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APPRENTICESHIP CURRICULUM
For
Lab Technician - Metal Testing Under
Capital Goods Skill Council
For
NSQF compliance
National Apprenticeship Promotion Scheme
1 Program Title Lab Technician - Metal Testing
2 Program Code, if any CSC/Q0602
3 Any related NSQF approved QP/Course/NOS and code
Lab Technician - Metal Testing, CSC/Q0602
4 Hours and months for Basic Training (Block I) 350 Hours (2 Months)
5 Hours and months for On the Job Training (Block II)
3528 Hours (21 Months)
6 Certifying body for Basic Training Program Capital Goods Skill Council
7 Certifying Body for On the Job training Industry Body
8 Any Licensing requirements, wherever applicable NA
9 Minimum eligibility criteria (Educational and/ or technical Qualification) Exemptions, if any
Diploma – Mechanical, Metallurgy B.E Mechanical, Metallurgy
10 Trainer’s Qualification and Experience (BT and OJT)
B.E Mechanical, Metallurgy with 3 to 4 years of relevant experience
11 NCO code and occupation NCO-2004/8223.69
12 Proposed NSQF level 4
13 Indicative list of training tools required to deliver this qualification (may be attached)
Refer Annexure A
14 Formal structure of the curriculum
Modules Notional hours- Theory
Notional hours- Practical
Total duration
Basic Training Program
1. Introduction to Industry rules & regulation 2.Industrial safety & Team work management 3. 5S concept and Health Safety 4.Basic of Metallurgy 5.Basic of Metal Testing
25
30
25 30
30
10
30
40
60
70
35
60
65
90
100
Total 140 210 350
3 Week
5 Week
8 Week
On the Job Training Program
1.Method of Metal testing 2.Prepare for testing on metal objects 3.Carry out testing on Metal Object 4.Metal Processing 5. Principles of metal testing 6.Quality Checking Method 7.Monitaor & controlling 8. Reporting & documentation
40
40
40
40
36
40
30
40
400
400
420
420 400
410
400
372
440
440
460
460
436
450
430
412
Total 306 3222 3528
7.3 Week
76.7 Week
84 Week
15 Total Pass marks
Total and Pass Marks- Theory
Total and Pass Marks- Practical
Basic Training Program
70 %
70 %
On the Job Training Program
70 %
70 %
16
Job description- It involves identifying and using relevant methods and skills to complete the testing and address problems. It involves initiating and completing testing and procedures using a range of different metal testing methods and
equipment’s used within the workplace.
17 Progression from the qualification (Please show Professional and academic progression)
The Apprentices after completion of this course can work in Metallurgy department, can handle different process of Material testing and work in Lab testing department
18 Employment avenues/opportunities
The Apprentices after completion of this course can find opportunities as Material testing engineer, Quality engineer.
19 Assessment strategy (Basic training and On the Job)
The assessment for the Basic Training and for On the Job Training will be conducted toward the end of the OJT duration
20 Curriculum update version and date 17- Feb-2021
21 Curriculum revision date 31 March-2021
Curriculum
Module Name with duration Key Learning outcomes
Theory/Basic Training Program- Block I
1. Introduction to Industry rules & regulation Theory Duration 25:00 hr. Practical duration 10:00 hr. Corresponding NOS:CSC/ N1335
Identify and observe evacuation procedures
according to company policy
Follow the rules and regulations of industry
Read and apply the knowledge of data sheet of raw
material
Give information to others clearly, at a pace and in a manner that helps them to understand
Maintain proper appropriate tone, pitch and language to convey politeness, assertiveness, care and professionalism
Demonstrate responsible and disciplined behaviours at the workplace
Identify the role and responsibility of a metal testing technician in industry
Acquire the knowledge of organizational structure and employment benefits in industry
Know the overview of Manufacturing industry
Follow the environmental controls of an Automotive Industry
Work considering overall equipment efficiency & evaluate
Follow quality management system for better productivity
Set goals, reflect and learn from experience of Industry
To adhere to procedures or systems in place for health and safety, personal protective equipment (PPE) and other relevant safety regulations for laboratory operations
2.Industrial safety & Team work management Theory Duration
Identify individual responsibilities in relation to maintaining workplace health safety and security requirements.
