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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