SYLLABUS OF SEMESTER SYSTEM

FOR THE ROLE OF

Press Operator

(CAPITAL GOODS)

Under

High Employment Potential

Courses through Flexi MOUs

(One Year/Two Semesters)

Designed in

2014

By

Government of India

Ministry of Labour & Employment (DGE&T)

FORMAT

1. Cover Page

2. Title

3. General Information

4. Week wise contents of TT and TP (In tabular form)

5. Tools and Equipment List- Broad Specification

6. List of Consumables

7. Trade Testing and Certification

8. Further Learning Options

9. List of Trade Committee Members

GENERAL INFORMATION

1.Name of the Course Certificate Course in Press Operations 2. N.C.O Code No. 3.Qualification Pack Code No. 4.Duration of Training One Year (Two semesters)

5.Entry Qualification 10th Pass

6.Unit Strength 20 Trainees (Two Batches of 10 Trainees each)

7.Space Norms a) Class room: 30sqm. b) Workshop: 80sqm.

8.Power Norms a) Class room: 1kw (6000lumen) b) Workshop: 2kw (30,000lumen)

9.Job Role: By the end of course the trainee will be able to:-

Study the drawings of incoming components and finished parts and carry out visual inspection

Carry out press set up

Identify press tools corresponding to the part

Perform press operations

Identify proper tool, tool handling and maintenance

Unload the components and carry out inspection/visual using measuring instruments and gauges

Identify problems and escalate as per the defined procedure

Conduct himself as per the guidelines related to behaviour and attitude for the industrial environment

Communicate effectively as per organisational hierarchy

Follow safety regulations without any deviation

Apply the principles of 5S in the work area

Perform quality checks

Carry out reporting and documentation

10. Instructor’s Qualification Graduate Degree holders in Mechanical Engineering at least2years post qualification experience in Manufacturing (Press Operation).

11.Trainer Qualifications (a) Academic Qualification: (i) Graduate Degree in Mechanical Engineering Or (ii) Diploma in Mechanical Engineering (b) Technical Qualification: (i) Graduate Degree holders in Mechanical Engineering with at least 2years post qualification experience in Manufacturing (Press Operation). Or (ii) Diploma holders in Mechanical Engineering with at least 4years post qualification experience n Manufacturing (Press Operation). (c) Desirable Qualification: N/A

Syllabus for the role of Press Operator (Capital Goods)

First Semester (Semester Code No – PRO: SEM-I)

Duration: Six Months

Syllabus for TP01 and TT01

Week wise content Index of First Semester

Sl. No.

Week No.

Contents Heading Duration

Practical Theory

1. 1,2 Introduction to Manufacturing Industry, Overview of the job role of Press Operator, Engineering work place skills

PRO-100 Introduction

2 Week

2. 3 Safety, health and environment PRO-200 SHE

1 Week

3. 4 Engineering materials PRO-300 ENG MAT

1 Week

4. 5 Reading of drawings PRO-400 REA DRA

1 Week

5. 6 Material handling PRO-500 MAT HAN

1 Week

6. 7 Press working terminology PRO-600 PRS TER

1 Week

7. 8, 9 Machines used in press shop PRO-700 MAC PRS

2 Weeks

8. 10, 11, 12 Press operation PRO-800 PRS OPR

3 Weeks

9. 13 Press tools PRO-900 PRS TLS

1 Week

10. 14 Tool and die sets PRO-1000 TLS DIE

1 Week

14. 15 to 23 OJT / Project work/ Site Visit 20+4 Weeks

15. 24 Revision 1 Week

16. 25,26 Examination 2 Weeks

Syllabus for the role of Press Operator (Capital Goods) First Semester (Semester Code No – PRO: SEM-I)

Duration: Six Months

Syllabus for TP01 and TT01

Week No.

Trade Practical

Trade Theory

1,2 Activities pertaining to the following: communication, writing skill, listening skills, presentation skills, time management, grooming, team work, work ethics, identification of safe areas with respect to floor marking, emergency response procedures

Introduction to Manufacturing Industry, Overview of the job role of Press Operator, Engineering work place skills

3 Study of work place to identify the hazards

and suggest mitigation, application of first

aid,

Activities pertaining to health awareness,

identification of hazardous wastes and

disposal as per the norms, activities

pertaining to electrical safety, lock out and

tag out procedures

Safety, health and environment Hazard identification and avoidance of accident,

Electrical safety ,

Preventive measures for electrical accidents,

Disposal procedure of waste materials,

4 Identification and selection of engineering

materials, visual inspection of materials,

measuring and sizing the raw materials,

material testing

Engineering materials, commonly used materials, metallurgy, physical and mechanical properties of materials, selection of materials for components and press tools, material testing,

5 Study and interpretation of engineering

drawings, preparation of engineering

drawings

Reading of drawings, types and formats of engineering drawings, graphic language and symbols of engineering drawing, dimensioning, isometric and orthographic projections, sectional views and shop floor drawings

6 Activities pertaining to manual handling

and material handling equipment viz

hydraulic trolley, forklift etc,.