Follow the organisation’s emergency procedures&
30:00 hr. Practical duration 30:00 hr Corresponding NOS:CSC/N1336
identify and recommend opportunities for improving health, safety, and security.
Use fire extinguishers.
Identify and Report unsafe working conditions to seniors
Observe Safety related to Mechanical and Manual Material Handling, Lifting Appliances, Transport / Earthmoving& Material Handling Equipment’s.
Report supervisor/ Competent of authority in the event of accident or sickness of any staff and record accident
Follow safe working practices when working with tools and machinery & follow and apply PPE & 5 S guidelines
use protective clothing/equipment for specific tasks and work conditions Protective clothing: leather or asbestos gloves, flame proof aprons, flame proof overalls buttoned to neck, cuffless (without folds), trousers, reinforced footwear, helmets/hard hats, cap and shoulder covers, ear defenders/plugs, safety boots, knee pads, particle masks, glasses/goggles/visors
To Identify job-site hazardous work and state possible causes of risk or accident in the workplace & preventative and remedial actions to be taken in the case of exposure to toxic materials
Accurately receive information and instructions from the supervisor and fellow workers, getting clarification where required & maintain competence within one’s role and field of practice
To Promote and demonstrate good practice as an individual and as a team member at all times & identify and manage potential and actual risks to the quality and safety of practice
Know how to deal with difficult working relationships with other people to sort out problems& identify the types of working relationships that help people to work well together and the types of relationships that need to be avoided.
3. 5S concept and Health Safety Theory Duration
Explain 5S principle.
Apply 5S principle at workplace
Practice the steps of 5S as per the requirement/necessity.
25:00 hr. Practical duration 40:00 hr. Corresponding NOS:CSC/N1335
Label red tags to segregated items
Keep segregated items at proper place.
Maintain standard process of 5s at workplace
Ensure that you are under safe condition
Keep needed items at workplace
Create empty space for more utilization
Check the availability of tools and consumables while
Practice 5S at the workshop.
Demonstrate procedure of materials, tools and Equipment’s and spares parts sorting.
To carry out safe working practices while dealing with hazards to ensure the safety of self and others
To Safe working practices: using protective clothing and equipment
state methods of accident prevention in the work environment of the job role
4.Basic of Metallurgy Theory Duration 30:00 hr. Practical duration 60:00 hr. Corresponding NOS:CSC/N0602
To know the different material property
To know the mechanical and physical property of
materials
Understand of common metals, metal alloys and
non-metals
To know the common terminology used in testing
procedures
Property of Materials: cast iron, bronzes, steels
(low-carbon, low alloy, high yield, stainless),
aluminium/aluminium alloys
To know the material/physical/metallurgy properties
pre metal processing.
To use appropriate measuring techniques and units
of measurement
Understand Metal composition
Effects of metal composition on metal strength
Understand Microscopic structures in metals and how they influence metal strength
Understand Metallurgical changes that occur in metals during cold working and heat treating
Effects of metallurgical changes on metal strength
Understand the concerns chemical, physical, and
atomic properties and structures of metals and the
principles
5.Basic of Metal Testing Theory Duration
To measurement of the characteristics and
behaviour of such substances as metals, ceramics,
or plastics under various conditions.
