Skills 2 Weeks
3. 5, 6, 7 & 8 Plasma welding, Progressive welding and Tig welding
ACM-1000 Welding
4 Weeks
4. 9, 10 11 Alkaline chemicals, cooling, quenching Tempering, Induction hardening
ACM-1100 Heat treatment
3 Weeks
5. 12, 13 & 14
Raw materials, mixing ratios of the raw materials, shot blasting, making of pre bonds, finishing of pre bonds, grinding of pre bonds, Air bleaching, Curing Ranking
ACM-1200 Glueing
3 Weeks
6. 15, 16 & 17
Assembly of dry clutch and wet clutch for 2 wheeler and four wheeler
ACM-1300 Assembly
3 Weeks
7. 18 & 19 Quality System,Measuring Instruments ACM-1400
Quality 2 Weeks
8. 1 to 19 Site visit /OJT /Project work 19 Weeks
9. 20, 21, 22 &
23 Revision 4 Weeks
10. 24 & 25 Examination 2 Weeks
Syllabus for the role of Automobile Clutch Manufacturing - Multiskilled Second Semester (Semester Code No – ACM: SEM-II)
Duration: Six Months
Syllabus for TP02 and TT02
Week No.
Trade Practical
Trade Theory
Week1 & 2
ACM-800
Basic Machine Maintenance
Practice Preventive maintenance
Applying grease
Checking the oil level
Checking for loose parts
Replacing the worn parts
Purpose of Maintenance
Principle Objectives in
Maintenance
Types of Maintenance
Preventive Maintenance
Advantages of preventive
maintenance
Week 3 & 4 ACM-900
EWPS
Activities pertaining to:
Work guide lines
Reading instructions on
machines
EMS, 5S and 5T
Introduction to engineering work
place skills
Work guide lines
Reading instructions on machines
EMS and 5T
Purpose of house keeping
Practice of good house keeping
Principle of 5S in house keeping
SEIRI SEITON SEISO SEIKETSU
SHITSUKE
Week 5, 6, 7 & 8
ACM-1000
Welding
OJT- Automobile industry
Practice plasma ,Progressive and Tig
welding
Practice welding inspection
Introduction to welding machines
Types of welding
Welding principle
Welding power sources
Step involved in the preparation of
base metal for welding
Welding consumables
Welding metallurgy
Plasma Welding
Progressive Welding
Tig Welding
Safety guidelines during welding
Welding defects
Week 9, 10 & 11
ACM-1100
Heat Treatment
OJT - Automobile industry
Practice heat treating of automobile
components
Practice Oil and Water Quenching
Practice induction hardening
Practice arranging of materials for
heat treatment
Introduction to heat treatment
Types of heat treatment
Advantages and disadvantages of
heat treatment
Imporving work ability and other
property such as machinability
forgeability stress relief magnetic
property microstructure realinement
Imporving mechanical property such
as wear resistance fatigue and
strength
Pre washing of components
Post washing of components
Tempering
Applications of heat treatment
Week 12, 13 & 14
ACM-1200
Glueing
OJT - Automobile industry
Practice weighing of chemicals
Practice mixing of chemicals
Practice shot blasting
Practice pressing of pre bond with the bush
Practice grinding of pre bond to required accuracy
Practice Air bleaching
Practice Curing Ranking
Introduction to Glueing
Chemicals used in Glueing and their ratios
Shot blasting and its uses
Pre bonds
Joining of components using glue
Grinding
Air bleaching
Curing Ranking
Week 15, 16 & 17
ACM-1300
Assembly
OJT- Automobile industry
Practice assembly of dry clutch for 2 wheeler and 4 wheeler
Practice assembly of wet clutch for 2 wheeler and 4 wheeler
Introduction to assembly line
Tools used in assembly line
Parts of wet clutch for 2 ad 4 wheeler
Parts of dry clutch for2 and 4 wheeler
Gauges used in assembly line
Rivetting Machines
Go and NO Go Gauges
Balancing machines
Week 18 & 19 ACM-1400
Quality
OJT- Automobile Industry
Practice usage of dial gauge,
height gauge, vernier calliper,
micrometre, Bore gauge, bevel
protractor and balancing
machine to test the accuracy of
the automobile components
Visual inspection of raw
material for rusting, scaling and
corrosion
Quality management system
Introduction to metrology
Importance of Inspection in
Industry
Quality requirements
Quality tools
Measuring Instruments like Dial
gauge, Height gauge venier
calliper, screw gauge, Balancing
machine, Leak tester, One out
check machine
1 to 19 Site visit /OJT/Practical’s
20, 21, 22 & 23
Revision
24 & 25 Examination
LIST OF TOOLS&EQUIPMENT
SL NO Items Quantity
Hand tools
1 Hammer 1
2 Adjustable Spanner 1
3 Allen key 1
4 Needle File Set 1
5 Centre punch set 1
6 Try square 1
7 Stainless steel 1
8 Rule tape 1
9 Ball peen hammer 1
10 Cross peen hammer 1
11 Screw driver set 1
12 Straight peen hammer 1
13 Digital verniercaliper 1
14 V ernier Gear Tooth Caliper 1
15 Bevel protractor 1
16 Balance Checker 1
17 Height gauge 1
18 Micrometer 1
19 Try square 1
20 Tap 1
21 Dies 1
22 Reamers 1
23 Pliers 1
24 PPE 1
25 Aprons 1
26 Ear plugs 1
27 Slitting saw cutter (100*4*27)mm 1
28 Side & face cutter 150*10*27 mm & 100*15*27 mm 1
29 Collet Chuck (for vertical milling) collet 10 and 12mm 1
30 Leak tester 1
31 Broaching tool 1
32 Drill bits 1 set
33 Surface plate 4 0 0 MM*4 0 0 MM GRADE 1 1
34 Vee Block 1
35 Dial T est Indicator w it h m ag net i c g auge 1
36 Radius Gauge Metric Set 1
39 First aid kit(triangular bandages also) 1
40 Fire extinguisher 1
41 Riveting machines 1
42 Central Grinding Machines 1
43 Bore Gauge 1
44 CNC Turning Machine 1
45 CNC Welding Machine 1
46 Die-Casting Machine 1
47 300T / 400T Press Machines 1
48 Manual Lever Weight Measurement Machine 1
Note: The above quantity given is for one batch (20 Trainees) out of which 4 will be grouped into 5teams.
LIST OF CONSUMABLES
SL.NO Materials Quantity
1 Cotton waste 1 kg 2 Bucket 2
3 Water 500 litres tank
4 Coolants Die lube coolant-10 litres
Trade Testing and Certification
As per the NCVT norms
Further Learning Options Upon successful completion of this Course the candidate will be eligible for attending the advanced Courses in Automobile Clutch Manufacturing.
List of Trade Committee Members
Sl.No NAME&DESIGNATIONS/SHRI
REPRESENTING ORGANIZATION
REMARKS
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