Material handling, manual handling, material handling equipment, loading and unloading practices, safe operations in shop environment

7 Preparation of machinery sketches

identifying the parts, explaining the parts

and functions of presses, activities

pertaining to safe operations

Press working terminology, blanking, drawing etc; parts of press, functional description, working principle, definition of stroke, shut height and die space, safety features

8, 9 Operations of machines in press shop,

operation of tool sharpening machinery Machines used in press shop, ,mechanical and hydraulic presses, tool sharpening machinery, accessories for press working machinery

10, 11, 12

Operation of various types of presses to

manufacture various components meeting

the quality and productivity norms, Press operation, operation of manual, NC, and CNC presses, safe operations, study of SOP

13 Selection of proper press tools, tool fitting,

activities pertaining to proper tool storage,

report on tool manufacturing and heat

treatment

Press tools, types of press tools, application of press tools, manufacturing and heat treatment of press tools, tool storage

14 Selection of proper tool and die sets, tool

fitting, activities pertaining to proper tool

and die sets storage, report on tool and

die sets manufacturing and heat treatment

Tool and die sets, types of tool and die sets, application of tool and die sets, manufacturing and heat treatment of tool and die sets, tool and die sets storage

15 to 23

Site visit/OJT /Practical’s

24

Revision

25, 26

Examination

Syllabus for the role of Press Operator (Capital Goods)

Second Semester (Semester Code No – PRO: SEM-II)

Duration: Six Months

Syllabus for TP02 and TT02

Week wise content Index of Second Semester

Sl. No.

Week No.

Contents Heading Duration

Practical Theory

1. 1

Cutting forces during press work

PRO-1100 CUT PRS

1 Week

2. 2 Handling and maintenance of press tools PRO-1200 CRE MNT

1 Week

3. 3

Introduction to press tool design PRO-1300 PRS TLD

1Week

4. 4, 5,

Introduction to tool and die making PRO-1400 INT TDM

2 Weeks

5. 6 Quality inspection PRO-1500 PRS QUT

1 Week

6. 7 Productivity PRO-1600 PRS PRO

1 Week

7. 8 Reporting and documentation PRO-1700 PRS DOC

1 Week

8. 9 to 23 OJT /Project work/Site Visit 9+16Weeks

9. 24 Revision 1 Week

10. 25,26 Examination 2 Weeks

Syllabus for the role of Press Operator (Capital Goods)

Second Semester (Semester Code No – PRO: SEM-II)

Duration: Six Months

Syllabus for TP02 and TT02

Week No.

Trade Practical

Trade Theory

1 Exercises in estimation of cutting forces,

study of factors affecting cutting forces,

preparation of chart relating tool

geometry and cutting process

Cutting forces during press work, estimation of

cutting forces, factors affecting cutting forces,

influence of tool geometry on cutting forces

2 Identification of defects in tools, practice

proper storage of tools on rack Handling and maintenance of press tools

3 Preparation of tool sketches, write-up on

press tool design, preparation of tool

drawings

Introduction to press tool design

4, 5 Report on tool and die making process,

practice tool and die making

Introduction to tool and die making

6 Use of measuring instruments,

equipment and gauges, practice visual

inspection, follow the quality working

instruction manuals,

Quality, importance of quality, defects in components, root cause analysis, quality management system, quality working instructions, quality circles, measuring instruments ,equipment and gauges, calibration of instruments

7 List hourly production rate of presses in

the shop, list factors affecting

productivity along with suggestions to

improve productivity, follow the SOP to

ensure productivity, calculation of scrap

wastage

Productivity, factors effecting productivity, production norms, components of cycle time, machine utilization, standard operating procedures

8 Study of all the reports pertaining to

production and quality, practice filling up

the documents related to shop floor

operations, maintain the documents, as

per the industry norms

Reporting and documentation ,reporting on production status, quality of inputs, error messages during the operation of the machines, conditions of machine and accessories ,defects in finished parts etc; and documentation as per the company norms

9 to 23

Working in press shop manufacturing

components meeting the quality and

productivity norms, OJT/Project work/Site Visit

24

Revision

25, 26

Examination

LIST OF TOOLS & EQUIPMENT

SL.

No.

Name of items Quantity

1. PPE 5 Sets

2. Basic tool kit 5 Sets

3. Fire extinguisher 1

4. First aid kit 1

5. Measuring tool set 5

6. Material Testing equipment

7. Desktop with Auto CAD software 2

8. Bending press* 1

9. Punching press* 1

10.

Tool and cutter grinder* 1

11 Machines used for tool and die making* (Drilling, milling, shaping, turning and grinding)

1

12 Hydraulic trolley, forklift 1 each

* Will be provided as part of OJT along with materials and consumables

Trade Testing and Certification

As per the NCVT norms

Further Learning Options Upon successful completion of this Course the candidate will be eligible for attending the advanced Courses in Press Operation.

List of Trade Committee Members Sl.No NAME&DESIGNATIONS

/SHRI REPRESENTING ORGANIZATION

REMARKS

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