30:00 hr. Practical duration 70:00 hr. Corresponding NOS:CSC/N0602
Understand materials testing breaks down into five
major categories: mechanical testing; testing for
thermal properties; testing for electrical properties;
testing for resistance to corrosion, radiation, and
biological deterioration; and non-destructive testing
To identify conditions required for tests of material
To understand basic of metallurgy testing process
To know different types of metallurgy testing process
Define common terms used metal testing
Explain principles of metal testing
List various methods and techniques used in testing various kinds of metals
List chemicals and equipment used for testing various kinds of metals
List parameters for metal testing – equipment omission, leaks, contamination, metallurgy properties pre metal processing, metallurgy properties post metal processing, etc
On the Job Training Program- Block II
1.Method of Metal testing Theory Duration 40:00 hr. Practical duration 400:00 hr. Corresponding NOS: CSC/ N0602
Interpret metal testing instructions, inspection &
testing procedure –job instruction sheet, job card,
work drawings and instructions, quality control
documents, process specifications, quality control
documents, standard operating procedure
Define & understand quality control specifications
Prepare the work area for metal testing
Prepare any tools and equipment required for
testing operation
Prepare test samples in accordance with the
standard procedure
Carryout metal testing as per instructions
Record the results of tests carried out in standard
formats- written or typed report, computer based
record or any other specific requirement
Perform numerical operations, geometry and
calculations
Maintain current knowledge of application
standards, legislation etc.
Demonstrate problem solving abilities
Plan, organize and sequence work operations as
per the job requirement
2.Prepare for testing on metal objects Theory Duration 40:00 hr. Practical duration 400:00 hr. Corresponding NOS: CSC/ N0602
Apply knowledge on Metal testing
To obtain job specification from a valid and
approved source Valid sources: job instruction
sheet/job card; work drawings and instructions;
planning documentation; quality control
documents; process specifications;
Apply standard operating procedures;
instructions from supervisor
To read and establish job requirements from the
job specification document accurately
Prepare the work area for the testing operations
as per procedure
Obtain correct work-pieces/raw materials to be
tested
Identify the metals, metal alloys and non-metals
and job specifications accurately
Ensure availability appropriate testing tools and
equipment as per job requirements
To set up tools and equipment for testing
3.Carry out testing on Metal Object Theory Duration 40:00 hr. Practical duration 420:00 hr. Corresponding NOS: CSC/ N0602
Identify conditions required for tests to be undertaken
select the appropriate testing methods to be undertaken
Prepare any tools and equipment required for the testing operations
To prepare the test samples in accordance with the procedures and check their integrity
Carry out the required tests in accordance with the procedures
To record the results of the tests undertaken in the appropriate format as per organisational procedures
To complete documentation post completion of work, as per organisational procedure
To secure tools and equipment in a safe condition on completion of the testing activities
various methods and techniques used in testing various kinds of metals
Procedures, tools and techniques required to set operational performance parameters on testing equipment and meters
Importance of monitoring the equipment settings and function during the testing process
4.Metal Processing Theory Duration 40:00 hr. Practical duration 420:00 hr. Corresponding NOS:CSC/ N0602
Understand material/physical/metallurgy properties pre metal processing.
Understand material/physical/metallurgy properties during metal processing
Understand material/physical/metallurgy properties post metal processing
Apply range of chemicals, equipment, meters to be used for testing different types of material Materials: cast iron, bronzes, steels (low-carbon, low alloy, high yield,
stainless), aluminium/aluminium alloys
To know the types of metal processing
To specific safe working practices, sampling collection, testing procedures and environmental regulations that need to be observed
To Maintain hazards associated with carrying out the testing procedures and (eg. as hot equipment and materials/products, moving loads,
rotating/moving equipment)
How to set up the metal testing equipment and resources correctly Resources: consumables, utilities/facilities, instruments, test materials, equipment.
Monitor and support the repair or modification activities within the limits of their personal authority
5. Principles of metal testing Theory Duration 36:00 hr. Practical duration 400:00 hr. Corresponding NOS: CSC/ N0602
Understand principles of metal testing and the types of tests available
importance to follow the specific testing procedure at all times
To know how to determine the required testing equipment to be used and the precautions to be taken when handling and using it
Importance of testing equipment calibration and how to check it
Factors may make the equipment, or the metal test samples obtained unsuitable for the testing activities and the action to be taken
To know what are the correct methods of preparing, handling and storing the samples
Understand how to carry out the tests on the metal products in line with production and quality control procedures
Understand how to deal with problems which affect aspects of sample collection, inspection and
testing activities and the interpretation of the results
Explain principles of metal testing
List chemicals and equipment used for testing various kinds of metals.
6.Quality Checking Method Theory Duration 40:00 hr. Practical duration 410:00 hr. Corresponding NOS: CSC/ N0602
Identify potential causes of non-conformities to quality assurance standards
Identify impact on final product due to non-conformance to company standards
To Evaluating the need for action to ensure that problems do not recur
To Suggest corrective action to address problem
The importance of quality control procedures
To know the relevance and importance of activities and how they contribute to the achievement of the quality objectives
To know the Proper procedure for selecting the material/product and performing quality checks without affecting the material
Apply the Characteristics of the product/material
Availability and use of monitoring and measuring devices
To know the cost of non-conformance to quality standards Identification of QC and QA procedure
Apply Proper procedure for selecting the material/product and performing quality checks without affecting the material
To know how to carry out the tests on the metal products in line with production and quality control procedures
7.Monitaor & controlling Theory Duration 30:00 hr. Practical duration 400:00 hr. Corresponding NOS: CSC/ N0602
To handle the ingredients and products using hand gloves and other safety equipment as directed by organizations safety department
Follow the standard operating procedures for controlling the process
Identifications of types of defects leading to rejections and their indicators, reasons and possible solutions.
Impact of various practices on cost, quality, productivity, delivery and safety.
Apply the importance of testing equipment calibration and how to check it
check and clarify task-related information
Understand basic concepts of shop-floor work productivity including waste reduction, efficient
material usage and optimization of time
8. Reporting & documentation Theory Duration 40:00 hr. Practical duration 372:00 hr. Corresponding NOS: CSC/N0602
Proper documentation and reporting procedures that should be used on conclusion of the testing
Importance of completing the documentation throughout the testing process
To know how to deal with problems which affect aspects of sample collection, inspection and testing activities and the interpretation of the results
To know how to report any problems you are not able to deal with yourself and why it is important to report faults, variations or problems immediately
Identify QA, QC documentation and Report Documentation Store Documentation
Identify requisition Documentation and the system documentation of industry
Practical knowledge of software’s PowerPoint, excel, Word
Apply different methods of recording information & Various documents that need to be maintained
To know the Company procedure for filling/maintaining up the documents
To know the Procedures for reporting to the appropriate authority & recording damage, breakages etc.
To reporting incidents where standard operating procedures are not followed
To know the importance of complete and accurate documentation
Apply the appropriate method for documentation
Guidelines for Assessment Criteria for assessment for each Qualification Pack will be created by the Sector Skill
Council. Each Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of marks for Theory and Skills Practical for each PC.
The assessment for the theory part will be based on knowledge bank of questions created by the SSC. Assessment will be conducted for all compulsory NOS, and where applicable, on the
selected elective/option NOS/set of NOS. Individual assessment agencies will create unique question papers for theory part
for each candidate at each examination/training center (as per assessment criteria below).
Individual assessment agencies will create unique evaluations for skill practical
For every student at each examination/training center based on this criterion. To pass the Qualification Pack, every trainee should score a minimum of 70% of
aggregate marks to successfully clear the assessment. In case of unsuccessful completion, the trainee may seek reassessment on the Qualification Pack.
List of Assessable outcomes/assessment criteria
Criteria For Assessment Of Trainees
Job Role: Lab Technician - Metal Testing Qualification Pack: CSC/Q0602
Sector Skill Council: Capital Goods Skill Council
Compulsory NOS
Total Marks: 300
Marks Allocation
Assessment
outcomes Assessment Criteria for outcomes
Total
Marks
Out
of Theory
Skills
Practic
al
CSC/N0602 Carry out testing on metals
PC1.work safely at all times, complying with health and safety legislation, regulations and other relevant guidelines
100
4
1
3
PC2.adhere to procedures or systems in place for health and safety, personal protective equipment (PPE) and other relevant safety regulations for laboratory operations
5
1
4
PC3.work following laid down procedures and instructions
4 1 3
PC4.ensure that all tools, equipment, power tool cables, extension leads are in a safe and usable condition and are kept at secured location
3
0
3
PC5.ensure that all measuring equipment are within calibration date and are approved for usage 3 0 3
PC6.ensure work area is clean and safe from hazards before and after the job is completed
3
0
3
PC7.obtain job specification from a valid and approved
source
3 0 3
PC8.read and establish job requirements from the job specification document accurately
3
0
3
PC9.report and rectify incorrect and inconsistent information in job specification documents as per organization procedures
5
1
4
PC10.prepare the work area for the testing operations as per procedure
6 2 4
PC11.obtain correct work-pieces/raw materials to be tested
3
0
3
PC12.identify the metals, metal alloys and non-metals and job specifications accurately 5 0 5
PC13.ensure availability appropriate testing tools and equipment as per job requirements 4 1 3
PC14.set up tools and equipment for testing 5 0 5
PC15.identify conditions required for tests to be undertaken 3 0 3
PC16.select the appropriate testing methods to be undertaken 3 0 3
PC17.prepare any tools and equipment required for the testing operations 4 0 4
PC18.prepare the test samples in accordance with the procedures and check their integrity 6 2 4
PC19.carry out the required tests in accordance with
the
procedures
7 2 5
PC20.record the results of the tests undertaken in the appropriate format as per organizational procedures 7 2 5
PC21.complete documentation post completion of work, as per organizational procedure 4 1 3
PC22.secure tools and equipment in a safe condition on completion of the testing activities 3 0 3
PC23.refer unresolved job related problems to appropriate personnel for support
3
0
3
PC24.monitor the problem and keep the supervisor informed about progress or any delays in resolving the problem
4
0
4
Total 100 14 86
CSC/N1335 Use basic health and safety practices at the workplace
PC1.use protective clothing/equipment for specific
tasks and work conditions
100
4 1 3
PC2.state the name and location of people
responsible for health and safety in the workplace
3 1 2
PC3.state the names and location of documents that
refer to health and safety in the workplace 3 1 2
PC4.identify job-site hazardous work and state possible causes of risk or accident in the workplace
5
2
3
PC5.carry out safe working practices while dealing with hazards to ensure the safety of self and others
4 2 2
PC6.state methods of accident prevention in the work environment of the job role
3 2 1
PC7.state location of general health and safety equipment in the workplace
5 2 3
PC8.inspect for faults, set up and safely use steps and ladders in general use
5 2 3
PC9.work safely in and around trenches, elevated places and confined areas
5 2 3
PC10.lift heavy objects safely using correct procedures
4 2 2
PC11.apply good housekeeping practices at all times 5 2 3
PC12.identify common hazard signs displayed in various areas
3 1 2
PC13.retrieve and/or point out documents that refer to health and safety in the workplace
4 1 3
PC14.use the various appropriate fire extinguishers on different types of fires correctly
3 1 2
PC15.demonstrate rescue techniques applied during fire hazard
3
1
2
PC16.demonstrate good housekeeping in order to prevent fire hazards
4
1
3
PC17.demonstrate the correct use of a fire extinguisher
4 1 3
PC18.demonstrate how to free a person from electrocution
4
1
3
PC19.administer appropriate first aid to victims where required eg. in case of bleeding, burns, choking, electric shock, poisoning etc.
3
1
2
PC20.demonstrate basic techniques of bandaging 3 1 2
PC21.respond promptly and appropriately to an accident situation or medical emergency in real or simulated environments
3
1
2
PC22.perform and organize loss minimization or rescue activity during an accident in real or simulated
3
1
environments 2
PC23.administer first aid to victims in case of a heart attack or cardiac arrest due to electric shock, before the arrival of emergency services in real or simulated cases
3
1
2
PC24.demonstrate the artificial respiration and the CPR Process
3 1 2
PC25.participate in emergency procedures 4 1 3
PC26.complete a written accident/incident report or dictate a report to another person, and send report to person responsible
3
1
2
PC27.demonstrate correct method to move injured people and others during an emergency
4 2 2
Total 100 36 64
CSC/N1336 Work effectively with others
PC1.receive information accurately and instructions from the supervisor and fellow workers, getting clarification where required
100
10
3
7
PC2.pass information accurately to authorized persons who require it and within agreed timescale and confirm its receipt
10
3
7
PC3.give information to others clearly, at a pace and
in a manner that helps them to understand 10 3 7
PC4.display helpful behavior by assisting others in performing tasks in a positive manner, where required and possible
10
3
7
PC5.consult with and assist others to
maximize effectiveness and efficiency in
carrying out tasks
10 3 7
PC6.display appropriate communication etiquette
while working
10 3 7
PC7.display active listening skills while interacting with
others at work 10 3 7
PC8.use appropriate tone, pitch and language to
convey politeness, assertiveness, care and
professionalism
10
3
7
PC9.demonstrate responsible and disciplined
behaviors at the workplace 10 3 7
PC10.escalate grievances and problems to
appropriate
authority as per procedure to resolve them and avoid
conflict
10
3
7
Total 100 30 70
Annexure A:
B: Workshop/ Lab Infrastructure (Tools, Equipment’s, Machines, etc.)
Sr. Name of Item Category Qty. Unit Remark
1 Safety shoes (Regular size) Consumable 10 Number Per 1 Unit in a Shift
2 Safety Goggles Consumable 10 Number Per 1 Unit in a Shift
3 Safety hand gloves leather ( Regular size )
Consumable 10 Number Per 1 Unit in a Shift
4 Ear plug Consumable 10 Number Per 1 Unit in a Shift
5 Helmet Consumable 10 Number Per 1 Unit in a Shift
6 Fire Extinguishers (C02) Equipment 1 Number Per 3 Unit in a shift
7 Fire Extinguishers ( Dry Chemical powder )
Equipment 1 Number Per 3 Unit in a shift
8 Sand bucket Equipment 2 Number Per 3 Unit in a shift
9 Fire blanket Equipment 2 Number Per 3 Unit in a shift
10 First Aid Kit Consumable 1 Number Per 1 unit in a shift
11 Metal samples
Consumable 5 Number Per 1 unit in a shift
12 Universal Testing Machine,
Equipment 1 Number As per required
specification
13 Carbon and sulphur determination Apparatus
Equipment 2 Number As per required specification
14 Melt flow index apparatus
Equipment 3 Number As per required
specification
15 Impact hardness tester
Equipment 2 Number As per required
specification
16 Measuring microscope
Equipment 1 Number As per required
specification
17 Ferrite meter
Equipment 1 Number As per required
specification
18 spectrometer and hand tools
Equipment 1 Number As per required
specification
19 Digital multimeter Equipment 2 Number Per 1 unit in a shift
20 Electroscope Equipment 2 Number As per required specification
21 Humidity Chamber Equipment 1 Number As per required specification
22 Glass Thermometer Equipment 1 Number As per required
specification
23 Dual Channel Digital
Thermometer Equipment 1 Number As per required
specification
24 Digital Lux Meter Equipment 1 Number As per required specification
25 Gas Flow Indicator of Smoke
visibility tester Equipment 1 Number As per required
specification
26 Impact Tester with weight Equipment 1 Number As per required specification
27 Flexibility & Adhesion tester Equipment 1 Number As per required specification
28 Digital Hygrometer Equipment 1 Number As per required specification
